Series TM Transit Mixer Drive System Service Manual - Sauer-Danfoss

Series TM
Transit Mixer Drive
System
Service Manual

Functional
Description
Technical
Specifications –
Axial Piston Pumps TMP
Dimensions –
Axial Piston Pumps TMP
Technical
Specifications –
Axial Piston Motors TMM
Dimensions –
Axial Piston Motors TMM
Technical
Specifications –
Gearbox TMG
Dimensions –
Gearbox TMG
Series TM Transit Mixer Drive System
Service Manual
Contents
General ............................................................................................................................................................... 4
Transit Mixer Pump – TMP ........................................................................................................................... 4
Cross Section – TMP ...................................................................................................................................... 4
Charge Pump ................................................................................................................................................... 5
Charge Relief Valve ........................................................................................................................................ 5
Multi-Function Valve ..................................................................................................................................... 5
Input Shaft ........................................................................................................................................................ 6
Auxiliary Mounting Pads .............................................................................................................................. 6
Transit Mixer Motor – TMM ......................................................................................................................... 7
Cross Section – TMM ..................................................................................................................................... 7
Loop Flushing Device ................................................................................................................................... 8
Transit Mixer Gearbox – TMG ..................................................................................................................... 9
Cross Section – TMG ...................................................................................................................................... 9
Speed Sensor .................................................................................................................................................10
Transit Mixer Electronic – TME .................................................................................................................11
Transit Mixer Drive System – TM .............................................................................................................12
Circuit Diagram – TM ...................................................................................................................................12
General Specifications ................................................................................................................................13
Specific Data...................................................................................................................................................13
Technical Data ...............................................................................................................................................13
Electrical Proportional Valves ...................................................................................................................13
Circuit Diagram .............................................................................................................................................14
Determination of Nominal Pump Sizes ................................................................................................14
2 DKMH.PS.800.B1.02 • 520L0482 • Rev A • 05/2004
Axial Piston Pumps – Size 070 and 089 ................................................................................................15
General Specifications ................................................................................................................................18
Specific Data...................................................................................................................................................18
Technical Data ...............................................................................................................................................18
Circuit Diagram .............................................................................................................................................19
Determination of Nominal Motor Sizes................................................................................................19
Axial Piston Motors – Size 070 and 089 ................................................................................................20
General Specifications ................................................................................................................................21
Specific Data...................................................................................................................................................21
Technical Data ...............................................................................................................................................21
Gearbox Size 51.2 .........................................................................................................................................22
Gearbox Size 61.2 .........................................................................................................................................23
Gearbox 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 specifications 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

Installation
Instructions
Hydraulic Fluid
Pressure
Measurement
Start-Up Procedure
Maintenance
Troubleshooting
Emergency
Discharging
Series TM Transit Mixer Drive System
Service Manual
Contents (continued)
General .............................................................................................................................................................26
Mounting the Motor ...................................................................................................................................26
Mounting the Speed Sensor ....................................................................................................................26
Mounting the Pump ....................................................................................................................................26
Mounting the Gearbox ...............................................................................................................................27
Mounting the Water Tank ..........................................................................................................................27
Mounting the Drum Flange ......................................................................................................................28
Mounting Controller TME ..........................................................................................................................29
Wiring Diagram TME....................................................................................................................................30
Installation Space TME ................................................................................................................................30
Fluid Specification ........................................................................................................................................31
Hydraulic Fluid ..............................................................................................................................................31
Cleanliness ......................................................................................................................................................31
Suction Filtration ..........................................................................................................................................31
Required Tools ...............................................................................................................................................32
Port Location Pump .....................................................................................................................................32
Port Location Motor ....................................................................................................................................32
General .............................................................................................................................................................34
Gearbox ...........................................................................................................................................................34
Hydrostatics ....................................................................................................................................................34
Gearbox TMG .................................................................................................................................................36
Safety ................................................................................................................................................................36
Hydrostatic TMP and TMM ........................................................................................................................36
Troubleshooting ...........................................................................................................................................38
Emergency Discharging .............................................................................................................................41
520L0482 • Rev BC • Dec 2010
3

General
Transit
Mixer Pump – TMP
Cross Section – TMP
4
Series TM Transit Mixer Drive System
Service Manual
Functional Description
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 fluid, which imparts the
input energy into hydraulic fluid. The high-pressure fluid is then ported out to provide
the hydraulic pressure and flow to the fixed displacement motor TMM.
The swash plate angle can be varied by the actuating piston via the electrical proportional
control valves depending on the current value, which is generated by the TME
controller.
Variable Displacement Pump TMP
JOINT FLANGE
520L0482 • Rev BC • Dec 2010
F300 692
SWASH PLATE
ACTUATING CYLINDER
ACTUATING PISTON
CYLINDER BLOCK
PISTON
CHARGE PUMP
INPUT SHAFT
VALVE PLATE
BEARING PLATE
P001 981E
F300 691

Series TM Transit Mixer Drive System
Service Manual
Functional Description
Charge Pump The charge pump is necessary to compensate internal leakages and supply cool fluid 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 specified pressure under
all conditions of acceleration and deceleration of the drum to prevent damage to the
transmission.
The charge pump is a fixed-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
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 flow, means in neutral position.
The setting level is specified on the model code.
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 flow 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 flow 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 fixed 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 flow to the
low-pressure side of the closed circuit system.
520L0482 • Rev BC • Dec 2010
CHARGE RElIEF
VAlVE
F300 691
F300 691
MulTI FuNCTION
VAlVE
F300 691
Cross Section
Cross Section
Cross Section
HIGH PRESSURE RELIEF VALVE
SYSTEM CHECK VALVE
HIGH PRESSURE
CHARGE PRESSURE
P001 982
P001 983
P001 984E
5

