Sauer_Series_TM_servicemanual.pdf

Series TM Transit Mixer Drive System

Service Manual

2 DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Series TM Transit Mixer Drive SystemService Manual

General ............................................................................................................................................................... 4Transit Mixer Pump TMP ........................................................................................................................... 4Cross Section TMP ...................................................................................................................................... 4Charge Pump ................................................................................................................................................... 5Charge Relief Valve ........................................................................................................................................ 5Multi-Function Valve ..................................................................................................................................... 5Input Shaft ........................................................................................................................................................ 6Auxiliary Mounting Pads .............................................................................................................................. 6Transit Mixer Motor TMM ......................................................................................................................... 7Cross Section TMM ..................................................................................................................................... 7Loop Flushing Device ................................................................................................................................... 8Transit Mixer Gearbox TMG ..................................................................................................................... 9Cross Section TMG ...................................................................................................................................... 9Speed Sensor .................................................................................................................................................10Transit Mixer Electronic TME .................................................................................................................11Transit Mixer Drive System TM .............................................................................................................12Circuit Diagram TM ...................................................................................................................................12

General Specifi cations ................................................................................................................................13Specifi c Data ..................................................................................................................................................13Technical Data ...............................................................................................................................................13Electrical Proportional Valves ...................................................................................................................13Circuit Diagram .............................................................................................................................................14Determination of Nominal Pump Sizes ................................................................................................14

Axial Piston Pumps Size 070 and 089 ................................................................................................15

General Specifi cations ................................................................................................................................18Specifi c Data ..................................................................................................................................................18Technical Data ...............................................................................................................................................18Circuit Diagram .............................................................................................................................................19Determination of Nominal Motor Sizes ................................................................................................19

Axial Piston Motors Size 070 and 089 ................................................................................................20

General Specifi cations ................................................................................................................................21Specifi c Data ..................................................................................................................................................21Technical Data ...............................................................................................................................................21

Gearbox Size 51.2 .........................................................................................................................................22Gearbox Size 61.2 .........................................................................................................................................23Gearbox Size 71.2 .........................................................................................................................................24

2002, Sauer-Danfoss

Sauer-Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Sauer -Danfoss reserves the right to alter its products without prior notice. This also applies to products already ordered provided that such alterations can be made without subsequent changes being necessary in specifi cations already agreed. All trademarks in this material are properties of the respective companies. Sauer-Danfoss and the Sauer-Danfoss logotype are trademarks of the Sauer-Danfoss Group. All rights reserved.

Front page: P4050028, P000853, P4050027, P000854, P4050026, P000861, P003001

Contents

FUNCTIONALDESCRIPTION

TECHNICALSPECIFICATIONS AXIAL PISTON PUMPS TMP

DIMENSIONS AXIAL PISTON PUMPS TMP

TECHNICALSPECIFICATIONS AXIAL PISTON MOTORS TMM

DIMENSIONS AXIAL PISTON MOTORS TMM

TECHNICALSPECIFICATIONS GEARBOX TMG

DIMENSIONS GEARBOX TMG

3Series TM Transit Mixer Drive SystemService Manual

DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Contents (continued)

General .............................................................................................................................................................26Mounting the Motor ...................................................................................................................................26Mounting the Speed Sensor ....................................................................................................................26Mounting the Pump ....................................................................................................................................26Mounting the Gearbox ...............................................................................................................................27Mounting the Water Tank ..........................................................................................................................27Mounting the Drum Flange ......................................................................................................................28Mounting Controller TME ..........................................................................................................................29Wiring Diagram TME ...................................................................................................................................30Installation Space TME ................................................................................................................................30

Fluid Specifi cation ........................................................................................................................................31Hydraulic Fluid ..............................................................................................................................................31Cleanliness ......................................................................................................................................................31Suction Filtration ..........................................................................................................................................31

Required Tools ...............................................................................................................................................32Port Location Pump .....................................................................................................................................32Port Location Motor ....................................................................................................................................32

General .............................................................................................................................................................34Gearbox ...........................................................................................................................................................34Hydrostatics ....................................................................................................................................................34

Gearbox TMG .................................................................................................................................................36Safety ................................................................................................................................................................36Hydrostatic TMP and TMM ........................................................................................................................36

Troubleshooting ...........................................................................................................................................38

Emergency Discharging .............................................................................................................................41

INSTALLATIONINSTRUCTIONS

HYDRAULIC FLUID

PRESSUREMEASUREMENT

START-UP PROCEDURE

MAINTENANCE

TROUBLESHOOTING

EMERGENCYDISCHARGING


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

This section describes the operation of pump, motor, gearbox and controller to drive the transit mixer drum in an electrical closed loop control system. It is a useful reference for readers, which are not familiar with the functioning of transit mixer drive systems.

The variable displacement pump TMP is designed to convert a mechanical input power into hydraulic power. The input shaft, driven by the engine PTO, turns the pump cylinder block, which contains a ring of pistons. The pistons run against a tilted plate, called swash plate. This causes the pistons to compress the hydraulic fl uid, which imparts the input energy into hydraulic fl uid. The high-pressure fl uid is then ported out to provide the hydraulic pressure and fl ow to the fi xed displacement motor TMM.The swash plate angle can be varied by the actuating piston via the electrical propor-tional control valves depending on the current value, which is generated by the TME controller.

Functional Description

GENERAL

TRANSITMIXER PUMP TMP

Variable Displacement Pump TMP

F300 692F300 691

CROSS SECTION TMP

JOINT FLANGE

ACTUATING CYLINDER

ACTUATING PISTON

CYLINDER BLOCK

PISTON

CHARGE PUMP

INPUT SHAFT

VALVE PLATE

BEARING PLATE

SWASH PLATE P001 981E


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004


CHARGE PUMP The charge pump is necessary to compensate internal leakages and supply cool fl uid to the system, to maintain positive pressure in the main system loop, as well as pressure to operate the control system. Charge pressure must be at its specifi ed pressure under all conditions of acceleration and deceleration of the drum to prevent damage to the transmission.The charge pump is a fi xed-displacement, gerotor type pump integral in the variable displacement pump and driven by the main shaft.A charge pressure relief valve limits charge pressure.

CHARGE RELIEF VALVE

MULTI-FUNCTION VALVE The multi-function valve incorporate the system check valve and also the high-pressure relief valve function. The system check valves allow pressurized fl ow from the charge pump to enter the low-pressure side of the loop whenever system pressure dips below a certain level. Two system check valves are used to direct the charge fl ow into the low-pressure side of the closed circuit system.The high-pressure relief valves are designed as direct operating poppet valve, which are a fi xed setting for differential pressure of 420 bar [6090 psi]. If the pressure reachs the setting value the valve will be open immediately by cross-porting the system fl ow to the low-pressure side of the closed circuit system.

The charge pressure relief valve on the charge pump serves to maintain charge pressure at a designated level. A direct-acting poppet valve relieves charge pressure whenever it surpasses a certain level which is nominally set at zero fl ow, means in neutral position. The setting level is specifi ed on the model code.

P001 982F300 691

P001 983

P001 984E

HIGH PRESSURE

HIGH PRESSURE RELIEF VALVE

SYSTEM CHECK VALVE

CHARGE PRESSURE

CHARGE RELIEFVALVE

F300 691

MULTI FUNCTIONVALVE

F300 691

Cross Section

Cross Section

Cross Section


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004


INPUT SHAFT

AUXILIARY MOUNTING PADS

The standard input shaft is designed with a joint fl ange diameter of 100 mm [3.94 in] (DIN/ISO) and allows the direct assembling to the joint shaft from the engine power take off. An optional splined shaft is available for direct assembling to engine power take off.

Auxiliary mounting pads are available in size A and B to drive auxiliary hydraulic pumps.

