Series TM Transit Mixer Drive System Service Manual Functional Description TRANSIT MIXER MOTOR – TMM
The fixed displacement motor TMM is designed to convert an input of hydraulic power into a mechanical torque and speed output power. The high-pressure hydraulic fluid enters through the input por t. The fluid pressure builds behind the piston causing them to move down the swash plate. As the pistons returns up t he swash plate again, the fluid 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
F000 857
F300 698
CROSS SECTION – TMM SHUTTLE SPOOL
ORIFICED LOOP FLUSHING VALVE
CYLINDER BLOCK
OUTPUT SHAFT
BEARING PLATE VALVE PLATE
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
PISTON P001 953E
7
Series TM Transit Mixer Drive System Service Manual Functional Description LOOP FLUSHING DEVICE
The integrated loop-flushing device in the motor is used to flush out a certain oil flow from the closed circuit system for cooling. The orifice loop flushing valve defines a fixed flow 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 flushing shuttle spool, controlled through the high-pressure side, provides a circuit between the low-pressure side of the closed loop and the orifice loopflushing valve. At the time of first operation a rapid air separation from the closed circuit is also achieved by the flushing device and in addition, it is ensured that unavoidable “installation dirt“ is flushed out at the same time and can be picked up by the suction filtering
LOOP FLUSHING DEVICE X
F000 857
VIEW “X” F000 857
Cross Section ORIFICED LOOP FLUSHING VALVE
LOOP FLUSHING SHUTTLE SPOOL
8
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
P001 954E
Series TM Transit Mixer Drive System Service Manual Functional Description TRANSIT MIXER 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 flange will be compensating for the deflection of the truck frame mainly under off-road conditions. The optional water pump drive is on the left or right drum flange side, if you see from drum flange side. TMG 61.2 with Water Pump Drive on the left side
TMG 61.2 without Water Pump Drive
F000 860
F000 872
CROSS SECTION – TMG 61.2 WATER PUMP DRIVE SHAFT (90 degree turned)
DRUM FLANGE
MAIN BEARING
INPUT SUN GEAR
2-ND STAGE 1-ST STAGE DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
CURVED TEETH COUPLING P001 986E
9
Series TM Transit Mixer Drive System Service Manual Functional Description 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 configuration - 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
F000 861
10
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Cross Section –Speed Sensor
P001 987
Series TM Transit Mixer Drive System Service Manual Functional Description TRANSIT MIXER ELECTRONIC – 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 flow, which is established, 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 controller. The desired and actual values are compared and the pump flow 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 flashes. 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 transfered to the remote controller. The flashing 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 flashing LED will change to full light, which means the controller is switched on. TME Remote Station ROTARY SWITCH
TME Cabin Station ROTARY SWITCH
LED
TOUCH SWITCH
P001 956
TOUCH SWITCH
LED
P001 957
Symbol used on the Controller
= Charging/Transport
P001 958
= Memory Switch “Stop/Start” Remote Station P001 960
= Discharging
P001 959
= Changeover Switch Cabin Station
P001 961
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
11
Series TM Transit Mixer Drive System Service Manual Functional Description 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 th e 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 actuating pressure is established on the actuating cylinder (7) and therefore a stroke, which adjusts the swash plate angle and defines the flow delivery of the main pump (2). Depending on the speed of the pump and displacement, the pump flow 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 preselected set point of the drum speed and controls the current to the electrical proportional valves (6) which sets the swashplate of the pump to the appropriate flow 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 filtered (12) oil. The integrated flushing device (11) in the TMM motor, comprising an alternating slide and permanently set nozzle flushing valve, ensures a defined 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 filtering system (12) connected upstream. At the time of first commissioning rapid air separation from the working circuit is also achieved by the flushing device (11) and, in addition, it is ensured that unavoidable “installation dirt” is flushed out at the same time and can be picked up by the suction filtering system (12).