Input Shaft
Auxiliary Mounting Pads
6
Series TM Transit Mixer Drive System
Service Manual
Functional Description
The standard input shaft is designed with a joint flange 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.
TMP with Joint Flange TMP with Splined Shaft
Auxiliary mounting pads are available in size ‘A‘ and ’B‘ to drive auxiliary hydraulic
pumps.
TMP with PTO ‘A’ Cross Section
520L0482 • Rev BC • Dec 2010
F300 693 F300 688
F300 683
P001 985

Transit
Mixer Motor – TMM
Cross Section – TMM
Series TM Transit Mixer Drive System
Service Manual
Functional Description
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 port. The fluid pressure builds behind the piston causing them
to move down the swash plate. As the pistons returns up the 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
SHUTTLE SPOOL
520L0482 • Rev BC • Dec 2010
ORIFICED LOOP
FLUSHING VALVE
F000 857
CYLINDER BLOCK
BEARING PLATE PISTON
VALVE PLATE
OUTPUT SHAFT
P001 953E
F300 698
7

8
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
system.
Cross Section
520L0482 • Rev BC • Dec 2010
ORIFICED LOOP
FLUSHING VALVE
LOOP FLUSHING
SHUTTLE SPOOL
X
F000 857
P001 954E
lOOP FluSHING DEVICE
VIEW “X”
F000 857

Transit
Mixer Gearbox – TMG
Cross Section –
TMG 61.2
Series TM Transit Mixer Drive System
Service Manual
Functional Description
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
INPUT
SUN GEAR
WATER PUMP
DRIVE SHAFT
(90 degree turned)
520L0482 • Rev BC • Dec 2010
F000 860
1-ST STAGE
TMG 61.2 without Water Pump Drive
2-ND STAGE
DRUM FLANGE
MAIN BEARING
CURVED TEETH
COUPLING
F000 872
P001 986E
9

10
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
520L0482 • Rev BC • Dec 2010
F000 861
Cross Section – Speed Sensor
P001 987

Transit Mixer
Electronic – TME
Series TM Transit Mixer Drive System
Service Manual
Functional Description
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
conjunction 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 TME Cabin Station
Symbol used on the Controller
P001 958
P001 959
= Charging/Transport
= Discharging
520L0482 • Rev BC • Dec 2010
ROTARy SWITCH LED
TOuCH SWITCH
P001 956
P001 960
ROTARy SWITCH
TOuCH SWITCH
= Memory Switch “Stop/Start”
Remote Station
= Changeover Switch
Cabin Station
P001
961
LED
P001 957
11

Transit Mixer Drive
System – TM
Circuit Diagram – TM
12
M3
M5
M4
1
6
6
Series TM Transit Mixer Drive System
Service Manual
Functional Description
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 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).
TMP TME TMM TMG
7
2 3
M10
S
12
L1 M1
L2
15
M2
520L0482 • Rev BC • Dec 2010
4
5
5
13
A 8 A
8
B B
L1 M1
N
10
11
L2
M3
M2
9
14
n
P001 962

General
Specifications
Specific Data
Technical Data
Electrical
Proportional Valves
Series TM Transit Mixer Drive System
Service Manual
Technical Specifications – Axial Piston Pumps TMP
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.
Pump type
Axial
piston
pump
with
variable
displacement
swashplate
axial
piston
design
Direction of
rotation
Clockwise
or
counter-clockwise
Istallation position
Discretionary,
the
housing
must
always
be
filled
with
hydraulic
fluid
Other system
requirements
Circuit
overpressure
protection,
suitable
reservoir
Theoretical Torque
Frame size
070 089
At.
maximum
Nm/
bar
1.
11
1.
42
displacement
[ lbf•in/
1000
psi]
[ 680]
[ 864]
520L0482 • Rev BC • Dec 2010
General Specifications
Specific Data
D i m e n s i o n
070 Frame
size
089
Displacement Vg
cm3 3 [ in
]
70
[ 4.
27]
89
[ 5.
43]
Maximum flow
Qmax l/
min
[ US
gal/
min]
203
[ 54]
258
[ 68]
Maximum corner
power
p cornermax
kW
[ hp]
142
[ 190]
180
[ 242]
Weight m
kg
[ lb]
61
[ 134]
Mass
moment
of
inertia
of
the
internal
rotation
parts
J
2 kgm
2 [ lbf•ft
]
0.
01777
[ 0.
42]
Type of
mounting
Four
( 4)
bolt
flange,
SAE
flange
configuration
Pipe
connections
Main
pressure
ports:
SAE
flange
Remaining
ports:
SAE
straight
thread
O-ring
boss
Shaft configuration
100
mm
[ 3.
94
in]
joint
flange
( DIN/
ISO)
or
Splined
ANSI
General Data
• Protection class: DIN VDE 0470: IP65/IPX7
• Electrical connections: AMP Junior Power Timer
• Supply pressure p Pmax : 50 bar [725 psi]
Electrical Data
• Insulation material: Class H, 180 °C [356 °F]
• Duty cycle: 100 %
Voltage 12V 24
V
R in Ω 20
5 . 3±
5 % 21.
2±
5 %
I inmA 1
600± 10
300±
10
inmA 1500± 10
750±
10
I 2
Case Pressure
bar [psi]
Rated pressure 3 [44.0]
Maximum pressure (cold start) 5 [73.0]
Electrical Data
Speed Limits
Frame size
min-1 (rpm)
070 089
Minimum speed 500
Rated speed 2500
Maximum speed 2900
System Pressure Range, Input
b ar
[ psi]
Maximum delta
pressure
4 20
[ 6090]
13