TMP with Joint Flange TMP with Splined Shaft

TMP with PTO A Cross Section

P001 985

F300 693 F300 688

F300 683


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004


TRANSITMIXER MOTOR TMM

The fi xed displacement motor TMM is designed to convert an input of hydraulic power into a mechanical torque and speed output power. The high-pressure hydraulic fl uid enters through the input port. The fl uid pressure builds behind the piston causing them to move down the swash plate. As the pistons returns up the swash plate again, the fl uid is allowed to exit through the exit port. The spinning pistons are housed in a cylinder bloc, which is connected to the output shaft.The mechanical output is used to turn the gearbox TMG.

Fixed Displacement Motor TMM

F300 698

CROSS SECTION TMM

P001 953E

OUTPUT SHAFT

CYLINDER BLOCKSHUTTLE SPOOL ORIFICED LOOP

FLUSHING VALVE

VALVE PLATEBEARING PLATE PISTON

F000 857


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004


LOOP FLUSHING DEVICE The integrated loop-fl ushing device in the motor is used to fl ush out a certain oil fl ow from the closed circuit system for cooling.The orifi ce loop fl ushing valve defi nes a fi xed fl ow value from the closed circuit system on the low-pressure side only when there is a pressure differential in the main loop. The spring centered loop fl ushing shuttle spool, controlled through the high-pressure side, provides a circuit between the low-pressure side of the closed loop and the orifi ce loop-fl ushing valve. At the time of fi rst operation a rapid air separation from the closed circuit is also achieved by the fl ushing device and in addition, it is ensured that unavoidable installa-tion dirt is fl ushed out at the same time and can be picked up by the suction fi ltering

LOOP FLUSHING DEVICE

X

VIEW X

P001 954E

ORIFICED LOOPFLUSHING VALVE

LOOP FLUSHINGSHUTTLE SPOOL

F000 857

F000 857

Cross Section


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

DRUM FLANGE

MAIN BEARING

CURVED TEETHCOUPLING

INPUTSUN GEAR

1-ST STAGE2-ND STAGE

WATER PUMPDRIVE SHAFT

(90 degree turned)

P001 986E


TRANSITMIXER GEARBOX TMG

The two-stage planetary gearbox has to turn and to carry one side of the drum of transit mixer. It is assembled to the mixer frame of base supports, which also carry the torque force of the drive. It also provides the option to carry a water tank which is located in the upper part of the housing. The dynamic swivel angle of the output/drum fl ange will be compensating for the defl ection of the truck frame mainly under off-road conditions.The optional water pump drive is on the left or right drum fl ange side, if you see from drum fl ange side.

TMG 61.2 with Water Pump Drive on the left side

F000 860

CROSS SECTION TMG 61.2

F000 872

TMG 61.2 without Water Pump Drive

10


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004


SPEED SENSOR All the available gearboxes TMG s are prepared to offer the required speed sensor option. At the factory an oil-tight cover closes the receiving bore for the speed sensor. The location of the speed sensor at TMG s with water pump drive is dependent on the confi guration - left or right water pump side - of the gearbox. On the right side, the speed sensor will be at the top of the motor, on the left side it is under the motor.

TMG with Water Pump Drive on the right side and installed Speed Sensor

Cross Section Speed Sensor

P001 987F000 861

11


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

= Discharging

= Memory Switch Stop/Start Remote Station

= Changeover Switch Cabin Station

= Charging/Transport


TRANSIT MIXERELECTRONIC TME

The controller constitutes a ready-to-install, operating unit, in dashboard design. The controller is available as a remote and cab mounted controller to supply the electrical pump control. The cab unit is an additional slave device and can be operated only in con-junction with the remote master unit.Using the rotary switch on the operating unit, the direction and speed rotation of the drum are selected and, corresponding to the position of the rotary switch, a current value is supplied to the electrical pump control. The pump output fl ow, which is estab-lished, determines the reference motor speed at the input of the gearbox.The speed sensor in the gearbox measures the actual speed as feedback for the control-ler. The desired and actual values are compared and the pump fl ow is controlled until both values equal. This is in operation at any selected drum speed. With the yellow touch switch on the remote controller, it is possible to stop and start the drum speed independent of the rotary switch position. In this case, the LED indicates changes from lighted to fl ashes.The yellow touch switch on the cabin controller permits a change over to the remote controller and vice versa. In this mode the cabin LED is off and all operatings are trans-fered to the remote controller. The fl ashing LED indicates stand by mode. When moving to the other control station the rotary switch position must be set to neutral. Touching the yellow switch with fl ashing LED will change to full light, which means the controller is switched on.

TME Remote Station TME Cabin Station

Symbol used on the Controller

ROTARY SWITCH LED

TOUCH SWITCHP001 956

TOUCH SWITCH

LEDROTARY SWITCH

P001 957

P001 958

P001 959

P001 960

P001 961

12


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004


TRANSIT MIXER DRIVE SYSTEM TM

In accordance with the rotary switch position on the TME controller unit (13), a current set point is generated and provides to the electrical proportional valve (6) of the TMP main pump (2) with a PWM signal. The necessary control oil supply is provided by the feed circuit of the charge pump (3) and is delivered to the actuating cylinder (7) via the electrical proportional valve (6). Depending on the current value, a proportional actuat-ing pressure is established on the actuating cylinder (7) and therefore a stroke, which adjusts the swash plate angle and defi nes the fl ow delivery of the main pump (2).

Depending on the speed of the pump and displacement, the pump fl ow determines the output speed of the TMM motor (9) as well as the input speed to the TMG gearbox (10). The selected drum speed of the controller keeps the drum speed constant. Independent of the engine speed or charging state.In order to meet the demand for a constant drum speed the actual value is measured via the speed sensor (14) in the TMG gearbox (10) and provided as an input signal to the TME controller unit (13). The electronic device compares the actual value with the pre-selected set point of the drum speed and controls the current to the electrical propor-tional valves (6) which sets the swashplate of the pump to the appropriate fl ow to keep the drum speed constant.The system presented completely meets the demand for a constant drum speed in accordance with the pre-selection on the rotary switch of the TME controller unit.The integrated charge pump (3) supplies the closed circuit via two multi-function valves (5) - feed and high-pressure protection - using cooled (14) and fi ltered (12) oil. The integrated fl ushing device (11) in the TMM motor, comprising an alternating slide and permanently set nozzle fl ushing valve, ensures a defi ned exchange of oil in the closed circuit. The oil led via the cooler (15) is feed in again via the charge pump (3) by means of a suction fi ltering system (12) connected upstream.At the time of fi rst commissioning rapid air separation from the working circuit is also achieved by the fl ushing device (11) and, in addition, it is ensured that unavoidable installation dirt is fl ushed out at the same time and can be picked up by the suction fi ltering system (12).

CIRCUIT DIAGRAM TM

L1 M1

M3

M5

M4

A A

B BM2L2SM10

P001 962

M2M3L2

M1 NL1 10

13

14

11

1215

9

6

6

2 3

14

5

8

85

7

n

TMP TME TMM TMG

13


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Technical Specifi cations Axial Piston Pumps TMP

GENERALSPECIFICATIONS

Specifi cations for axial piston variable displacement pump are listed on these pages.For defi nitions of the various specifi cations, see the related pages in this publication.