CIRCUIT DIAGRAM – TM TMP
TME
6
TMM
TMG
13
L1
6
M1
L1
M1
N
10
n
M3
A 8 A
M5 M4
14
5 2
3 9
1
5
4
11
8
7
B M10
S
L2 12
M2
B L2
M3
M2
15 P001 962
12
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Series TM Transit Mixer Drive System Service Manual Technical Specifications – Axial Piston Pumps TMP GENERAL SPECIFICATIONS
Specifications for axial piston variable displacement pump are listed on these pages. For definitions of the various specifications, see the related pages in this publication. General Specifications Pump type
Axial piston pump with variable displacement swashplate axial piston design
Direction of rotation
Clock wise or counter-clock wise
Istallation position
Discretionary, the housing must always be f illed with hydraulic f luid
Other system requirements Circuit overpressure protection, suitable reser voir
Specific Data
SPECIFIC DATA
Frame size
Dimension Vg
cm3 [in3]
070 70 [4.27]
089 89 [5.43]
Qmax
l /min [US gal /min]
203 [54]
258 [68]
k W [hp] k g [lb]
142 [190]
180 [242]
Displacement Maximum f low Maximum corner power
p cornermax
Weight
m
Mass moment of inertia of the internal rotation parts
J
k gm2 [lbf •f t2]
0.01777 [0.42]
Type of mounting
Four (4) bolt f lange, SAE f lange conf iguration
Pipe connections
Main pressure por ts: SAE f lange Remaining ports: SAE straight thread O-ring boss
Shaf t conf iguration
∅ 100 mm [3.94 in] joint f lange (DIN /ISO) or Splined ANSI
Speed Limits
Case Pressure
TECHNICAL DATA
bar
[psi]
Rated pressure
3
[44.0]
Maximum pressure (cold start)
5
[73.0]
Frame size At. maximum displacement
Nm /bar [lbf •in /1000 psi]
Frame size
min-1 (rpm) 070
089
Minimum speed
500
Rated speed
2500
Maximum speed
2900
System Pressure Range, Input
Theoretical Torque
ELECTRICAL PROPORTIONAL VALVES
61 [134]
070 1.11 [680]
089 1.42 [864]
Maximum delta pressure
General Data • Protection class: • Electrical connections: • Supply pressure pPmax:
DIN VDE 0470: IP65/IPX7 AMP Junior Power Timer 50 bar [725 psi]
Electrical Data • Insulation material: • Duty cycle:
Class H, 180 °C [356 °F] 100 %
bar
[psi]
420
[6090]
Electrical Data Voltage
12 V
24 V
R20 in Ω I1 in mA
5.3±5 %
21.2±5 %
600±10
300±10
I2 in mA
1500±10
750±10
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
13
Series TM Transit Mixer Drive System Service Manual Technical Specifications – Axial Piston Pumps TMP CIRCUIT DIAGRAM Ports:
CB
A, B
= Main pressure lines
L1, L2
= Case pressure or drain ports
M1,M2 = Gage port system pressure port “A” + “B”
CA
M3
= Gage port charge pressure
M4,M5 = Gage port servo pressure L1
M10
M1
= Gage port charge pump inlet pressure
A
S
M3
= Charge pump inlet
CA, CB = Electrical proporti onal valve
M5 M4
B
M10
S
L2
M2 P001955E
DETERMINATION OF NOMINAL PUMP SIZES
14
Metric System
Inch System
Output flow:
Vg • n • ηv Qe = _________ 1000
l/min
Vg • n • η Qe = _________v 231
[US gal/min]
Input torque:
Vg • ∆p Me= __________ 20 • π • ηmh
Nm
Vg • ∆p Me = _________ 2 • π • ηmh
[lbf•in]
Input power:
Me • n Qe • ∆p Pe = ______ = ______ 9550 600 • ηt
kW
Vg • n • ∆p Pe = ___________ 396 000 • ηt
[hp]
Input Speed:
Qe • 1000 • ηv n = _____________ Vg
min-1
n
cm3 bar
[in3] [psid]
bar bar
[psid] [psid]
Vg ∆p ηv ηmh
= = = =
ηt pHD pND
= = =
Pump displacement per rev. pHD - pND Pump volumetric efficiency Pump mechanical-hydraulic (Torque) efficiency Pump overall efficiency High pressure Low pressure
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Qe • 231 • ηv = ___________ Vg
min-1 (rpm)
Series TM Transit Mixer Drive System Service Manual Dimensions – Axial Piston Pumps TMP AXIAL PISTON PUMPS – SIZE 070 AND 089 Connector CA AMP Junior Power Timer
106.0 [4.175] 49.0 [1.92]
Case drain port L1 use highest port as outlet M22x1.5 11.0 min. [0.433] depth
Ø15.0 +0.8 -0.3 [0.591+0.31] -0.12
] 5 5 2 . 2 . 7 2 ] 5 [ 0 . 4 5 ] 8 3 . 4 . 0 6 6 4 1 1 5 . [ 1 4 [
54.8 [2.157]
2.3 [0.091] 8.5 [0.335] (CCW)
(CW)
] 0 . 3 5 7 . 9 3 [
Ø12.0 [0.472] 17.0 [0.679]
12.4 [0.49]
57.2 [2.25]
] 0 . 6 0 5 . 9 [ 3
Ø60.0 [2.362]
5 2 0 . ] . 3 1 0 0 0 . 0 ] ] ± ± . 1 0 0 5 . . 0 ± 4 3 7 5 0 . 8 4 [ 9 3 . 0 9 [ . Ø 6 1 3 2 Ø [ 1 Ø
114.5 [4.51]
] 8 . 9 7 0 . 2 1 ] [ 0 . 3 0 3 . 1 4 1 [
] 0 . 5 . 2 1 9 1 2 [
X
M42x2 20.0 [0.79] depth
149.0 [5.86]
Case drain port L2 M22x1.5 11.0 min. [0.433] depth
57.25 [2.25]
Split flange boss DN 25 Typ I 40MPa series per ISO 6162 4 Thread: M12 21 [0.83] full thread depth
Size and rotation direction are machinde beside the name plate; as example • 7L for 70 cc, left hand.