Circuit Diagram
14
M3
M5
M4
Series TM Transit Mixer Drive System
Service Manual
Technical Specifications – Axial Piston Pumps TMP
M10
Determination of
Nominal Pump Sizes Metric System Inch System
Vg • n • η Vg • n • η v
v
Output flow: Q = e _________ l/min Q = e _________ [uS gal/min]
1000 231
Vg • ∆p Vg • ∆p
Input torque: M = __________ Nm Me = e _________ [lbf•in]
20 • π • η 2 • π • η mh
mh
M • n Q • ∆p Vg • n • ∆p
e e
Input power: P = e ______ = ______ kW P = e ___________ [hp]
9550 600 • η 396 000 • η t
t
Q e • 1000 • η v Q e • 231 • η v
Input Speed: n = _____________ min -1 n = ___________ min -1 (rpm)
Vg Vg
Vg = Pump displacement per rev. cm 3 [in 3 ]
∆p = p HD - p ND bar [psid]
η v = Pump volumetric efficiency
η mh = Pump mechanical-hydraulic
(Torque) efficiency
η t = Pump overall efficiency
p HD = High pressure bar [psid]
p ND = low pressure bar [psid]
520L0482 • Rev BC • Dec 2010
S
L2
CB
CA
L1 M1
M2
A
B
P001955E
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

Axial Piston Pumps
– Size 070 and 089
Ø15.0 +0.8
-0.3
[0.591 +0.31 ]
-0.12
163.0
[6.44]
114.5
[4.508]
57.25
[2.25]
Connector CA
AMP Junior Power Timer
Connector CB
AMP Junior
Power Timer
57.25
[2.25]
114.5
[4.51]
146.0
[5.75]
216.0
[8.50]
49.0
[1.92]
(CCW) (CW)
Series TM Transit Mixer Drive System
Service Manual
Dimensions – Axial Piston Pumps TMP
Case drain port L1
use highest port as outlet
M22x1.5
11.0 min. [0.433] depth
95.0
[3.73]
Clockwise
( cw)
Counterclockwise
( ccw)
Gage port M1
System pressure port "A"
M12x1.5
12.7 [0.5] min. depth
Charge pump inlet S
Gage port M10
Charge pump
inlet pressure
M12x1.5
12.7 [0.5] min. depth
Gage port M2
System pressure port "B"
M12x1.5
12.7 [0.5] min. depth
2.3
[0.091]
8.5
[0.335]
Ø126.975±0.025
[5.0]
Ø100.0±0.3
[3.94±0.01]
Ø84.0
[3.31]
Ø57.0
-0.019
[2.244
-0.001
]
Case drain port L2
M22x1.5
11.0 min. [0.433] depth
520L0482 • Rev BC • Dec 2010
54.8
[2.157]
12.4
[0.49]
Ø8.0
[0.315]
Direction of Rotation
P ort
" A"
Port
" B"
105.00
[4.13]
89.00
[3.50]
X
106.0
[4.175]
Ø12.0
[0.472]
17.0
[0.679]
90.0
[3.56]
NFPE
valve
Output Input CA
Input Output CB
149.0
[5.86]
Size and rotation direction
are machinde beside the
name plate; as example
• 7L for 70 cc, left hand.
254.0
[9.98]
262.0
[10.32]
304.0
[11.96]
313.0
[12.32]
Gage port M4
Servo pressure
M12x1.5
High pressure
relief valve port A
Charge pressure
relief valve
High pressure
relief valve port B
Gage port M3
Charge pressure
M12x1.5
12.7 [0.5] min. depth
Gage port M5
Servo pressure
M12x1.5
P001 989E
57.2
[2.25]
Ø60.0
[2.362]
M42x2
20.0 [0.79] depth
Split flange boss
DN 25 Typ I 40MPa series
per ISO 6162
4 Thread: M12
21 [0.83]
full thread depth
27.8
[1.09]
110.0
[4.33]
292.0
[11.5]
P001 988E
mm
[in]
X
15

Axial Piston Pumps
– Size 070 and 089
(continued)
16
Series TM Transit Mixer Drive System
Service Manual
Dimensions – Axial Piston Pumps TMP
Option Spline Shaft – Size 070 Option Spline Shaft – Size 089
33.00 [1.31]
Full spline lenght
Ø80.00 max
[3.15]
Ø34.5 0
-0.17
[1.358 0 -0.007
]
M10
331.00
[13.05]
317.00
[12.49]
56.00
[2.207]
R6
[0.24]
Spline data
Pitch dia : 33.338
[1.313]
Pressure angle : 30˚
Number of teeth :21
Pitch : 16/32
ANSI B92.1-1970 class 5
fillet root side fit 51.00
[2.00]
Option Auxiliary Pad SAE ”A” – Size 070 and 089
520L0482 • Rev BC • Dec 2010
20.00
[0.792]
28.50 max
[1.122]
45.00 max
[1.772]
10.50
[0.41]
Ø29.00
[1.13]
P001 990E
15.00
[0.591]
1.20
[0.05]
Ø82.6 +0.13
0
[3.25 +0.005 ]
0
Ø87.12
[3.43]
for O-ring
1.78x82.3
[0.07x3.24]
Spline data
Pitch dia : 14.288
[0.563]
Pressure angle : 30˚
Number of teeth : 9
Pitch : 16/32
ANSI B92.1-1970 class 6
fillet root side fit
Full spline lenght : 17.0
[0.669]
33.00 [1.31]
Full spline lenght
Ø80.00 max
[3.15]
Ø37.60±0.09
[1.48±0.004]
Thread (2x)
M10,
19.0 [0.748] deep
M10
56.00
[2.207]
R6
[0.24]
Spline data
Pitch dia : 36.513
[1.438]
Pressure angle : 30˚
Number of teeth :23
Pitch : 16/32
ANSI B92.1-1970 class 5
fillet root side fit 51.00
[2.00]
106.375
[4.188]
20.00
[0.792]
28.50 max
[1.122]
45.00 max
[1.772]
Ø32.00
[1.26]
P001 991E
106.375
[4.188]
P001 992E
mm
[in]