SPECIFIC DATA

TECHNICAL DATA

ezisemarF 070 980

mumixam.tAtnemecalpsid

rab/mN]isp0001/nifbl[

11.1]086[

24.1]468[

Theoretical Torquerab ]isp[

erusserpatledmumixaM 024 ]0906[

System Pressure Range, Input

epytpmuP ngisednotsiplaixaetalphsawstnemecalpsidelbairavhtiwpmupnotsiplaixA

noitatorfonoitceriD esiwkcolc-retnuocroesiwkcolC

noitisopnoitallatsI diulfciluardyhhtiwdellifebsyawlatsumgnisuoheht,yranoitercsiD

stnemeriuqermetsysrehtO riovreserelbatius,noitcetorperusserprevotiucriC

General Specifications

noisnemiDezisemarF

noisnemiD070 980

tnemecalpsiD gVmc 3

ni[ 3]07

]72.4[98

]34.5[

wolfmumixaM Qxam

nim/l]nim/lagSU[

302]45[

852]86[

rewoprenrocmumixaM renrocpxam

Wk]ph[

241]091[

081]242[

thgieW mgk

]bl[16

]431[

aitrenifotnemomssaMstrapnoitatorlanretniehtfo

Jmgk 2

tffbl[ 2]77710.0

]24.0[

gnitnuomfoepyT noitarugifnocegnalfEAS,egnalftlob)4(ruoF

snoitcennocepiPegnalfEAS:stroperusserpniaM

ssobgnir-OdaerhtthgiartsEAS:stropgniniameR

noitarugifnoctfahS ISNAdenilpSro)OSI/NID(egnalftnioj]ni49.3[mm001

Specific Data

ELECTRICALPROPORTIONAL VALVES

General Data Protection class: DIN VDE 0470: IP65/IPX7 Electrical connections: AMP Junior Power Timer Supply pressure p

Pmax: 50 bar [725 psi]

Insulation material: Class H, 180 C [356 F] Duty cycle: 100 %

egatloV V21 V42

R02

ni %53.5 %52.12I1

Amni 01006 01003

I2

Amni 010051 01057

Electrical Data

Electrical Data

Case Pressure

bar [psi]

Rated pressure 3 [44.0]

Maximum pressure (cold start) 5 [73.0]

Speed Limits

Frame sizemin-1 (rpm)

070 089

Minimum speed 500

Rated speed 2500

Maximum speed 2900

14


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Vg n v Vg n

vOutput fl ow: Qe

= _________ l/min Qe

= _________ [US gal/min] 1000

231

Vg p

Vg p Input torque: M

e = __________ Nm M

e = _________ [lbfin]

20

mh 2

mh

Me n Q

e p

Vg n p

Input power: Pe

= ______ = ______ kW Pe = ___________ [hp]

9550 600 t 396 000 t Q

e 1000

v Q

e 231

vInput Speed: n = _____________ min-1 n = ___________ min-1 (rpm) Vg Vg

Vg = Pump displacement per rev. cm3 [in3]p =

p

HD -

p

ND bar [psid]

v = Pump volumetric effi ciency

mh

= Pump mechanical-hydraulic (Torque) effi ciency

t = Pump overall effi ciency

pHD

= High pressure bar [psid]p

ND = Low pressure bar [psid]

Technical Specifi cations Axial Piston Pumps TMP

CIRCUIT DIAGRAM

DETERMINATION OF NOMINAL PUMP SIZES Metric System Inch System

L1 M1

CB

CA

M3

M5

M4

P001955E

A

B

M2L2SM10

Ports:

A, B = Main pressure lines

L1, L2 = Case pressure or drain ports

M1,M2 = Gage port system pressure

port A + B

M3 = Gage port charge pressure

M4,M5 = Gage port servo pressure

M10 = Gage port charge pump inlet

pressure

S = Charge pump inlet

CA, CB = Electrical proportional valve

15


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Dimensions Axial Piston Pumps TMP

AXIAL PISTON PUMPS SIZE 070 AND 089

90.0

[3.5

6]

110.

0[4

.33]

292.

0[1

1.5]

27.8

[1.0

9]

8.

0[0

.315

]

60.0[2.362]

Split flange bossDN 25 Typ I 40MPa seriesper ISO 61624 Thread: M12

21 [0.83]full thread depth

84

.0[3

.31]

57

.0-0

.019

[2.2

44-0

.001

]

12

6.97

50.

025

[5.0

]

100.

00.

3[3

.94

0.01

]

57.2[2.25]

17.0[0.679]

8.5[0.335]

2.3[0.091]

12.4[0.49]

149.0[5.86]

254.0[9.98]

P001 988E

262.0[10.32]

313.0[12.32]

304.0[11.96]

54.8[2.157]

106.0[4.175]

12.0[0.472]

57.25[2.25]

57.2

5[2

.25]

95.0

[3.7

3]

114.

5[4

.508

]

163.

0[6

.44]

114.5[4.51]

146.0[5.75]

216.0[8.50]

15.0 +0.8 -0.3

[0.591+0.31] -0.12

49.0[1.92]

Connector CAAMP Junior Power Timer

Case drain port L1use highest port as outletM22x1.511.0 min. [0.433] depth

Size and rotation directionare machinde beside the name plate; as example 7L for 70 cc, left hand.

Case drain port L2M22x1.511.0 min. [0.433] depth

Connector CBAMP Junior

Power Timer

(CCW) (CW)

X

M42x2

20.0 [0.79] depth

105.00[4.13]

89.00[3.50]

Gage port M1System pressure port "A"

M12x1.512.7 [0.5] min. depth

Gage port M2System pressure port "B"

M12x1.512.7 [0.5] min. depth

Gage port M3Charge pressureM12x1.512.7 [0.5] min. depth

Gage port M5Servo pressureM12x1.5

Gage port M4Servo pressureM12x1.5

Gage port M10Charge pumpinlet pressure

M12x1.512.7 [0.5] min. depth

Charge pump inlet S High pressurerelief valve port B

High pressurerelief valve port A

Charge pressurerelief valve

P001 989E

X

mm[in]

"A"troP "B"troPEPFN

evlav

esiwkcolC

)wc(tuptuO tupnI AC

esiwkcolcretnuoC

)wcc(tupnI tuptuO BC

Direction of Rotation

16


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004


Spline dataPitch dia : 14.288

[0.563]Pressure angle : 30Number of teeth : 9Pitch : 16/32ANSI B92.1-1970 class 6fillet root side fitFull spline lenght : 17.0

[0.669] P001 992E

Thread (2x)M10,

19.0 [0.748] deep

for O-ring1.78x82.3[0.07x3.24]

106.

375

[4.1

88]

87

.12

[3.4

3]

106.375[4.188]

331.00[13.05]

317.00[12.49] 15.00

[0.591]10.50[0.41] 1.20

[0.05]

82

.6 +

0.13

0

[3.2

5 +

0.00

5 ]

0

AXIAL PISTON PUMPS SIZE 070 AND 089(continued)

Option Auxiliary Pad SAE A Size 070 and 089

Option Spline Shaft Size 070 Option Spline Shaft Size 089

56.00[2.207]

33.00 [1.31]

R6[0.24]

45.00 max[1.772]


[1.313]Pressure angle : 30Number of teeth : 21Pitch : 16/32ANSI B92.1-1970 class 5fillet root side fit 51.00

[2.00]

80

.00

max

[3.1

5]

29

.00

[1.1

3]M10

Full spline lenght

34

.5 0

-0

.17

[1.3

58 0

]

-0

.007

P001 990E

28.50 max[1.122]

20.00[0.792]

56.00[2.207]

33.00 [1.31]

R6[0.24]

45.00 max[1.772]


[1.438]Pressure angle : 30Number of teeth : 23Pitch : 16/32ANSI B92.1-1970 class 5fillet root side fit 51.00

[2.00]

80

.00

max

[3.1

5]

32

.00

[1.2

6]M10

Full spline lenght

37

.60

0.09

[1.4

80.

004]

P001 991E

28.50 max[1.122]

20.00[0.792]

mm[in]

17


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

for O-ring1.78x101.35 [3.99 x 0.07]

334.00[13.15]

317.00[12.49]

15.00[0.591]

146.