] ] 9 1 0 . 5 1 0 1 0 3 . 0 . 8 . Ø 0 0 - 0 [ 0 4 . 4 7 5 2 . 2 Ø [
Connector CB AMP Junior Power Timer
mm [in]
254.0 [9.98] 262.0 [10.32] 304.0 [11.96] 313.0 [12.32]
146.0 [5.75] 216.0 [8.50]
P001 988E
Direction of Rotation NFPE
Por t "A" Por t "B" Clock wise (cw) Counterclock wise (ccw)
valve
Output
Input
CA
Input
Output
CB
X 105.00 [4.13] 89.00 [3.50]
Gage port M1 System pressure port "A" M12x1.5 12.7 [0.5] min. depth
Gage port M4 Servo pressure M12x1.5 High pressure relief valve port A Charge pressure relief valve
Charge pump inlet S
High pressure relief valve port B
Gage port M10 Charge pump inlet pressure M12x1.5 12.7 [0.5] min. depth
Gage port M3 Charge pressure M12x1.5 12.7 [0.5] min. depth
Gage port M2 System pressure port "B" M12x1.5 12.7 [0.5] min. depth
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Gage port M5 Servo pressure M12x1.5
P001 989E
15
Series TM Transit Mixer Drive System Service Manual Dimensions – Axial Piston Pumps TMP AXIAL PISTON PUMPS – SIZE 070 AND 089 (continued)
Option Spline Shaft – Size 070
Option Spline Shaft – Size 089
mm [in] 56.00 [2.207] 45.00 max [1.772]
33.00 [1.31] Full spline lenght 7 ] 1 . 7 0 0 0 - 0 . 5 . 0 0 4 8 3 5 Ø 3 . 1 x [ a ] m 5 0 1 . 0 . 3 0 [ 8 0 1 Ø M
56.00 [2.207]
R6 [0.24]
x a ] m 5 0 1 . 0 . 3 [ 0 8 Ø
0 ] 0 . 3 9 1 . 2 [ 1 Ø
Spline data Pitch dia
: 3 3.338 [1.313] Pr es su re a ng le : 3 0˚ Number of teeth : 21 Pitch : 16/32 ANSI B92.1-1970 class 5 fillet root side fit
45.00 max [1.772]
33.00 [1.31] Full spline lenght 9 ] 0 . 4 0 0 0 . ± 0 0 6 . ± 7 8 . 3 4 1 [ Ø
R6 [0.24]
0 1 M
0 ] 0 . 6 2 2 . 3 [ 1 Ø
Spline data Pitch dia
: 3 6.513 [1.438] Pr es su re a ng le : 3 0˚ Number of teeth : 23 Pitch : 16/32 ANSI B92.1-1970 class 5 fillet root side fit
20.00 [0.792] 28.50 max [1.122] 51.00 [2.00]
P001 990E
20.00 [0.792] 28.50 max [1.122] 51.00 [2.00]
P001 991E
Option Auxiliary Pad SAE ”A” – Size 070 and 089
331.00 [13.05] 317.00 [12.49] 10.50 [0.41]
15.00 [0.591]
Thread (2x) M10, 19.0 [0.748] deep
1.20 [0.05]
] 3 5 0 1 . . 0 0 0 + 0 0 + 6 . 2 5 8 2 . Ø 3 [
2 ] 1 . 3 7 4 . 8 [ 3 Ø
5 ] 7 8 3 . 8 6 1 . 0 [ 4 1
for O-ring 1.78x82.3 [0.07x3.24] Spline data Pitch dia
: 1 4.288 [0.563] Pressure angle : 30˚ Number of teeth : 9 Pitch : 16/32 ANSI B92.1-1970 class 6 fillet root side fit Full spline len ght : 17 .0 [0.669]
16
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
106.375 [4.188]
P001 992E
Series TM Transit Mixer Drive System Service Manual Dimensions – Axial Piston Pumps TMP AXIAL PISTON PUMPS – SIZE 070 AND 089 (continued)
Option Auxiliary Pad SAE ”B” – Size 070 and 089
mm [in]
317.00 [12.49]
334.00 [13.15] 15.00 [0.591]
Thread M12 (2x) deep min. [0.787]
10.50 [0.41] 1.20 [0.05]
] 3 5 1 . 0 0 0 0 . + 0 0 5 + 6 . 1 2 0 0 . 1 0 Ø 4 [
0 8 . ] 6 2 . 0 4 1 [ Ø
0 ] 0 . 5 6 7 . 4 [ 5 1
for O-ring 1.78x101.35 [3.99 x 0.07] Spline data Pitch dia
: 20.6375 [0.8125] Pressure angle : 30˚ Number of teeth : 13 Pitch : 16/32 ANSI B92.1-1970 class 6 fillet root side fit Full spline leng ht : 34. 0 [1.330]
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
P001993E
17
Series TM Transit Mixer Drive System Service Manual Technical Specifications – Axial Piston Motors TMM GENERAL SPECIFICATIONS
Specifications for axial piston fixed displacement motors are listed on these pages.
General Specifications Motor type
Axial piston motor with f ixed displacement swashplate axial piston design
Direction of rotation
Clock wise or counter-clock wise (bi-directional)
Istallation position
Discretionary, the housing must always be f illed with hydraulic f luid
Other system requirements Circuit overpressure protection, suitable reser voir
SPECIFIC DATA Specific Data Frame size
Dimension
070
089
3
Qmax
cm [in3] l /min [US gal /min]
70 [4.27] 203 [54]
89 [5.43] 258 [68]
p cornermax
k W [hp]
142 [190]
180 [242]
Weight
m
k g [lb]
35 [77]
Mass moment of inertia of the internal rotation par ts
J
k gm2 [lbf •f t2]
0.01777 [0.42]
Displacement
Vg
Maximum f low Maximum corner power
Type of mounting
Four (4) bold f lange, SAE f lange conf iguration
Pipe connections
Main pressure ports: SAE f lange Remaining ports: SAE straight thread O-ring boss
Shaf t conf iguration
Splined ANSI
TECHNICAL DATA Speed Limits
Case Pressure bar
[psi]
3
[44.0]
Rated pressure Maximum pressure (cold start)
5
[73.0]
Theoretical Torque Frame size At. maximum displacement
18
Nm /bar [lbf •in /1000 psi]
min-1 (rpm) 070
089
Rated speed
2500
Maximum speed
2900
System Pressure Range, Input 070
089
1.11 [680]
1.42 [864]
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Frame size
Maximum delta pressure
bar
[psi]
420
[6090]
Series TM Transit Mixer Drive System Service Manual Technical Specifications – Axial Piston Motors TMM CIRCUIT DIAGRAM