Axial Piston Pumps
– Size 070 and 089
(continued)
Series TM Transit Mixer Drive System
Service Manual
Dimensions – Axial Piston Pumps TMP
Option Auxiliary Pad SAE ”B” – Size 070 and 089
317.00
[12.49]
334.00
[13.15]
520L0482 • Rev BC • Dec 2010
15.00
[0.591]
10.50
[0.41]
1.20
[0.05]
Ø101.65 +0.13
0
[4.002 +0.005 ]
0
Ø106.80
[4.2]
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 lenght : 34.0
[1.330]
Thread M12 (2x)
deep min.
[0.787]
mm
[in]
146.00
[5.75]
P001993E
17

18
Series TM Transit Mixer Drive System
Service Manual
520L0482 • Rev BC • Dec 2010
Technical Specifications – Axial Piston Motors TMM
General
Specifications
Specifications for axial piston fixed displacement motors are listed on these pages.
Specific Data
Technical Data
e
p
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General Specifications
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Specific Data
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Speed Limits
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[
Theoretical Torque
r
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b ]
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s
p
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x
a
M 0
2
4 ]
0
9
0
6
[
System Pressure Range, Input
Case Pressure
bar [psi]
Rated pressure 3 [44.0]
Maximum pressure (cold start) 5 [73.0]

Circuit Diagram
Series TM Transit Mixer Drive System
Service Manual
Technical Specifications – Axial Piston Motors TMM
A
B
L2
L1
520L0482 • Rev BC • Dec 2010
M3
M1
M2
P003 021
Determination of
nominal motor sizes Metric System Inch System
Vg • n Vg • n
Input flow: Q e = ________ l/min Q e = _______ [uS gal/min]
1000 • η v 231• η v
Vg • ∆p • ηmh Vg • ∆p • ηmh Output torque: M = ___________ Nm Me = e ___________ [lbf-in]
20 • π 2 • π
M • n Q • ∆p • η Vg • n • ∆p • η e e t t
Output power: P = e ______ = __________ kW P = e ____________ [hp]
9550 600 396 000
Q e • 1000 • η v Q e • 231 • η v
Output Speed: n = _____________ min -1 n = ___________ min -1 (rpm)
Vg Vg
Vg = Motor displacement per rev. cm 3 [in 3 ]
∆p = p HD - p ND bar [psid]
η v = Motor volumetric efficiency
η mh = Motor mechanical-hydraulic
(Torque) efficiency
η t = Motor overall efficiency
p HD = 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 flushing
pressure
19

Axial Piston Motors –
Size 070 and 089
20
95.00
[3.740]
Size identification
are machined here :
7 for 70 cc
9 for 89 cc
Gage port M2
System pressure port B
M12x1.5
249.00
[9.803] 207.00
[8.150]
L2
Case drain port L1
M22x1.5
218.00
[8.583]
251.00
[9.882]
164.00
[6.460]
A
Series TM Transit Mixer Drive System
Service Manual
Dimensions – Axial Piston Motors TMM
118.00
[4.650]
Case drain port L2
use highest port as outlet
M22x1.5
12.00
[0.470]
L1
72.00
[2.835]
122.00
[4.803]
Gage port M1
System pressure port A
M12x1.5
12.40
[0.490]
31.20
[1.228]
46.30 max.
[1.823]
55.00
[2.169]
Loop flushing
shuttle spool
Ø66.50 max.
[2.618]
Gage port M3
Loop flushing pressure
520L0482 • Rev BC • Dec 2010
Full spline lenght
85.00
[3.346]
85.00
[3.346]
Ø127.00
-0.05
[4.999
-0.002
]
Spline data
Pitch dia : 33.338
[1.313]
Pressure angle : 30˚
Number of teeth :21
Pitch : 16/32
ANSI B92.1-1970, class 5
fillet root side fit
Direction of Rotation
P ort
" A"
Port
" B"
Clockwise ( cw)
Output Input
Counterclockwise ( ccw)
Input Output
190.30
[7.492]
Ø15.00 +0.8
-0.3
[0.591 +0.031 -0.012
]
A
Split flange boss
DN 25 Typ I 40MPa series
per ISO 6162
4 Thread: M12
21 [0.83]
full thread depth
L
(ccw)
41.60
[1.64]
114.50
[4.508]
146.00
[5.748]
57.20
[2.250]
Orificed loop
flushing valve
R
(cw)
27.80
[1.09]
P001 996E
114.50
[4.508]
164.00
[6.457]
mm
[in]

21
Series TM Transit Mixer Drive System
Service Manual
520L0482 • Rev BC • Dec 2010
Technical Specifications – Gearbox TMG
General
Specifications
x
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General Specifications
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u
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r
e
t
a
w
h
t
i
w
d
e
e
p
s
t
u
p
t
u
o
.
x
a
M n
i
m 1
- )
m
p
r
( 8
1 6
1 6
1
e
r
u
t
a
r
e
p
m
e
t
g
n
i
t
a
r
e
p
o
.
x
a
m
/
.
n
i
M
C
˚
]
F
˚
[
]
5
8
1
+
[
5
8
+
o
t
p
u
]
4
-
[
0
2
-
Technical Data
Specific Data
Technical Data