00[5

.75]

10

6.80

[4.2

]

Thread M12 (2x)deep min.[0.787]

1.20[0.05]

10.50[0.41]

P001993E

10

1.65

+0.

13

0

[4.0

02 +

0.00

5 ]

0


[0.8125]Pressure angle : 30Number of teeth : 13Pitch : 16/32ANSI B92.1-1970 class 6fillet root side fitFull spline lenght : 34.0

[1.330]

Option Auxiliary Pad SAE B Size 070 and 089AXIAL PISTON PUMPS SIZE 070 AND 089(continued)


mm[in]

18


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Technical Specifi cations Axial Piston Motors TMM


Specifi cations for axial piston fi xed displacement motors are listed on these pages.

SPECIFIC DATA

TECHNICAL DATA

epytrotoM ngisednotsiplaixaetalphsawstnemecalpsiddexifhtiwrotomnotsiplaixA

noitatorfonoitceriD )lanoitcerid-ib(esiwkcolc-retnuocroesiwkcolC

noitisopnoitallatsI diulfciluardyhhtiwdellifebsyawlatsumgnisuoheht,yranoitercsiD

stnemeriuqermetsysrehtO riovreserelbatius,noitcetorperusserprevotiucriC


noisnemiDezisemarF

noisnemiD070 980

tnemecalpsiD gVmc 3

ni[ 3]07

]72.4[98

]34.5[

wolfmumixaM Qxam

nim/l]nim/lagSU[

302]45[

852]86[

rewoprenrocmumixaM renrocpxam

Wk]ph[

241]091[

081]242[

thgieW mgk

]bl[53

]77[

aitrenifotnemomssaMstrapnoitatorlanretniehtfo

Jmgk 2

tffbl[ 2]77710.0

]24.0[

gnitnuomfoepyT noitarugifnocegnalfEAS,egnalfdlob)4(ruoF

snoitcennocepiPegnalfEAS:stroperusserpniaM

ssobgnir-OdaerhtthgiartsEAS:stropgniniameR

noitarugifnoctfahS ISNAdenilpS

Specific Data

ezisemarFnim 1- )mpr(

ezisemarF070 980

deepsdetaR 0052

deepsmumixaM 0092

Speed Limits

ezisemarF 070 980

mumixam.tAtnemecalpsid

rab/mN]isp0001/nifbl[

11.1]086[

24.1]468[

Theoretical Torque

rab ]isp[

erusserpatledmumixaM 024 ]0906[

System Pressure Range, Input

Case Pressure

bar [psi]

Rated pressure 3 [44.0]

Maximum pressure (cold start) 5 [73.0]

19


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Technical Specifi cations Axial Piston Motors TMM

CIRCUIT DIAGRAM

P003 021M2M3L2

M1L1

A

B

DETERMINATION OFNOMINAL MOTOR SIZES Metric System Inch System

Vg n Vg nInput fl ow: Q

e = ________ l/min Q

e = _______ [US gal/min]

1000 v

231 v

Vg p mh Vg p mh Output torque: Me = ___________ Nm M

e = ___________ [lbf-in]

20 2

Me n Q

e p

t Vg n p

tOutput power: Pe = ______ = __________ kW P

e = ____________ [hp]

9550 600 396 000

Qe 1000

v Q

e 231

vOutput Speed: n = _____________ min-1 n = ___________ min-1 (rpm) Vg Vg

Vg = Motor displacement per rev. cm3 [in3]p =

p

HD -

p

ND bar [psid]

v = Motor volumetric effi ciency

mh

= Motor mechanical-hydraulic (Torque) effi ciency

t = Motor overall effi ciency

pHD

= High pressure bar [psid]p

ND = Low pressure bar [psid]

Ports:

A, B = Main pressure lines

L1, L2 = Case pressure or drain ports

M1,M2 = Gage port system pressure

port A + B

M3 = Gage port loop fl ushing

pressure

20


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Dimensions Axial Piston Motors TMM

AXIAL PISTON MOTORS SIZE 070 AND 089

249.00[9.803]

207.00[8.150]

118.00[4.650]

114.50[4.508]

114.

50[4

.508

]

190.

30[7

.492

]

85.0

0[3

.346

]85

.00

[3.3

46]

66

.50

max

.[2

.618

]

95.0

0[3

.740

]

164.

00[6

.457

]

146.00[5.748]

12.00[0.470]

L2

L1

12.40[0.490]

31.20[1.228]

46.30 max.[1.823]

55.00[2.169]

72.00[2.835]

122.00[4.803]

218.00[8.583]

251.00[9.882]

Full spline lenghtOrificed loopflushing valve


[1.313]Pressure angle : 30Number of teeth : 21Pitch : 16/32ANSI B92.1-1970, class 5fillet root side fit

15.00 +0.8 -0.3

[0.591 +0.031] -0.012

12

7.00

-

0.05

[4.9

99

]

-0

.002

Case drain port L2use highest port as outletM22x1.5

Case drain port L1M22x1.5

L(ccw)

R(cw)

164.00[6.460]

57.20[2.250]

P001 996E

41.60[1.64]

27.8

0[1

.09]

Gage port M1System pressure port AM12x1.5

Loop flushing shuttle spool

Gage port M3Loop flushing pressure

Gage port M2System pressure port B

M12x1.5

A

ASplit flange bossDN 25 Typ I 40MPa seriesper ISO 61624 Thread: M12

21 [0.83]full thread depth

Size identificationare machined here :

7 for 70 cc9 for 89 cc

"A"troP "B"troP

)wc(esiwkcolC tuptuO tupnI

)wcc(esiwkcolcretnuoC tupnI tuptuO

Direction of Rotation

mm[in]

21


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Technical Specifi cations Gearbox TMG


xobraeGyratenalpegats-owT:2.16dna2.15eziS

egatsraegrupslaitinihtiwyratenalpegats-owT:2.17eziS

noitatorfonoitceriD esiwkcolcretnuocdnaesiwkcolC

esopruP thgiewmurdehtfotrapadnasecrofeuqrotehtyrrac,murdehtevirD

snoitpO evirdpmupretawtuohtiwrohtiW

srehtO knatretawayrracotderaperP


epytxobraeG GMT

ezisxobraeG 2.15 2.16 2.17

oitarxobraeG i 9.101 5.111 3.131

ycneiciffexobraeG 69.0 69.0 59.0

egnalfmurdehtfoelgnaleviwscimanyd.xaM 6 7 7

)ngised(tfahsniamxobraegehtfoepolS 51 51 51

elgnanoitallatsnimurd.xaM)troppusemarfhguorhtdetsujda(

m7otpu 3 51.xam:m9dna8 3 21.xam:

m01 3 11.xam:m21 3 11.xam:

thgieWgk

]bl[352

]855[523

]717[333

]537[

emulovtnacirbuLnim/l

]nim/lagSU[21

]2.3[61

]2.4[61

]2.4[

epyttnacirbuL tnacirbulraeG-PE )1

ssalc-IPA 5-LG

45315NIDot.ccaegatsrewopGZF 21>

edargytisociV 09EAS)1 08ybefilehtecudersevitiddA-PEo/wtnacirbulraeG .%

Specific Data

Attention:

ezisxobraeG 2.15 2.16 2.17

euqrottuptuo.xaMmN

]tf-bl[00015

]00673[00016

]00054[00017

]05325[

murdllufehtfothgiewelbissimrePt

]bl[5.12

]01474[23

]36507[23

]36507[

murdehtotdaollaidarcitatselbissimrePegnalf

Nk]fbl[

031]42292[

081]46404[

081]46404[

murdehtotdaollaidarcimanydelbissimreP)tnettimretni(egnalf

Nk]fbl[

562]27595[

053]08687[

053]08687[

murdehtotdaollaixacitatselbissimrePegnalf

Nk]fbl[

05]04211[

56]21641[

56]21641[

murdehtotdaollaixacimanydelbissimreP)tnettimretni(egnalf

Nk]fbl[

061]86953[

032]40715[

032]40715[

ecnamrofrep-MTdeepstuptuO nim 1- )mpr( 51 41 41

evirdpmupretawo/wdeepstuptuo.xaM nim 1- )mpr( 81 81 61

evirdpmupretawhtiwdeepstuptuo.xaM nim 1- )mpr( 81 61 61

erutarepmetgnitarepo.xam/.niMC

]F[]581+[58+otpu]4-[02-

Technical Data

SPECIFIC DATA

TECHNICAL DATA

22


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Dimensions Gearbox TMG

GEARBOX SIZE 51.2

M1220.0[0.79] deep

Oil dip stickand oil inlet

Cover for speed sensor connection

M816.0 [0.63]

deep

26.0

[1.0

2]13

.0 [0

.51]