L1
M1
Ports:
A
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 flushing pressure
B L2
DETERMINATION OF NOMINAL MOTOR SIZES
M3
M2
P003 021
Metric System Input flow:
Inch System Vg • n Qe = ________ 1000 • ηv
Vg • ∆p • ηmh Output torque: Me= ___________ 20 • π
l/min
Vg • n Qe = _______ 231• ηv
[US gal/min]
Nm
Vg • ∆p • ηmh Me = ___________ 2•π
[lbf-in]
Me • n Qe • ∆p • ηt Output power: Pe = ______ = __________ kW 9550 600
Vg • n • ∆p • η Pe = ____________t [hp] 396 000
Qe • 1000 • ηv Output Speed: n = _____________ Vg
min-1
n
cm3 bar
[in3] [psid]
bar bar
[psid] [psid]
Vg ∆p ηv ηmh
= = = =
ηt pHD pND
= = =
Motor displacement per rev. pHD - pND Motor volumetric efficiency Motor mechanical-hydraulic (Torque) efficiency Motor overall efficiency High pressure Low pressure
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Qe • 231 • ηv = ___________ Vg
min-1 (rpm)
19
Series TM Transit Mixer Drive System Service Manual Dimensions – Axial Piston Motors TMM AXIAL PISTON MOTORS – SIZE 070 AND 089 249.00 [9.803]
mm [in] 207.00 [8.150] 118.00 [4.650] Case drain port L2 use highest port as outlet M22x1.5 12.40 [0.490] 12.00 [0.470] 31.20 Full spline lenght [1.228]
Size identification are machined here : 7 for 70 cc 9 for 89 cc
L2
. x a ] 8 m 1 0 6 . 5 . 2 6 [ 6 Ø
] 0 0 0 . 4 7 5 . 9 3 [
] 0 6 0 . 4 5 3 . 8 3 [
] 0 6 0 . 4 5 3 . 8 3 [
Orificed loop flushing valve Ø15.00 +0.8 -0.3 [0.591 +0.031] -0.012
5 ] 0 . 2 0 - 0 0 0 0 . . 7 0 2 9 1 9 Ø 9 . 4 [
L (ccw)
] 0 2 3 . 9 0 4 . 9 7 1 [
L1 Case drain port L1 M22x1.5
72.00 [2.835] 122.00 [4.803]
46.30 max. [1.823] 55.00 [2.169]
218.00 [8.583] 251.00 [9.882]
R (cw)
] 0 ] 8 0 7 5 . 0 0 . 5 4 5 4 . 4 . 1 4 6 6 1 [ 1 [
114.50 [4.508]
Spline data Pitch dia
: 3 3.338 [1.313] Pr es su re a ng le : 3 0˚ Number of teeth : 21 Pitch : 16/32 ANSI B92.1-1970, class 5 fillet root side fit
146.00 [5.748]
Direction of Rotation
Gage port M2 System pressure port B M12x1.5
Por t "A"
Por t "B"
Clock wise (cw)
Output
Input
Counterclock wise (ccw)
Input
Output
Gage port M1 System pressure port A M12x1.5 Loop flushing shuttle spool
Split flange boss DN 25 Typ I 40MPa series per ISO 6162 4 Thread: M12 21 [0.83] full thread depth
A
41.60 [1.64]
] 0 9 8 . 0 . 7 1 2 [
Gage port M3 Loop flushing pressure
57.20 [2.250]
164.00 [6.460]
P001 996E
A
20
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Series TM Transit Mixer Drive System Service Manual Technical Specifications – Gearbox TMG GENERAL SPECIFICATIONS General Specifications Gearbox
Size 51.2 and 61.2: Two-stage planetary Size 71.2 : Two-stage planetary with initial spur gear stage
Direction of rotation
Clock wise and counterclock wise
Purpose Options
Drive the drum, carry the torque f orces and a par t of the drum weight With or without water pump drive
Others
Prepared to carry a water tank
SPECIFIC DATA Specific Data Gearbox type
TMG
Gearbox size
51.2
61.2
71.2
Gearbox ratio Gearbox ef f iciency
i
101.9 0.96
111.5 0.96
131.3 0.95
Max. dynamic swivel angle of the drum f lange
˚
±6˚
±7˚
±7˚
Slope of the gearbox main shaf t (design)
˚
15˚
15˚
15˚
Max. drum installation angle (ad justed through f rame support) Weight Lubricant volume
up to 7 m3 : max. 15˚ 8 and 9 m3 : max. 12˚ 10 m3 : max. 11˚ 12 m3 : max. 11˚
˚ k g [lb]
253 [558]
325 [717]
333 [735]
l /min [US gal /min]
12 [3.2]
16 [4.2]
16 [4.2]
Lubricant type
EP-Gear lubricant
API-class FZG powerstage acc. to DIN 51 354
GL-5 >12
Vicosity grade 1)
1)
SAE 90
Attention: Gear lubricant w /o EP-Additives reduce the lif e by 80 %.
TECHNICAL DATA Technical Data Gearbox size
51.2
61.2
71.2
Nm [lb-f t]
51 000 [37 600]
61 000 [45 000]
71 000 [52 350]
Permissible weight of the f ull drum
t [lb]
21.5 [47 410]
32 [70 563]
32 [70 563]
Permissible static radial load to the drum f lange Permissible dynamic radial load to the drum f lange (intermittent)
k N [lbf ] k N [lbf ]
130 [29 224] 265 [59 572]
180 [40 464] 350 [78 680]
180 [40 464] 350 [78 680]
Permissible static axial load to the drum f lange Permissible dynamic axial load to the drum f lange (intermittent)
k N [lbf ] k N [lbf ]
50 [11 240] 160 [35 968]
65 [14 612] 230 [51 704]
65 [14 612] 230 [51 704]
min-1 (rpm)
15
14
14
18 18
18 16
16 16
Max. output torque
Output speed TM-perf ormance Max. output speed w /o water pump drive Max. output speed with water pump drive Min / . max. operating temperature
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
-1
min (rpm) min-1 (rpm) ˚C [˚F]
-20 [-4] up to +85 [+185]
21
Series TM Transit Mixer Drive System Service Manual Dimensions – Gearbox TMG GEARBOX SIZE 51.2 mm [in]
458.0 [18.03] 200.0 [7.87]
12 x 30 ˚
159.0 [6.260]
200.0 [7.87] Cover for speed sensor connection