Gearbox Size 51.2
22
200.0
[7.87]
159.0
[6.260]
200.0
[7.87]
458.0
[18.03]
114.6
[4.51]
R225.0
[8.86]
Series TM Transit Mixer Drive System
Service Manual
Dimensions – Gearbox TMG
12 x 30˚
Ø426.0
[16.77]
200.0
[7.87]
30˚
O-ring 124x4
[4.88x0.16] NBR 70
Ø127.0 +0.04 (H7)
0
[5.00 +0.002 ] 0
200.0
[7.87]
114.6
[4.51]
14.0
[0.55]
Spline data
Pitch dia : 33.34
[1.313]
Pressure angle : 30˚
Number of teeth :21
Pitch : 16/32
ANSI B92.1-1970, class 6
fillet root side fit
70.0
[2.756]
57.0
[2.24]
520L0482 • Rev BC • Dec 2010
26.0
[1.02]
13.0
[0.51]
Ø120.0
[4.72]
M8
16.0 [0.63]
deep
Connection for
waterpump
i = 0.41
Cover for speed sensor
connection
5.0
[0.20]
Parallel key
A 6x6x20 DIN6885
Cover for water-pump-connection
205.0
[8.06]
Air breather
15.0
[0.59]
Ø22.0
[0.87]
50.0
[1.97]
17.0
[0.67]
10.0
[0.39]
Ø40.0
[1.57]
53.0 67.0
[2.09] [2.64]
30.0
[1.18]
188.0
[7.4]
454.0
[17.87]
21.0 +3.0
Ø31.5
[1.24]
Ø40.0
[1.57]
Ø22.0
[0.87]
6 x 60˚
60˚
198.0
[7.78]
110.0
[4.43]
[0.84 +0.12 ]
0
0
74.5
[2.93]
105.0
[4.13]
10.5
[0.41]
55.0
[2.165]
194.5
[7.66]
20.0 max.
[0.787]
Ø100.0 +0.054 (H8)
0
[3.937 +0.0021 ] 0
Ø18.0 0 (h6)
-0.011
[0.7087 0 ] -0.0004
Ø17.0
[0.67]
41.0
[1.63]
6˚
6˚
18.0
[0.71]
246.3
[9.70]
Securing device during transport
Displayed position turned 62.5˚
Variation of
drum flange
Dynamic swivel
angle max.
15˚
400.0
[15.75]
R168.0
[6.614]
Ø500.0 ±0.2
[19.685 ±0.008]
Oil dip stick
and oil inlet
Lubrication oil outlet
P001 997E
Ø530.0 0 (h9)
-0.155
[20.87 0 ] -0.0061
M12
20.0
[0.79] deep
75.0 0
-5.0
[2.953 0 ] -0.2
mm
[in]

Gearbox Size 61.2
R245.0
[9.65]
241.0
[9.488]
200.0
[7.87]
147.5
[5.81]
200.0
[7.87]
Ø465.0
[18.31]
O-ring 124x4
[4.88x0.16] NBR 70
Spline data
Pitch dia : 33.34
[1.313]
Pressure angle : 30˚
Number of teeth :21
Pitch : 16/32
ANSI B92.1-1970, class 6
fillet root side fit
458.0
[18.03]
14.0
[0.55]
Ø127.0 +0.04 (H7)
0
[5.00 +0.002 ] 0
114.6
[4.51]
Series TM Transit Mixer Drive System
Service Manual
Dimensions – Gearbox TMG
7.5˚ 15˚
57.0
[2.24]
200.0
[7.87]
200.0
[7.87]
24x15˚
114.6
[4.51]
252.0
[9.92]
81.5
[3.209]
70.0
[2.76]
520L0482 • Rev BC • Dec 2010
Ø120.0
[4.72]
M8
16.0 [0.63]
deep
Connection for
waterpump
i = 0.41
26.0
[1.02]
13.0
[0.51]
5.0
[0.2]
Parallel key
A 6x6x20 DIN6885
Cover for water-pump-connection
Air breather
17.3
[0.68]
Ø22.0
[0.87]
Ø40.0
[1.57]
50.0
[1.97]
17.0
[0.67]
Ø40.0
[1.57]
505.0
[19.88]
192.0
[7.577]
110.0
[4.33]
35.0
[1.379]
6.0
[0.236]
12.0
[0.484]
53.0 67.0
[2.09] [2.64]
32.6
[1.28]
190.0
[7.48]
94.0
[3.689]
Ø22.0
[0.87]
Cover for speed sensor
connection
6x60˚
60˚
129.0
[5.08]
66.0
[2.6]
7˚
Ø17.0±0.2
[0.67±0.01]
7˚
1˚30'
18.5
[0.73]
241.7
[9.516]
18.0
[0.71]
215.0
[8.5]
20.0 max.
[0.787]
Ø100.0 +0.054 (H8)
0
[3.937 +0.0021 ] 0
Ø18.0 0 (h6)
-0.011
[0.7087 0 ] -0.0004
Securing device during transport
Displayed position turned 62.5˚
15˚
400.0
[15.75]
Variation of
drum flange
Dynamic swivel
angle max.
Ø419.0
[16.5]
Ø500.0 ±0.2
[19.685 ±0.008]
Ø530.0 0 (h9)
-0.155
[20.87 0 ] -0.0061
Oil dip stick
and oil inlet
M12
20.0 [0.79]
deep
75.0
Lubrication oil outlet
0
-5.0
[2.953 0 ] -0.2
P001 998E
mm
[in]
23