5.0

[0.2

0]

194.5[7.66]

Connection forwaterpumpi = 0.41

Parallel keyA 6x6x20 DIN6885

Cover for water-pump-connection

20.0

max

.[0

.787

]

Lubrication oil outlet

12

0.0

[4.7

2]

60

6 x 60

70.0[2.756]

458.0[18.03]

200.0[7.87]

200.0[7.87]

200.0[7.87]

200.0[7.87]

159.0[6.260]

30

12 x 30

Air breather

Variation ofdrum flange

Dynamic swivelangle max.

14.0[0.55]

O-ring 124x4[4.88x0.16] NBR 70

57.0[2.24]

205.0[8.06]

454.0[17.87]

10.5[0.41]

55.0[2.165]

R225

.0[8

.86]

42

6.0

[16.

77]

17

.0[0

.67]

53.0[2.09]

67.0[2.64]

30.0[1.18]188.0

[7.4]

22.0[0.87]

18.0[0.71]

31.5[1.24]

22.0[0.87]

40.0[1.57]

10.0[0.39]

198.0[7.78]110.0

[4.43]

41.0[1.63]

50.0

[1.9

7]

17.0

[0.6

7]

246.

3[9

.70]

400.

0[1

5.75

]

R168

.0[6

.614

]

15.0

[0.5

9]

15

66

114.6[4.51]

114.

6[4

.51]

105.0[4.13]

74.5[2.93]

40.0[1.57]



100.0 +0.054 (H8)

0 [3.937 +0.0021]

0

21.0

+3.

0

0

[0

.84

+0.

12]

0

18.0 0 (h6)

-0.011 [0.7087 0 ]

-0.0004

75.0 0

-5.0 [2.953 0 ]

-0.2

12

7.0

+0.

04 (

H7)

0

[5

.00

+0.

002

]

0

53

0.0

0

(h

9)

-0

.155

[20.

87 0

]

-

0.00

61

50

0.0

0.

2

[19.

685

0.

008 ]

P001 997E

Securing device during transportDisplayed position turned 62.5

mm[in]

23


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004


GEARBOX SIZE 61.2mm[in]

M1220.0 [0.79]deep


O-ring 124x4[4.88x0.16] NBR 70

458.0[18.03]

200.0[7.87]

200.0[7.87]

147.5[5.81]

200.0[7.87]

200.0[7.87]

70.0[2.76]

M816.0 [0.63]

deep

120.

0[4

.72]


215.0[8.5]

Connection forwaterpump

i = 0.41


Cover for water-pump-connection

Variation ofdrum flangeDynamic swivelangle max.

Securing device during transportDisplayed position turned 62.5

20.0

max

.[0

.787

]

26.0

[1.0

2]13

.0[0

.51]

5.0

[0.2

]

Air breather

130

'

41

9.0

[16.

5]

18.5[0.73]

18.0[0.71]

66.0 [2.6]505.0

[19.88]

252.0[9.92]

57.0[2.24]

14.0[0.55]R2

45.0

[9.6

5]

241.

0[9

.488

]

46

5.0

[18.

31]

15

77

192.0 [7.577]110.0

[4.33]

6.0[0.236]

35.0[1.379]

12.0[0.484]

40.0[1.57]

22.0[0.87]

17.3

[0.6

8]

22.0[0.87]

32.6[1.28]

53.0[2.09]

67.0[2.64]

190.0[7.48]

17.0

[0.6

7]

50.0

[1.9

7]

400.

0[1

5.75

]

241.

7[9

.516

]

60

6x60

7.5 1524x15

81.5[3.209]

114.6[4.51]

114.

6[4

.51]

129.0[5.08]

40.0[1.57] 94.0[3.689]



P001 998E

75.0 0

-5.0 [2.953 0 ]

-0.2

100.0 +0.054 (H8)

0 [3.937 +0.0021]

0

18.0 0 (h6)

-0.011 [0.7087 0 ]

-0.0004

17

.0

0.2

[0.6

70.

01]

53

0.0

0

(h

9)

-0

.155

[20.

87 0

]

-

0.00

61

50

0.0

0.

2

[19.

685

0.

008 ]

12

7.0

+0.

04 (

H7)

0

[5

.00

+0.

002

]

0


24


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004


GEARBOX SIZE 71.2mm[in]

114.6[4.51]


M1220.0 [0.79]deep

O-ring 124x4[4.88x0.16] NBR 70

458.0[18.03]

200.0[7.87]

200.0[7.87]

154.0[6.063]

7.5 15

24x15

114.

6[4

.51]

200.0[7.87]

200.0[7.87]

215.0[8.5]

123.5[4.86]

70.0[2.76]

M816.0 [0.63]

deep

12

0.0

[4.7

2]

606x6

0

215.0[8.5]


20.0

max

.[0

.787

]Connection for

waterpumpi=0.41


Cover for water-pump connection

26.0

[1.0

2]

13.0

[0.5

1]5.

0[0

.2]

Air breatherSecuring device during transportDisplayed position turned 61.5

Variation ofdrum flangeDynamic swivelangle max.

41

9.0

[16.

5]

1.5

15

77

18.0[0.71]

66.0[2.6]

505.0[19.88]

252.0[9.92]

57.0[2.24]

14.0[0.55]

R245

.0[9

.65]

241.

0[9

.488

]

46

5.0

[18.

31]

192.0[7.577]110.0

[4.33]

6.0[0.236]

35.0[1.379]

12.0[0.484]

40.0[1.57]

22.0[0.87]

17.3

[0.6

8]

22.0[0.87]

400.

0[1

5.75

]

241.

7[9

.516

]

50.0

[1.9

7]17

.0[0

.67]

190.0[7.48]

53.0[2.09]

67.0[2.64]

32.6[1.28]

18.5[0.73]

100.0 +0.054 (H8)

0 [3.937 +0.0021]

0

12

7.0

+0.

04 (

H7)

0

[5

.00

+0.

002

]

0

18.0 0 (h6)

-0.011 [0.7087 0 ]

-0.0004

53

0.0

0

(h

9)

-0

.155

[20.

87 0

]

-

0.00

61

75.0 0

-5.0 [2.953 0 ]

-0.2



129.0[5.08]

17

.0

0.2

[0.6

70.

01]

50

0.0

0.

2

[19.

685

0.

008 ]

P001 999E

94.0[3.689]

40.0[1.57]


25


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Notes

26


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Installation Instructions

GENERAL

MOUNTING THE MOTOR

MOUNTING THESPEED SENSOR

MOUNTING THE PUMP

Prior to the system installation please inspects the units for damage occuring during shipping and handling. Remove plugs and covers just before you start to assemble fi ttings and hoses. Make sure that all the other system components (reservoir, fi ttings, hoses, heat exchanger) are cleaned.