3 0 ˚
Oil dip stick and oil inlet
˚ 6 0 6 x
114.6 [4.51]
˚ 0 6
0 . ] 0 2 . 2 7 4 1 [ Ø
] 6 . 1 4 5 . 1 4 1 [
M8 16.0 [0.63] deep
Connection for waterpump i = 0.41
70.0 [2.756] 200.0 [7.87]
M12 20.0 [0.79] deep
194.5 [7.66]
] ] 0 . 2 0 ] 0 . . 1 0 6 0 . 2 5 . . 5 2 1 [ 3 0 0 1 [ [
200.0 [7.87]
0 75.0 -5.0
. x ] a 7 8 m 7 . 0 . 0 0 [ 2
Parallel key A 6x6x20 DIN6885
0 [2.953-0.2 ]
Lubrication oil outlet
0 Ø18.0 -0.011 (h6) 0 -0.0004 ]
[0.7087
Cover for water-pump-connection
Ø100.0 +0.054 (H8) 0 [3.937 +0.0021 ] 0 19 8 . 0 [ 7. 7 8 ] 110 . 0 [ 4 .4 3 ]
Air breather
. 0 9 ] 5 5 1 0. [
0 . ] 6 0 . ] 5 8 6 7 7 2 . 2 . 2 [ 8 4 6 R 1 [ Ø
14.0 [0.55]
10 .0 [ 0 .3 9 ]
0. 3 0 +
. 0 1 2
Securing device during transport Displayed position turned 62.5˚ ] 0 . 7 7 . 1 6 0 [ Ø
]
2 1. 0 + 0
Variation of drum flange Dynamic swivel 4 1.0 angle max. [
4 . 8 [ 0
Ø 2 2 .0 [ 0 .8 7 ]
1.6 3 ]
Ø 3 1 .5 [ 1.2 4 ]
O-ring 124x4 [4.88x0.16] NBR 70
105.0 [4.13]
Ø 4 0 .0 [ 1.5 7 ]
) 7 H ] (
2 0 4 0 . 0 . 0 0 0 0 + +
˚ 6
0 0 . 0 . 7 5 2 [ 1 Ø
˚ 6
Ø 4 0 .0 [ 1.5 7 ] ]
Spline data Pitch dia
: 33.34 [1.313] Pr es su re a ng le : 3 0˚ Number of teeth : 21 Pitch : 16/32 ANSI B92.1-1970, class 6 fillet root side fit
. 0 7 0 9 5 1. [
. 0 7 ] 7 6 1 0. [
57.0 [2.24] 205.0 [8.06]
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
˚ 5 1
18.0 [0.71]
Ø 2 2 .0 [ 0. 8 7 ]
454.0 [17.87]
22
7 4 .5 [ 2. 9 3 ]
5 3 .0 6 7 . [ 2. 0 9 ] [ 2 0 .6 4 ] 3 0 .0 [ 1.18 ] 18 8 . 0 [ 7. 4 ]
. 0 ] 8 4 6 1 1 . 6 R [6
]
8 2 . 0 0 0 . ± 0 ±
0 . 0 5 0 8 . 5 6 9 Ø 1 [
) 9 ] h ( 1 6 5 0 5 0 . 1 . 0 0 0 0 -
7 0 . 8 . 0 0 3 2 5 [ Ø
. 0 5 ] 0 7 0 5. 4 1 [
. 3 ] 6 0 4 . 7 2 9 [
10.5 [0.41] 55.0 [2.165]
P001 997E
Series TM Transit Mixer Drive System Service Manual Dimensions – Gearbox TMG GEARBOX SIZE 61.2 200.0 [7.87] 147.5 [5.81]
458.0 [18.03] 7.5˚
mm [in]
200.0 [7.87] 15 ˚
Cover for speed sensor connection
2 4 x 1 5 ˚
81.5 [3.209]
Oil dip stick and oil inlet
114.6 [4.51]
˚ 6 0 6 x ˚ 6 0 0 . ] 0 2 2 7 . 1 4 [ Ø
] 6 . 1 4 5 . 1 4 1 [
M8 16.0 [0.63] deep M12 20.0 [0.79] deep Connection for waterpump i = 0.41
70.0 [2.76] 200.0 [7.87]
215.0 [8.5]
. x a ] 7 8 m 7 . 0 . 0 0 [ 2
] ] 1 ] 0 . 2 0 . 5 . 0 . 2 . 6 0 . 3 0 5 [ 0 2 1 1 [ [
200.0 [7.87]
0 75.0-5.0
Parallel key A 6x6x20 DIN6885
0 [2.953-0.2 ]
Lubrication oil outlet
0 Ø18.0 -0.011 (h6) 0 [0.7087 -0.0004 ]
Cover for water-pump-connection
Ø100.0 +0.054 (H8) 0 [3.937 +0.0021 ] 0
19 2 . 0 [ 7 .5 7 7 ] 110 . 0 [ 4 .3 3 ] 3 5 .0 [ 1.3 7 9 ] 6 .0 [ 0 .2 3 6 ]
Air breather
0 . ] 5 5 4 6 . 2 9 R [
] 0 . 8 1 8 4 4 . 2 9 [
] 0 . 1 5 3 . 6 8 4 1 [ Ø
. 3 8 ] 7 6 1 0. [
14.0 [0.55]
O-ring 124x4 [4.88x0.16] NBR 70
Ø 2 2 .0 [ 0. 8 7 ] Ø 4 0 .0 [ 1.5 7 ]
] 2 . 1 0 0 . ± 0
0 . ± 7 7 1 6 . 0 Ø [ ' 0 3 ˚ 1
Variation of drum flange Dynamic swivel angle max.
12 .0 [ 0 .4 8 4 ]
) 7 H ] (
129.0 [5.08]
2 0 4 0 . 0 . 0 0 0 0 + +
0 0 . 0 . 7 5 2 [ 1 Ø
Ø 4 0 .0 [ 1.5 7 ]
: 33.34 [1.313] Pr es su re a ng le : 3 0˚ Number of teeth : 21 Pitch : 16/32 ANSI B92.1-1970, class 6 fillet root side fit
. 0 7 ] 7 6 1 0. [
57.0 [2.24] 252.0 [9.92]
505.0 [19.88]
. 7 6 ] 1 1 4 . 5 2 9 [
) ] 9 ] h 1 (
8 2 . 0 0 0 . ± 0 ±
0 . 0 5 0 8 . 5 6 9 Ø 1 [
˚ 5 1
18.5 [0.73]
9 4 .0 [ 3. 6 8 9 ] Ø 2 2 .0 [ 0 .8 7 ]
. 0 7 ] 0 9 5 1. [
0 . ] 9 5 . 1 6 4 1 [ Ø
˚ 7
˚ 7
Spline data Pitch dia
Securing device during transport Displayed position turned 62.5˚
6 5 0 5 0 . 1 . 0 0 0 0 -
7 0 . 8 . 0 0 3 2 5 [ Ø
. 0 5 ] 0 7 0 5. 4 1 [
5 3 .0 [ 2 .0 9 ]
6 7 .0 [ 2. 6 4 ] 3 2. 6 [ 1.2 8 ] 19 0 . 0 [ 7. 4 8 ]
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
18.0 [0.71] 66.0 [2.6]
P001 998E
23
Series TM Transit Mixer Drive System Service Manual Dimensions – Gearbox TMG GEARBOX SIZE 71.2 458.0 [18.03]
200.0 [7.87] 154.0 [6.063]
7.5˚
mm [in]
200.0 [7.87] 2 4 x 15 ˚
Cover for speed sensor connection
15 ˚
114.6 [4.51]
Oil dip stick and oil inlet
˚ 6 0 6 x ˚ 6 0
0 . ] 0 2 2 7 . 1 [ 4 Ø
] 6 . 1 4 5 . 1 4 1 [
M8 16.0 [0.63] deep M12 20.0 [0.79] deep
123.5 [4.86]
200.0 [7.87] 215.0 [8.5]
Connection for waterpump i=0.41
70.0 [2.76]
215.0 [8.5]
] ] 0 ] . 2 0 . 1 5 . 3 6 0 . 0 . 2 . 2 1 0 [ 1 0 [ 5 [
200.0 [7.87]
0 75.0-5.0
. x ] a 7 8 m 7 . 0 . 0 0 [ 2
Parallel key A 6x6x20 DIN6885
0 -0.011
Ø18.0
Lubrication oil outlet
(h6)
0 -0.0004 ]
[0.7087
Cover for water-pump connection
0 [2.953-0.2 ]
Ø100.0 +0.054 (H8) 0 [3.937 +0.0021 ] 0 19 2 . 0 [ 7 .5 7 7 ] 110 . 0 [ 4. 3 3 ]
Air breather
7 7 1 6 . 0 Ø [
6 .0 [ 0. 2 3 6 ]
˚ 5 . 1
14.0 0 0 . ] . ] 0 ] [0.55] 8 5 1 5 5 . 6 . 8 6 3
. 3 8 ] 7 6 1 0. [
4 . 1 4 4 8 2 [ 9 4 . 1 [ R 2 [ 9 Ø
O-ring 124x4 [4.88x0.16] NBR 70
3 5 .0 [ 1.3 7 9 ]
Ø 2 2 .0 [ 0 .8 7 ]
Ø 4 0 .0 [ 1.5 7 ]
) 7 H ] (
Variation of drum flange Dynamic swivel angle max.