Gearbox Size 71.2
24
200.0
[7.87]
154.0
[6.063]
200.0
[7.87]
215.0
[8.5]
R245.0
[9.65]
241.0
[9.488]
Ø465.0
[18.31]
458.0
[18.03]
O-ring 124x4
[4.88x0.16] NBR 70
Ø127.0 +0.04 (H7)
0
[5.00 +0.002 ] 0
14.0
[0.55]
Spline data
Pitch dia : 33.34
[1.313]
Pressure angle : 30˚
Number of teeth :21
Pitch : 16/32
ANSI B92.1-1970, class 6
fillet root side fit
Series TM Transit Mixer Drive System
Service Manual
Dimensions – Gearbox TMG
7.5˚ 15˚
200.0
[7.87]
24x15˚
123.5
[4.86]
200.0
[7.87]
57.0
[2.24]
114.6
[4.51]
70.0
[2.76]
114.6
[4.51]
520L0482 • Rev BC • Dec 2010
Ø120.0
[4.72]
M8
16.0 [0.63]
deep
6x60˚
60˚
Connection for
waterpump
i=0.41
26.0
[1.02]
13.0
[0.51]
5.0
[0.2]
Parallel key
A 6x6x20 DIN6885
Cover for water-pump connection
Air breather
252.0
[9.92]
17.3
[0.68]
Ø40.0
[1.57]
50.0
[1.97]
Ø22.0
[0.87]
17.0
[0.67]
Ø40.0
[1.57]
505.0
[19.88]
192.0
[7.577]
110.0
[4.33]
6.0
[0.236]
35.0
[1.379]
12.0
[0.484]
94.0
[3.689]
Ø22.0
[0.87]
53.0 67.0
[2.09] [2.64]
32.6
[1.28]
190.0
[7.48]
Cover for speed sensor
connection
129.0
[5.08]
66.0
[2.6]
7˚
7˚
20.0 max.
[0.787]
1.5˚
18.5
[0.73]
18.0
[0.71]
215.0
[8.5]
Ø18.0 0 (h6)
-0.011
[0.7087 0 ] -0.0004
Ø100.0 +0.054 (H8)
0
[3.937 +0.0021 ] 0
Ø17.0±0.2
[0.67 ±0.01]
15˚
241.7
[9.516]
Oil dip stick
and oil inlet
Lubrication oil outlet
Securing device during transport
Displayed position turned 61.5˚
Variation of
drum flange
Dynamic swivel
angle max.
400.0
[15.75]
Ø419.0
[16.5]
Ø500.0 ±0.2
[19.685 ±0.008]
P001 999E
Ø530.0 0 (h9)
-0.155
[20.87 0 ] -0.0061
M12
20.0 [0.79]
deep
75.0 0
-5.0
[2.953 0 ] -0.2
mm
[in]

Series TM Transit Mixer Drive System
Service Manual
Notes
520L0482 • Rev BC • Dec 2010
25

General
Mounting the Motor
Mounting the
Speed Sensor
26
New self-sealing screw
must be use to fix the
speed sensor. Tightening
torque: 8 ± 2 Nm
[71 ± 18 lbf•in]
Mounting the Pump
Series TM Transit Mixer Drive System
Service Manual
Installation Instructions
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.
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.
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 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).
520L0482 • Rev BC • Dec 2010
F000 874 F000 861

Mounting the
Gearbox
Mounting the
Water Tank
Series TM Transit Mixer Drive System
Service Manual
Installation Instructions
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.
520L0482 • Rev BC • Dec 2010
WASHER IN ACC. TO
DIN 6916-21
GEARBOX FOOT
MIXER FRAME
10 +5 x70 (Stops)
STOPS (REAR DISCHARGE)
3.2
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:
410.0
[16.14]
WATER TANK
500.0 max.
[19.7]
0.15 A
P001 497E
mm
[in]
0,3
P001 498E
27

Mounting the
Drum Flange
28
The bolt must not be
removed until adjusting
the drum
The exact alignment of
gearbox and drum is
required for proper component
life.
Series TM Transit Mixer Drive System
Service Manual
Installation Instructions
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.
530.1+0.6 Drum flange dia
[20.87+0.024]
6.3
140.0 max. Drum flange dia
[5.51]
6.3
1 A
1.5 max. x 45˚
[0.6]
GEARBOX OUTPUT FLANGE
Drum flange
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]
between the drum flange and gearbox housing for the whole circumference; see below
10.5
[0.41]
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.
520L0482 • Rev BC • Dec 2010
A
mm
[in]
DRUM FLANGE
P003 002
P001 499E
TMG 51.2 TMG 61.2 / 71.2
18.5
[0.73]
P003 003

Mounting
Controller TME
Warning
Separate high current
wires from speed sensor
wire.
Series TM Transit Mixer Drive System
Service Manual
Installation Instructions
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 in 2 ]
• 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: 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 connectors:
• 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.
520L0482 • Rev BC • Dec 2010
29

Wiring Diagram – TME
Installation
Space – TME
30
Series TM Transit Mixer Drive System
Service Manual
Installation Instructions
Battery (+)
Battery (-)
VCC Voltage (+)
1
2
3
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].
520L0482 • Rev BC • Dec 2010
External
stop switch
F
4A
+
-
Batt.
12/24V
DC
Remote Station Cabin Station
Setpoint from Cabin
12V Valve (-)
24V Valve (-)
Remote/ON
Memoblink
PPU (-)
4
5
6
7
8
9
VCC/2
10
PPU signal
11
GND
12
Disable lost of feedback 13
Ext. Stop
14
Valve 0 (+)
15
Valve 1 (+)
16
(+)
Proportional valve 0
CHARGE
PPU (2-wire)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
VCC Voltage (+)
Setpoint to Remote
Remote/ON
Memoblink
VCC/2
AMP connector, 16-pin AMP connector, 16-pin
Proportional valve 1
DISCHARGE
P003 022E
R3 ±0.1
[0.12 ±0.004]
72.4 ± 0.3
[2.85 ±0.01]
Option: Safety function can be
invalidate by connecting.
93.4 ±0.3
[3.68 ±0.01]
max. 5
[0.20]
min. 1
[0.04]
min. 50
[1.97]
GND
mm
[in]
P001 937E
P001 938