Remove the plastic protective cover on the motor side of the gearbox drive in a sealing of the motor with an O-ring.Case has to be taken that there is no axial load on the pinion with the motor mounting into the gearbox.Fasteners for the motor: 4 bolts M12, grade 8.8, tighten to a torque of 80 Nm [708 lbfin]Hardened washers (acc. to DIN 6916) are necessary under the bolt heads.

Remove the screw holding the sealed sensor cover plate. Remove the cover plate. Assemble the new O-ring on speed sensor and position into place.

If the pump is driven from the rear of the engine via a joint shaft, case has to be taken that the pump and engine power take off is correctly aligned. This means the joint shaft is exactly in confi guration Z or W. A misalignment will reduce the life of both the pump bearings and joint shaft.The pump support must have a solid structure to prevent any unnecessary noise.

Fasteners for the pump: 4 bolts M12, grade 8.8, tighten to a torque of 80 Nm [708 lbfin].Hardened washers (acc. to DIN 6916) are necessary under the bolt heads (and the nuts if through bolts are used).

New self-sealing screw must be use to fi x the

speed sensor. Tightening torque: 8 2 Nm

[71 18 lbfin]

F000 874 F000 861

27


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004


MOUNTING THEGEARBOX

MOUNTING THEWATER TANK

Gearbox mounting must be on a solid, distortion free, and fl at support face.Min. tensile strength of material: 400 N/mm [57 200 psi]Mounting surface roughness average peak-to-valley height: Ra = 3,2 m in acc. to DIN 4768, part1 Allowable fl atness over the whole mounting area is 0.15 mm [0.006 in].Fasten the gear box foot with 3 bolts M20 (on each side); min. grade10.9; tightening torque 540 Nm [4780 lbfin] Hardened washers are necessary under the bolt heads (and the nuts if through bolts are used).Mounting plate stops are required to absorb the axial load of the drum when the truck decelerates, so that the bolt force is relieved. Stops should be welded in front of the foot, shown here for a rear discharge truck. Front discharge trucks must have the welded stops on the opposite side.

A water tank with max. 1500 l [396 US gal] volume can be attached to the upper part of the housing.Fasten the water tank with 2 bolts M20 on each side; min. grade 8.8; tightening torque 540 Nm [4780 lbfin]Hardened washers are necessary under the bolt heads and the nuts:

WASHER IN ACC. TODIN 6916-21

3.2

0.15 A

10+5x70 (Stops)

GEARBOX FOOT

MIXER FRAME

STOPS (REAR DISCHARGE) P001 497E

500.

0 m

ax.

[19.

7]

410.0[16.14]

WATER TANK

mm[in]

0,3

P001 498E

28


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004


MOUNTING THEDRUM FLANGE

Unit will be shipped with the fl ange locked in the zero degree position.This is to protect the main bearing and the fl ange seal from damage. Tolerances of the drum fi t are showed below.

The total run-out tolerance of max. 1 mm [0.04 in] for the drum rotation axis is strictly required.Fastening the drum to the fl ange TMG 51.2 with 12 bolts TMG 61.2 / 71.2 with 24 boltsM16; min. grade 8.8; tightening torque 195 Nm [1726 lbfin]

The exact alignment of gearbox and drum is required. Both must be in line with a gap tolerance TMG 51.2 : 10.5 0.5 mm [0.41 0.02 in] TMG 61.2 / 71.2 : 18.5 0.5 mm [0.73 0.02 in] between the drum fl ange and gearbox housing for the whole circumference; see below

If there is misalign of drum and gearbox or a wide total run-out tolerance, the main bear-ing and the fl ange sealing will have reduced life.

A

1 A

6.3

6.3DRUM FLANGE

140.

0 m

ax. D

rum

flan

ge

dia

[5.5

1]

530.

1+0.

6 D

rum

flan

ge

dia

[20.

87+

0.02

4]

GEARBOX OUTPUT FLANGE

mm[in]

Drum flange

P001 499E

1.5 max. x 45[0.6]

P003 00318.5

[0.73]P003 00210.5

[0.41]

The bolt must not be removed until adjusting

the drum

TMG 51.2 TMG 61.2 / 71.2

The exact alignment of gearbox and drum is

required for proper com-ponent life.

29


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004


MOUNTINGCONTROLLER TME

Machine wiring, see guidelines below:

The wiring must be done according to the connection diagram. All wires must be protected from mechanical abuse. Wires can be run in fl exible metal

or plastic conduits. Use 85 C [185 F] wire with abrasive resistant insulation. 105 C [221F] wire should be

considered near hot surfaces The minimum wire gage should be 1 mm [0.002 in2] Separate high current wires - >0,3 A - such as solenoids, lights, alternator or fuel

pumps from control wires. Run wires along the inside of, or close to, metal machine frame surface, where possible.

This simulates a shield, which will help minimize the effects of EMI/RFI radiation. Do not run the wires near sharp metal corners. Consider running the wire through a

grommet when rounding corners. Avoid running wires near moving or vibrating components. An experienced person should carry out the installation of CB-radios and mobile

phones. Special attention should be paid to the routing of the wires and the position of the antenna. In any case, the wiring should be separated from other wiring. TME controllers from Sauer-Danfoss are insensitive to electromagnetic fi elds up to a level of 100V/m. Should there be a problem, the radiation interference is probably too high. Possible reasons could be the antenna position, refl ection or interference through the wiring.

The electronics should be mounted in a way that the wiring is facing down. Unused cavities in connectors must be fi lled with cavity plugs.

Recommended tools for assembling wires to pins are available and help insure that the connections are mounted in the correct way.See below

Crimp Tool for Power Timer - AMP/16-pin: Id. No. 509 575 Die Set for 509 575: Id. No. 509 576

If you push in the pin into a wrong connector position you can remove the mechanical locked pin with the following tool:

Contact Extraction Tool for Power timer: Id. No. 517 024

The tools below are also available to assemble wire-pins for the proportional valve con-nectors: Crimp Tool for Micro Timer - AMP/2-pin: Id. No. 515 895 Die Set for 515 895: Id. No. 515 896 Contact Extraction Tool for Micro Timer: Id. No. 517 023

The wiring diagram is on the next page.

30


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004


WIRING DIAGRAM TME

INSTALLATIONSPACE TME

In order to accommodate the TME in the customer-specifi c housing, it is necessary to produce a cutout as illustrated below. Tightening torque max. 1 Nm [0.7 lbfft].

Externalstop switch

P003 022E

-+

F

4A

Batt.12/24V

DC

Battery (+)

Battery (-)

VCC Voltage (+)

1

2

3

Remote Station Cabin Station

4

5

6

7

8

9

10

11

12

13

14

15

16

Setpoint from Cabin

12V Valve (-)

24V Valve (-)

Remote/ON

Memoblink

PPU (-)

GND

Disable lost of feedback

PPU signal

Ext. Stop

VCC/2

VCC Voltage (+)

Setpoint to Remote

Remote/ON

Memoblink

GND

VCC/2

Valve 1 (+)

Valve 0 (+)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

(+)

Proportional valve 0CHARGE

Proportional valve 1DISCHARGE

PPU (2-wire)

AMP connector, 16-pin AMP connector, 16-pin

Option: Safety function can be invalidate by connecting.

72.4 0.3[2.85 0.01]

93.4

0.

3[3

.68

0.

01]

R3 0.1[0.12 0.004]

max. 5[0.20]min. 1[0.04]

min. 50[1.97]

mm[in]

P001 937E P001 938

31


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Hydraulic Fluid

FLUID SPECIFICATION

HYDRAULIC FLUID

CLEANLINESS

SUCTION FILTRATION

Please see Sauer-Danfoss literature 520L0463 (Hydraulic Fluids and Lubricants, Technical Information).Also refer to Sauer-Danfoss literature 520L0465 (Experience with Bio Fluids, Technical Information).