12 .0 [ 0 .4 8 4 ]
129.0 [5.08]
2 0 4 0 . 0 . 0 0 0 0 + +
0 0 . 0 . 7 5 2 [ 1 Ø
Ø 4 0 .0 [ 1.5 7 ]
9 4. 0 [ 3 .6 8 9 ] Ø 2 2 .0 [ 0 .8 7 ]
. 0 7 ] 0 9 5 1. [
18.5 [0.73]
. 0 7 ] 7 6 1 0. [
57.0 [2.24] 252.0 [9.92]
0 . ± 0 ±
0 . 0 5 0 8 . 5 6 9 Ø 1 [
˚ 5 1
. 7 6 ] 1 1 4 . 5 2 9 [
. 0 5 ] 0 7 0 5. 4 1 [
5 3 .0 [ 2 .0 9 ]
6 7 .0 [ 2. 6 4 ] 3 2. 6 [ 1.2 8 ]
19 0. 0 [ 7 .4 8 ]
505.0 [19.88]
24
0 . ] 9 5 . 1 6 4 1 [ 2 ] 8 Ø . 0 0
˚ 7
˚ 7
Spline data Pitch dia
: 33.34 [1.313] Pr es su re a ng le : 3 0˚ Number of teeth : 21 Pitch : 16/32 ANSI B92.1-1970, class 6 fillet root side fit
Securing device during transport Displayed position turned 61.5˚
] 2 . 1 0 0 . ± 0 0 . ±
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
18.0 [0.71] 66.0 [2.6]
P001 999E
) 9 ] h ( 1 6 5 0 5 0 . 1 . 0 0 0 0 -
7 0 . 8 . 0 0 3 2 5 [ Ø
Series TM Transit Mixer Drive System Service Manual Notes
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
25
Series TM Transit Mixer Drive System Service Manual Installation Instructions GENERAL
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 fittings and hoses. Make sure that all the other system components (reservoir, fittings, hoses, heat exchanger) are cleaned.
MOUNTING THE MOTOR
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 lbf•in] Hardened washers (acc. to DIN 6916) are necessary under the bolt heads.
F000 874
MOUNTING THE SPEED SENSOR
F000 861
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.
New self-sealing screw must be use to fix the speed sensor. Tightening torque: 8 ± 2 Nm [71 ± 18 lbf•in] MOUNTING THE PUMP
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 configuration ‚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 lbf•in]. Hardened washers (acc. to DIN 6916) are necessary under the bolt heads (and the nuts if through bolts are used).
26
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Series TM Transit Mixer Drive System Service Manual Installation Instructions MOUNTING THE GEARBOX
Gearbox mounting must be on a solid, distortion free, and flat support face. Min. tensile strength of material: 400 N/mm² [57 200 psi] Mounting surface roughness average peak-to-valley height: Ra = 3,2 µm in acc. to DIN 4768, part1 Allowable flatness 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 lbf•in] 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. WASHER IN ACC. TO DIN 6916-21
GEARBOX FOOT
0.15 A 3.2
MIXER FRAME
10
+5 x70 (Stops)
STOPS (REAR DISCHARGE)
MOUNTING THE WATER TANK
P001 497E
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 lbf•in] Hardened washers are necessary under the bolt heads and the nuts: mm [in] 410.0 [16.14]
WATER TANK
. x a m ] 0 . 7 0 . 0 9 1 5 [
0,3 P001 498E
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
27
Series TM Transit Mixer Drive System Service Manual Installation Instructions MOUNTING THE DRUM FLANGE
Unit will be shipped with the flange locked in the zero degree position. This is to protect the main bearing and the flange seal from damage. Tolerances of the drum fit are showed below. mm [in]
The bolt must not be removed until adjusting the drum
1
A
1.5 max. x 45˚ [0.6] 6.3 a i d e g n a l f m ] u r 4 D 2 0 6 . . 0 0 + + 7 1 . 8 . 0 0 3 2 5 [
DRUM FLANGE 6.3
a i d e g n a l f m u r D . x a m ] 0 . 1 0 5 . 4 5 1 [
GEARBOX OUTPUT FLANGE A
Drum flange
P001 499E
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 flange • TMG 51.2 with 12 bolts • TMG 61.2 / 71.2 with 24 bolts M16; min. grade 8.8; tightening torque 195 Nm [1726 lbf•in] 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] The exact alignment of between the drum flange and gearbox housing for the whole circumference; see below gearbox and drum is required for proper comTMG 51.2 TMG 61.2 / 71.2 ponent life.
10.5 [0.41]
P003 002
18.5 [0.73]
P003 003
If there is misalign of drum and gearbox or a wide total run-out tolerance, the main bearing and the flange sealing will have reduced life. 28
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Series TM Transit Mixer Drive System Service Manual Installation Instructions MOUNTING CONTROLLER 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 flexible metal or plastic conduits. • Use 85 °C [185 °F] wire with abrasive resistant insulation. 105 °C [221°F] wire should be considered near hot surfaces • The minimum wire gage should be 1 mm² [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 fields 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, reflection 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 filled 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: • Die Set for 509 575:
Id. No. 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 connectors:
• Crimp Tool for Micro Timer - AMP/2-pin: • Die Set for 515 895: • Contact Extraction Tool for Micro Timer:
Id. No. 515 895 Id. No. 515 896 Id. No. 517 023
The wiring diagram is on the next page.