Fluid Specification
Hydraulic Fluid
Cleanliness
Suction Filtration
Improper filter selection
can cause charge pump
cavitation.
Series TM Transit Mixer Drive System
Service Manual
Hydraulic Fluid
˚ C [ ˚F]
Minimum - 40
[ -40]
intermittent,
cold
start
Rated 1 04
[ 220]
Maximum 1 15
[ 240]
intermittent
1 ) At
the
hottest
point,
normally
the
motor
case
drain
port.
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 filter should be placed in the circuit between the reservoir and the
inlet to the pump.
TO LOW
PRESSURE
SIDE AND
CONTROL
Temperature Range 1)
Cleanliness Level and β x-Ratio
Required
fluid
cleanliness
level
Recommended β -ratio
x
for
suction
filtration
520L0482 • Rev BC • Dec 2010
ISO
4406
β3 5-45
HYDRAULIC FLUID RESERVOIR
CHARGE PUMP
FILTER
ADJUSTABLE
CHARGE PRESSURE RELIEF VALVE
TO PUMP CASE
lass
18/
13
MANO-
VACUUMMETER
P000 797E
Recommended β-ratio can be found on cleanliness level table.
C
= 75
( β ≥ 2)
10 Viscosity
mm2/ s [ SUS]
Minimum 7 [ 49]
intermittent
Recommended
operating
range
1 2-80
[ 70-370]
Maximum 1 600
[ 7500]
intermittent
cold
start
31

Required Tools
Port Location Pump
Port Location Motor
32
Series TM Transit Mixer Drive System
Service Manual
Pressure Measurement
The service procedures described in this manual for Series TM pumps and motors can be
performed using common mechanic‘s tools.
The following is a list of the ports for each type of hydraulic unit. The recommended
pressure gage and fitting are also specified.
Port Function Gage size
Fitting
M 1 S ystem
pressure
port
" A"
600 bar
[ 10
000
psi]
M12x1.
5 O-ring
boss
M 2 S ystem
pressure
port
" B"
600 bar
[ 10
000
psi]
M12x1.
5 O-ring
boss
M3C harge
pressure
60bar [ 1000
psi]
M12x1.
5 O-ring
boss
M4+ M5
A ctuating
piston
pressure
60bar [ 1000
psi]
M12x1.
5 O-ring
boss
M10 Vacuum charge
pump
M12x1.
5 O-ring
boss
L1+ L2
C ase
pressure
or
drain
ports
10bar [ 100
psi]
M22x1.
5 O-ring
boss
S Charge pump
inlet
M42x2
O-ring
boss
L1
L2
520L0482 • Rev BC • Dec 2010
Port Location Pump
X
Port Location Motor
Port Function Gage size
Fitting
M 1 S ystem
pressure
port
" A"
600 bar
[ 10
000
psi]
M12x1.
5 O-ring
boss
M 2 S ystem
pressure
port
" B"
600 bar
[ 10
000
psi]
M12x1.
5 O-ring
boss
M3L oop
flushing
pressure
60bar [ 1000
psi]
M12x1.
5 O-ring
boss
L1+ L2
C ase
pressure
or
drain
ports
10bar [ 100
psi]
M22x1.
5 O-ring
boss
X
L2
L1
M1
S
M10
M2
M2
X
X
M5
M1
M4
A
B
M3
P003 004
M3
P003 007

Series TM Transit Mixer Drive System
Service Manual
Notes
520L0482 • Rev BC • Dec 2010
33

General
Pump, motor and gearbox
are shipped without oil!
Gearbox
34
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
Series TM Transit Mixer Drive System
Service Manual
Start-up Procedure
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.
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 proportional 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
520L0482 • Rev BC • Dec 2010

Hydrostatics
(continued)
Tighten up any leaking
joints and other connections
while system is not
under pressure.
Series TM Transit Mixer Drive System
Service Manual
Start-up Procedure
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.
The transmission is now ready for operation!
520L0482 • Rev BC • Dec 2010
35

Gearbox TMG
When cleaning with a high
pressure water jet do not
direct the jet onto the
flange 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.
Safety
Hydrostatic
TMP and TMM
36
Tighten up any leaking
joints and other connections
while system is not
under pressure.
Replace defective seals.
Series TM Transit Mixer Drive System
Service Manual
Maintenance
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 (Hydraulic
Fluids and lubricants, Technical Information).
The level of the oil should be checked daily. In case of loss of oil, the leak should be rectified
and refill 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 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.
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.
520L0482 • Rev BC • Dec 2010

Hydrostatic
TMP and TMM
(continued)
Without this safety precautions
there could be
danger for body and life
e. g. danger for machines
and property.
use only recommended
fluids acc. Sauer-Danfoss
literature 520L0463.
It is not permissible to mix
oil of different brands.
Series TM Transit Mixer Drive System
Service Manual
Maintenance
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 ports 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.
520L0482 • Rev BC • Dec 2010
37

Drum Speed doesn‘t
Reached Maximum
Speed
System Operating Hot
38
Series TM Transit Mixer Drive System
Service Manual
Troubleshooting
Check
Pump input 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.
Proportional Valve
Value: 20 bar [290 psi]
at maximum current.
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.
Oil cooler.
Electrical fan drive.
Electrical fan drive.
520L0482 • Rev BC • Dec 2010
Description
Engine speed to low.
Incorrect setting on the
charge pressure relief valve.
Control pressure to low.
Dirty filter will increase the
inlet vacuum.
Dirty oil cooler will be influence
cooling capability.
Temperature switch failed.
Electrical motor failed.
Action
Select required engine
speed.
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.
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.
Check inlet pressure.
If too high, change the filter.
Clean the cooler.
Change temperature
switch.
Change electrical motor.