Please see Sauer-Danfoss literature 520L0467 (Design Guideline for Hydraulic Fluid Cleanliness, Technical Information).

The proper suction fi lter should be placed in the circuit between the reservoir and the inlet to the pump.

CHARGE PUMP FILTER

HYDRAULIC FLUID RESERVOIR

ADJUSTABLE CHARGE PRESSURE RELIEF VALVE

TO PUMP CASE

TO LOW PRESSURE SIDE ANDCONTROL

MANO-VACUUMMETER

P000 797E

Recommended -ratio can be found on cleanliness level table.

C ]F[

muminiM 04- ]04-[ tratsdloc,tnettimretni

detaR 401 ]022[

mumixaM 511 ]042[ tnettimretni)1 ,tnioptsettohehttA

.tropniardesacrotomehtyllamron

Temperature Range1)

mm 2 s/ ]SUS[

muminiM 7 ]94[ tnettimretni

dednemmoceRegnargnitarepo

08-21 ]073-07[

mumixaM 0061 ]0057[tnettimretni

tratsdloc

Viscosity

ssenilnaelcdiulfderiuqeRlevel

31/81ssalC6044OSI

dednemmoceR x

oitar-noitartlifnoitcusrof 54-53 (57= 01 )2

Cleanliness Level and x-Ratio

Improper fi lter selection can cause charge pump

cavitation.

32


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Pressure Measurement

REQUIRED TOOLS

PORT LOCATION PUMP

PORT LOCATION MOTOR

The service procedures described in this manual for Series TM pumps and motors can be performed using common mechanics tools.

The following is a list of the ports for each type of hydraulic unit. The recommended pres-sure gage and fi tting are also specifi ed.

troP noitcnuF ezisegaG gnittiF

1M "A"troperusserpmetsyS ]isp00001[rab006 ssobgnir-O5.1x21M

2M "B"troperusserpmetsyS ]isp00001[rab006 ssobgnir-O5.1x21M

3M erusserpegrahC ]isp0001[rab06 ssobgnir-O5.1x21M

5M+4M erusserpnotsipgnitautcA ]isp0001[rab06 ssobgnir-O5.1x21M

01M pmupegrahcmuucaV ssobgnir-O5.1x21M

2L+1L stropniardroerusserpesaC ]isp001[rab01 ssobgnir-O5.1x22M

S telnipmupegrahC ssobgnir-O2x24M

Port Location Pump

troP noitcnuF ezisegaG gnittiF

1M "A"troperusserpmetsyS ]isp00001[rab006 ssobgnir-O5.1x21M

2M "B"troperusserpmetsyS ]isp00001[rab006 ssobgnir-O5.1x21M

3M erusserpgnihsulfpooL ]isp0001[rab06 ssobgnir-O5.1x21M

2L+1L stropniardroerusserpesaC ]isp001[rab01 ssobgnir-O5.1x22M

Port Location Motor

L2

L1

X

M1

M2 M3

M5

M4

M10

S B

A

P003 004

X

P003 007

M1

M3

M2X

L2

L1

X

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DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Notes

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DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Start-Up Procedure

GENERAL

GEARBOX

HYDROSTATICS

Before start-up fi ll with EP-Gear lubricant SAE 90, API-Classifi cation GL 5, FZG power stage > 12 acc. DIN 51 354 (see table gear box Specifi c Data).Fill the lubricant up to the mark of the oil dipstick and check oil level regularly.

Before start-up fi ll the system in following way with oil acc. to Sauer-Danfoss literature520L0463.

After installing the transmission and corresponding pipeline connections, remove the plug from the gage pressure port M3 of the variable displacement pump. Fit a gage with a measuring range up to 60 bar [1000 psi] at this port.

Disconnect the charge pump inlet line from the charge pump inlet connection pipe. Fill the pump and motor housing by pouring fi ltered oil into the upper case drain

port. Fill the reservoir with recommended hydraulic fl uid. As soon as oil emerges from the

end of the disconnected charge pump inlet line tighten the pipe connection and continue to fi ll the reservoir.

Remove both connectors on the proportional valves of the variable displacement pump.

Allow the engine to turn app. 15 seconds by using the starter. Then start the engine and allow the pump to turn at idle speed [app. 650-700 min-1 (rpm)].After initial fl uctuations in pressure the charge pressure should be settle downto 191 bar [27514.5 psi]. Check the oil level in the sight glass. Refi ll, if necessary. Raise the speed to normal operating speed. The gage should now indicate the pres-

sure setting of the charge pressure relief valve. If charge pressure is not maintained at the proper setting, stop the engine and fi nd

the fault in accordance with the troubleshooting guide. Stop the engine and fi t the connectors to the proportional valves of the variable dis-

placement pump. Restart the engine, check the pump should remain in the neutral position (no drum

rotation). With engine at normal operating speed, app. 1500-1600 min-1 (rpm), select the lowest

position of on the TME rotary switch for the drum rotation direction for charge and discharge.

If the drum turns in the wrong direction, stop the engine. Remove the connectors for the proportional valves on the variable displacement pump. Switch and connect again.

Restart the engine and check the rotation direction of the drum once more. If okay, turn the drum slowly in both directions for 5 minutes.

Check all joints and connections for leaks. Check CSD-function with the pre-selected Transport Mode on the controller while

varying the engine output speed. Under these circumstances, the drum speed should

Pump, motor and gearbox are shipped without oil!

Level measurement by screwed in dipstick.

The pump must be in zero position.

Check and make sure that the rotary switch on the controller - Remote and

Cabin - are in neutral posi-tion

35


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

be constant at 2 min-1 (rpm). Check the functions for TME controllers at a engine speed approximately

1500-1600 min-1 (rpm) (direction/speed/stop-start on the remote/switch over from the cabin to remote).

Warm up the system and check again for leaks. Stop the engine. Remove the gage from the connection port M3. Replace the plug

and tighten with the proper torque. Check oil level in the sight glass of the reservoir and fi ll to the proper level, if neces-

sary.

Start-Up Procedure

HYDROSTATICS(continued)

Tighten up any leaking joints and other connec-tions while system is not

under pressure.

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DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Maintenance

GEARBOX TMG

HYDROSTATICTMP AND TMM

First oil change should be after 100 hours, then after every 1000 hours, but at least once a year. Use only recommended gear lubricants; see Sauer-Danfoss literature 520L463 (Hydrau-lic Fluids and Lubricants, Technical Information).

The level of the oil should be checked daily. In case of loss of oil, the leak should be recti-fi ed and refi ll oil, if necessary.

Periodically clean the gear housing and inspect for loosened screws and bolts.

Gearboxes Series TMG 51.2, 61.2 and 71.2 are designed and manufactured for safe opera-tion and the highest level of technology. However, there are certain dangers inherent if they are improperly operated or if they are used for other purposes than they were intended, for example, by unskilled personnel. This may result in dangers for life and limb dangers for machines and other company assests adverse effects on the effi ciency of the operation Any person involved in the start up, maintenance, and inspection of the gearbox TMG or the hydrostatic transmission, must read and understand the appropriate Service Manual.

Sauer-Danfoss offers training programs.

The fi lter must be also changed if the inlet vacuum pressure is less than 0.7 bar absolute [-9 in. Hg] with oil operating temperatures higher than 50 C [122 F].A continuous inlet pressure of less than 0.5 bar absolute [-15 in. Hg] is not permissible.The fi lter may require changing, or the oil temperature is to low, or the viscosity of the oil is too high (too thick oil).

The oil should be changed after maximum 100 hours of operation. The second oil change should be after 500 hours. Thereafter, every 1000 hours or at least once a year.It is not permissible to mix oils of different brands.Change oil fi lters when changing the oil.