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
29
Series TM Transit Mixer Drive System Service Manual Installation Instructions WIRING DIAGRAM – TME F 4A + External stop switch
Batt. 12/24VDC
Remote Station
Cabin Station
Battery (+)
1
1
Battery (-)
2
2
VCC Voltage (+)
3
3
VCC Voltage (+)
Setpoint from Cabin
4
4
Setpoint to Remote
12V Valve (-)
5
5
24V Valve (-)
6
6
Remote/ON
7
7
Remote/ON
Memoblink
8
8
Memoblink
PPU (-)
9
9
VCC/2
10
PPU signal
11
GND
12
Disable lost of feedback 13 Ext. Stop
14
Valve 0 (+)
15
Valve 1 (+)
16
10
(+) PPU (2-wire)
11 12
Option: Safety function can be invalidate by connecting.
VCC/2
GND
13 14 15
Proportional valve 0 CHARGE
16
AMP connector, 16-pin
AMP connector, 16-pin
Proportional valve 1 DISCHARGE
INSTALLATION SPACE – TME
P003 022E
In order to accommodate the TME in the customer-specific housing, it is necessary to produce a cutout as illustrated below. Tightening torque max. 1 Nm [0.7 lbf•ft].
max. 5 [0.20] min. 1 [0.04]
72.4 ± 0.3 [2.85 ±0.01]
mm [in] min. 50 [1.97]
] 3 . 1 . 0 0 ± 0 ± 4 . 8 3 6 . 9 3 [
R3 ±0.1 [0.12 ±0.004] P001 937E
30
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
P001 938
Series TM Transit Mixer Drive System Service Manual Hydraulic Fluid FLUID SPECIFICATION
Temperature Range1)
Viscosity mm2 /s
[SUS]
7
[49]
Recommended operating range
12-80
[70-370]
Maximum
1600
[7500]
˚C
[˚F]
Minimum
-40
[-40] intermittent, cold star t
Minimum
Rated
104
[220]
Maximum 115 [240] intermittent 1) At the hottest point, normally the motor case drain port.
intermittent
intermittent cold start
Cleanliness Level and βx-Ratio Required f luid cleanliness level Recommended βx-ratio f or suction f iltration
HYDRAULIC FLUID
ISO 4406 Class 18 /13
β35-45=75 (β10≥2)
Please see Sauer-Danfoss literature
520L0463
Also refer to Sauer-Danfoss literature 520L0465
(Hydraulic Fluids and Lubricants, Technical Information). (Experience with Bio Fluids, Technical Information).
CLEANLINESS
Please see Sauer-Danfoss literature
520L0467 (Design Guideline for Hydraulic Fluid Cleanliness, Technical Information).
SUCTION FILTRATION
The proper suction filter should be placed in the circuit between the reservoir and the inlet to the pump. MANOVACUUMMETER
Improper filter selection can cause charge pump cavitation.
HYDRAULIC FLUID RESERVOIR
CHARGE PUMP
TO LOW PRESSURE SIDE AND CONTROL
FILTER
ADJUSTABLE CHARGE PRESSURE RELIEF VALVE TO PUMP CASE
P000 797E
Recommended β-ratio can be found on cleanliness level table.
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
31
Series TM Transit Mixer Drive System Service Manual Pressure Measurement REQUIRED TOOLS
The service procedures described in this manual for Series TM pumps and motors can be performed using common mechanic‘s tools.
PORT LOCATION PUMP
The following is a list of the ports for each type of hydraulic unit. The recommended pressure gage and fitting are also specified. Port Location Pump Port
Function
Gage size
Fitting
M1
System pressure port "A"
600 bar [10 000 psi]
M12x1.5 O-ring boss
M2
System pressure port "B"
600 bar [10 000 psi]
M12x1.5 O-ring boss
M3
Charge pressure
60 bar [1000 psi]
M12x1.5 O-ring boss
M4+M5
Actuating piston pressure
60 bar [1000 psi]
M12x1.5 O-ring boss
M10
Vacuum charge pump
L1+L2
Case pressure or drain por ts
S
Charge pump inlet
M12x1.5 O-ring boss 10 bar [100 psi]
M22x1.5 O-ring boss M42x2 O-ring boss X
L1
M4
M1
A
S
B
X M10
M3
M2 M5
L2
P003 004
PORT LOCATION MOTOR Port Location Motor Port
Function
Gage size
Fitting
M1
System pressure port "A"
600 bar [10 000 psi]
M12x1.5 O-ring boss
M2
System pressure port "B"
600 bar [10 000 psi]
M12x1.5 O-ring boss
M3 L1+L2
Loop f lushing pressure Case pressure or drain ports
60 bar [1000 psi] 10 bar [100 psi]
M12x1.5 O-ring boss M22x1.5 O-ring boss M2
L2
X
M1
X M3
P003 007
L1
32
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Series TM Transit Mixer Drive System Service Manual Notes
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
33
Series TM Transit Mixer Drive System Service Manual Start-Up Procedure GENERAL
Pump, motor and gearbox are shipped without oil! GEARBOX
Before start-up fill with EP-Gear lubricant SAE 90, API-Classification GL 5, FZG power stage > 12 acc. DIN 51 354 (see table gear box „Specific Data“). Fill the lubricant up to the mark of the oil dipstick and check oil level regularly.
Level measurement by screwed in dipstick. HYDROSTATICS
The pump must be in zero position.
Check and make sure that the rotary switch on the controller - Remote and Cabin - are in neutral position
34
Before start-up fill the system in following way with oil acc. to Sauer-Danfoss literature 520L0463.
• 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 filtered oil into the upper case drain port. • Fill the reservoir with recommended hydraulic fluid. As soon as oil emerges from the end of the disconnected charge pump inlet line tighten the pipe connection and continue to fill 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 fluctuations in pressure the charge pressure should be settle down to 19±1 bar [275±14.5 psi]. • Check the oil level in the sight glass. Refill, if necessary. • Raise the speed to normal operating speed. The gage should now indicate the pressure setting of the charge pressure relief valve. • If charge pressure is not maintained at the proper setting, stop the engine and find the fault in accordance with the troubleshooting guide. • Stop the engine and fit the connectors to the proport ional valves of the variable displacement 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
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Series TM Transit Mixer Drive System Service Manual Start-Up Procedure HYDROSTATICS (continued)
•
• • • Tighten up any leaking joints and other connections while system is not under pressure.
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 fill to the proper level, if necessary.
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
35
Series TM Transit Mixer Drive System Service Manual Maintenance GEARBOX TMG
First oil change should be after 100 hours, then after every 1000 hours, but at least once a year.
When cleaning with a high Use only recommended gear lubricants; see Sauer-Danfoss literature 520L463 (Hydraupressure water jet do not lic Fluids and Lubricants, Technical Information). direct the jet onto the flange shaft seal, because The level of the oil should be checked daily. In case of loss of oil, the leak should be rectithis may lift the seal lip fied and refill oil, if necessary. and force contamination underneath the seal lip, Periodically clean the gear housing and inspect for loosened screws and bolts. resulting in premature wear and damage of the lip seal. SAFETY
Gearboxes Series TMG 51.2, 61.2 and 71.2 are designed and manufactured for safe operation 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 efficiency 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.
HYDROSTATIC TMP AND TMM
The filter 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 filter 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 filters when changing the oil. Carry out a leak test on transmission (inlet line, filter, pipe- and hose lines, valves, pump and motor) giving due consideration to service life, environmental protection and reduction of oil consumption. Check the reservoir for proper oil level via the sight glass and refill, if necessary.
Tighten up any leaking joints and other connections while system is not under pressure. Replace defective seals.
36
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Series TM Transit Mixer Drive System Service Manual Maintenance HYDROSTATIC TMP AND TMM (continued)
Without this safety precautions there could be danger for body and life e. g. danger for machines and property.
Check hydraulic hoses periodical and change when there is any damage or ageing (see manufacturers instruction). Replacement hoses should be in accordance to specifications. When reassembling do not exchange connection por ts of pipes and hoses. When exchanging system pressure ports, the direction of drum rotation will be changed.
Make certain that the oil filter 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 rectified and refilled, if necessary.
Use only recommended fluids acc. Sauer-Danfoss literature 520L0463. It is not permissible to mix oil of different brands.
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
37
Series TM Transit Mixer Drive System Service Manual Troubleshooting DRUM SPEED DOESN‘ T REACHED MAXIMUM SPEED
SYSTEM OPERATING HOT
Check
Description
Action
Pump input speed.
Engine speed to low.
Select required engine speed.
Charge pump pressure in neutral Values: 21.5±1bar [312±14.5 psi // 1500 rev/min // suction line temperature 50±3 °C [122±37 °F // Gage Port M3.
Incorrect setting on the charge pressure relief valve.
Stop the engine. Install gage in port M3 Start the engine and measure 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.
Proportional Valve Value: 20 bar [290 psi] at maximum current.
Control pressure to low.
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 [290±14.5 psi], change the proportional valve.
Charge pump inlet vacuum Values: > 0,7 bar [10 psi] // 1500 rev/min // suction line temperature 50 ± 3° C [122±37 °F // Gage Port M10.
Dirty filter will increase the inlet vacuum.
Check inlet pressure. If too high, change the filter.
Oil cooler.
Dirty oil cooler will be influence cooling capability.
Clean the cooler.
Electrical fan drive.
Temperature switch failed.
Change temperature switch.
Change electrical motor. Electrical fan drive.
Electrical motor failed.
Action 38
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Series TM Transit Mixer Drive System Service Manual Troubleshooting DRUM SPEED DROOPS DOWN DEPENDING ON INCREASED LOAD
Check
Description
Charge pump pressure in neutral Values: 21.5±1bar [312±14.5 psi // 1500 rev/min // suction line temperature 50±3 °C [122±37 °F // Gage Port M3.
Drum speed will be go slower if the load increases and charge pressure droops too low.
DRUM ROTATING IN ONE DIRECTION ONLY
Loop flushing shuttle spool.
Pre-selected direction and speed but the drum doesn‘ t turn.
Change the transmission, pump and motor.
Check loop flushing shuttle spool which maybe “sticking” in one direction Check the springs of the shuttle spool, too.
Make cross-check with both Pump displacement control. Electrical proportional valve controller (Remote/Cabin). is operating improperly. If the problem changed, replace the failed controller. If not, use the “Emergency Tool Kit”1) to discharge the drum and later, change the proportional valve.
DRUM DOESN‘ T STOP IF THE ROTARY SWITCH TURNED TO NEUTRAL
REMOTE STATION IN “STAND BY”; SIGNALLED BY FLASHING LED
Multifunction valve.
Interchanging the valve to see and how the failure is related to the valve function.
Stop the engine immediately!
Proportional valve is sticking from contamination.
Set the rotary switch to neutral; touch the yellow switch; confirmed by lights up LED.
1)
Light on signalls active status. If not, this means continuously flashing and the switch operating improperly. Description
If the problem changes direction, replace the valve.
Using the “Emergeny Tool Kit”1) for discharging and later on, replace the proportional valve.
Replace the Remote Station.
Action
Or valve manual override on units with this options.
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
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Series TM Transit Mixer Drive System Service Manual Troubleshooting CABIN STATION ACTIVE; SIGNALLED BY LIGHTS UP LED
DRUM STOPPED DURING OPERATION
Check Means, function transfer to LED still on, the switch is operating improperly.
Set the rotary switch to neutral; touch the yellow switch; confirmed by off LED.
Active controller signalled through lighted LED.
If not, the required supply
Check the fuse in the supply
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
HOW TO REPLACE THE TME-CONTROLLER RED FIXTURE
SCREW DRIVER
F000 873
P001 938
• 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 fixture). • 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.
Active controller signalled through lighted LED.
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DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
sensor connector and operate once more. If the system works now - but in open loop control- change the speed sensor. After change check the correct function again.
Series TM Transit Mixer Drive System Service Manual Emergency Discharging EMERGENCY DISCHARGING Rear Cover Actuating cylinder “A”
STOP the truck engine at first!
Main pressure port “A”
Main pressure port “B” Actuating cylinder “B” F000 876
F300 684
• Remove plug M12x1.5 from the actuating cylinder “B” 1)
F000 875
F300 689 TMP, right hand rotation
P001 963
TMM, main ports show downwards 1)
F300 685
• Install screw M12x1.5 with seal lock nut into the actuating cylinder until (appr. 80mm [3.15 in]) you feel noticeable resistance, (when the screw comes in contact with actuating piston).
F300 690
F300 686
IMPORTANT: The special tool is an • Start truck engine (low idle is recomessential part of the truck manded for slow discharge). mixer emergency tool kit. • Turn screw clockwise against actuating 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. F300 687 1)
This description concerns to our recommended standard installation. If drums turns with the tool on ser vo cylinder “B” in wrong direction, change the tool to servo cylinder “A”.
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
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Series TM Transit Mixer Drive System Service Manual Notes
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DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Series TM Transit Mixer Drive System Service Manual Notes
DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
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