Carry out a leak test on transmission (inlet line, fi lter, pipe- and hose lines, valves, pump and motor) giving due consideration to service life, environmental protection and reduc-tion of oil consumption. Check the reservoir for proper oil level via the sight glass and refi ll, if necessary.

SAFETY

When cleaning with a high pressure water jet do not

direct the jet onto the fl ange shaft seal, because

this may lift the seal lip and force contamination

underneath the seal lip, resulting in premature

wear and damage of the lip seal.

Tighten up any leaking joints and other connec-tions while system is not

under pressure.Replace defective seals.

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DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Maintenance

Check hydraulic hoses periodical and change when there is any damage or ageing (see manufacturers instruction). Replacement hoses should be in accordance to specifi ca-tions. When reassembling do not exchange connection ports of pipes and hoses.When exchanging system pressure ports, the direction of drum rotation will be changed.

Make certain that the oil fi lter for ventilation of the oil reservoir is regularly cleaned, since the input pressure may be affected if it is dirty. The cooler surface should be kept free from contamination.Cotton rags or lint cleaning cloths must not be used for cleaning. Use lint-free materials only.When changing the oil, be sure the area around the cap is free from foreign objects. The level of the oil should be checked daily using the gage glass. In case of loss oil, the leak must be rectifi ed and refi lled, if necessary.

HYDROSTATICTMP AND TMM(continued)

Without this safety pre-cautions there could be danger for body and life

e. g. danger for machines and property.

Use only recommended fl uids acc. Sauer-Danfoss

literature 520L0463.It is not permissible to mix

oil of different brands.

38


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Troubleshooting

Check

Pump input speed.

Charge pump pressure in neutral Values: 21.51bar [31214.5 psi //1500 rev/min // suction line temperature 503 C[12237 F //Gage Port M3.

Proportional ValveValue: 20 bar [290 psi]at maximum current.

Charge pump inlet vacuumValues: > 0,7 bar [10 psi] // 1500 rev/min //suction line temperature50 3 C [12237 F //Gage Port M10.

Oil cooler.

Electrical fan drive.

Electrical fan drive.

Description

Engine speed to low.

Incorrect setting on the charge pressure relief valve.

Control pressure to low.

Dirty fi lter will increase the inlet vacuum.

Dirty oil cooler will be infl u-ence cooling capability.

Temperature switch failed.

Electrical motor failed.

Action

Select required engine speed.

Stop the engine.Install gage in port M3Start the engine and mea-sure the pressure in neutral. If the pressure is low, turn the screw clockwise to the correct value. If not, please check and change the relief valve.

Stop the engine.Disconnect the speed sensor, install gage port in M4 (M5) Start the engine. Select maximum position on the TME rotary switch.If the control pressure is less than 20 1 bar[29014.5 psi], change the proportional valve.

Check inlet pressure.If too high, change the fi lter.

Clean the cooler.

Change temperature switch.

Change electrical motor.

Action

DRUM SPEED DOESN T REACHED MAXIMUM SPEED

SYSTEM OPERATING HOT

39


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Troubleshooting

DRUM SPEED DROOPS DOWN DEPENDING ON INCREASED LOAD

DRUM ROTATING IN ONE DIRECTION ONLY

DRUM DOESN T STOP IF THE ROTARY SWITCH TURNED TO NEUTRAL

REMOTE STATION IN STAND BY; SIGNALLED BY FLASHING LED

Check

Charge pump pressure in neutral Values: 21.51bar [31214.5 psi //1500 rev/min // suction line temperature 503 C[12237 F //Gage Port M3.

Loop fl ushing shuttle spool.

Pump displacement control.

Multifunction valve.

Stop the engine immedi-ately!

Set the rotary switch to neutral; touch the yellowswitch; confi rmed by lights up LED.

Change the transmission, pump and motor.

Check loop fl ushing shuttle spool which maybe stick-ing in one direction Check the springs of the shuttle spool, too.

Make cross-check with both controller (Remote/Cabin).If the problem changed, replace the failed controller. If not, use the Emergency Tool Kit1) to discharge the drum and later, change the proportional valve.

If the problem changes direction, replace the valve.

Using the Emergeny Tool Kit1) for discharging and later on, replace the propor-tional valve.

Replace the Remote Station.

Action

Description

Drum speed will be go slower if the load increases and charge pressure droops too low.

Pre-selected direction and speed but the drumdoesn t turn.

Electrical proportional valveis operating improperly.

Interchanging the valve to see and how the failure isrelated to the valve func-tion.

Proportional valve is stick-ing from contamination.

Light on signalls active status.If not, this means con-tinuously fl ashing and the switch operating improp-erly.Description

1) Or valve manual override on units with this options.

40


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Troubleshooting

Check

Set the rotary switch to neutral; touch the yellow switch; confi rmed by off LED.

Active controller signalled through lighted LED.

Means, function transfer toLED still on, the switch is operating improperly.

If not, the required supply Check the fuse in the supply

DRUM STOPPED DURING OPERATION

voltage is not present. LED indicats active status.

wire.If destroyed, replace the fuse and check the reason for the short circuit.Disconnect the speed

Open the control panel in order to get access to back of TME -Controller.

Disconnect AMP wire connector from the TME controller (use screw driver to unlock red fi xture).

Remove the (4) screws. (Use Allen-Key Torx T9 or 2 mm metric).

Remove the (2) clamp-caps.

Remove the TME-controller and install the new one in the reverse method.

Remark: Torque screws to max. 1 Nm.

P001 938

SCREW DRIVER

RED FIXTURE

F000 873

HOW TO REPLACE THE TME-CONTROLLER

CABIN STATION ACTIVE; SIGNALLED BY LIGHTS UP LED

Active controller signalled through lighted LED.

sensor connector andoperate once more. If the system works now - but in open loop control- change the speed sensor. After change check thecorrect function again.

41


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

EMERGENCYDISCHARGING

Emergency Discharging

STOP the truck engine at fi rst!

Remove plug M12x1.5 from the actu-ating cylinder B 1)

Install screw M12x1.5 with seal lock nut into the actuating cylinder until (appr. 80mm [3.15 in]) you feel notice-able resistance, (when the screw comes in contact with actuating piston).

Start truck engine (low idle is recom-manded for slow discharge).

Turn screw clockwise against actuat-ing piston so the pump displacement increases and the drum turns in discharge direction at desired speed.

Tighten lock nut to prevent external leakage during operation.

1) This description concerns to our recommended standard installation. If drums turns with the tool on servo cylinder B in wrong direction, change the tool to servo cylinder A.

IMPORTANT:The special tool is an

essential part of the truck mixer emergency tool kit.

Main pressure port A

Main pressure port B

Rear CoverActuating cylinder A

Actuating cylinder B

TMM, main ports show downwards 1) TMP, right hand rotation

F000 876 F300 684

F000 875

F300 689P001 963 F300 685

F300 686F300 690

F300 687

42


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Notes

43


DKMH.PS.800.B1.02 520L0482 Rev A 05/2004

Notes

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Sauer-Danfoss specializes in integrating a full range of system components to provide vehicle designers with the most advanced total system design.

Sauer-Danfoss provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world.

Sauer-Danfoss (US) Company2800 East 13th StreetAmes, IA 50010, USAPhone: +1 515 239-6000, Fax: +1 515 239 6618

Sauer-Danfoss (Neumnster) GmbH & Co. OHGPostfach 2460, D-24531 NeumnsterKrokamp 35, D-24539 Neumnster, GermanyPhone: +49 4321 871-0, Fax: +49 4321 871 122

Sauer-Danfoss ApSDK-6430 Nordborg, DenmarkPhone: +45 7488 4444, Fax: +45 7488 4400

www.sauer-danfoss.comDKMH.PS.800.B1.02 520L0482 Rev A 05/2004

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