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
Series TM Transit Mixer Drive System
Service Manual
Troubleshooting
Check
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.
loop flushing shuttle spool.
Pump displacement control.
Multifunction valve.
Stop the engine immediately!
Set the rotary switch to
neutral; touch the yellow
switch; confirmed by lights
up LED.
520L0482 • Rev BC • Dec 2010
Description
Drum speed will be go
slower if the load increases
and charge pressure droops
too low.
Pre-selected direction and
speed but the drum
doesn‘ t turn.
Electrical proportional valve
is operating improperly.
Interchanging the valve to
see and how the failure is
related to the valve function.
Proportional valve is sticking
from contamination.
1) Or valve manual override on units with this options.
Light on signalls active
status.
If not, this means continuously
flashing and the
switch operating improperly.
Description
Action
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
controller (Remote/Cabin).
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.
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.
39

Cabin Station Active;
Signalled by Lights Up
LED
Drum Stopped During
Operation
How to Replace the
TME-Controller
40
Series TM Transit Mixer Drive System
Service Manual
Troubleshooting
Check
Set the rotary switch to
neutral; touch the yellow
switch; confirmed by off
LED.
Active controller signalled
through lighted lED.
P001 938
520L0482 • Rev BC • Dec 2010
Means, function transfer to
lED still on, the switch is
operating improperly.
If not, the required supply
voltage is not present.
lED indicats active status.
Action
Check the fuse in the supply
wire.
If destroyed, replace the
fuse and check the reason
for the short circuit.
• 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.
RED FIXTuRE
SCREW DRIVER
• 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.
F000 873
Disconnect the speed
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.

Emergency
Discharging
STOP the truck engine at
first!
IMPORTANT:
The special tool is an
essential part of the truck
mixer emergency tool kit.
Series TM Transit Mixer Drive System
Service Manual
Emergency Discharging
In case of a failed TME controller or pump control valve proceed as follows:
Main pressure port “A”
Main pressure port “B”
• Remove plug M12x1.5 from the actuating
cylinder “B” 1)
• 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).
• Start truck engine (low idle is recommanded
for slow discharge).
• 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.
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”.
520L0482 • Rev BC • Dec 2010
Rear Cover
Actuating cylinder “A”
Actuating cylinder “B”
TMM, main
ports show
P001 TMP, 963 right hand F300 689 rotation
F300 685
downwards 1)
F300 690
F000 876 F300 684
F000 875
F300 686
F300 687
41

42
Series TM Transit Mixer Drive System
Service Manual
Notes
520L0482 • Rev BC • Dec 2010

Series TM Transit Mixer Drive System
Service Manual
Notes
520L0482 • Rev BC • Dec 2010
43

Products we off er:
• Bent Axis Motors
• Closed Circuit Axial Piston Pumps
and Motors
• Displays
• Electrohydraulic Power Steering
• Electrohydraulics
• Hydraulic Power Steering
• Integrated Systems
• Joysticks and Control Handles
• Microcontrollers and Software
• Open Circuit Axial Piston Pumps
• Orbital Motors
• PluS+1 GuIDE
• Proportional Valves
• Sensors
• Steering
• Transit Mixer Drives
Members of the Sauer-Danfoss Group:
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmueller-inverter.com
Turolla
www.turollaocg.com
Hydro-Gear
www.hydro-gear.com
Sauer-Danfoss-Daikin
www.sauer-danfoss-daikin.com
520L0482 • Rev BC • Dec 2010
Sauer-Danfoss is a global manufacturer and supplier of highquality
hydraulic and electronic components. We specialize in
providing state-of-the-art technology and solutions that excel in
the harsh operating conditions of the mobile off -highway market.
Building on our extensive applications expertise, we work closely
with our customers to ensure exceptional performance for a broad
range of off -highway vehicles.
We help OEMs around the world speed up system development,
reduce costs and bring vehicles to market faster.
Sauer-Danfoss – your Strongest Partner in Mobile Hydraulics.
Go to www.sauer-danfoss.com for further product information.
Wherever off -highway vehicles are at work, so is Sauer-Danfoss.
We off er expert worldwide support for our customers, ensuring
the best possible solutions for outstanding performance. And with
an extensive network of Global Service Partners, we also provide
comprehensive global service for all of our components.
Please contact the Sauer-Danfoss representative nearest you.
local address:
Sauer-Danfoss (uS) Company
2800 East 13th Street
Ames, IA 50010, uSA
Phone: +1 515 239 6000
Fax: +1 515 239 6618
Sauer-Danfoss GmbH & Co. OHG
Postfach 2460, D-24531 Neumünster
Krokamp 35, D-24539 Neumünster, Germany
Phone: +49 4321 871 0
Fax: +49 4321 871 122
Sauer-Danfoss ApS
DK-6430 Nordborg, Denmark
Phone: +45 7488 4444
Fax: +45 7488 4400
Sauer-Danfoss-Daikin lTD.
Shin-Osaka TERASAKI 3rd Bldg. 6F
1-5-28 Nishimiyahara, yodogawa-ku
Osaka 532-0004, Japan
Phone: +81 6 6395 6066
Fax: +81 6 6395 8585
www.sauer-danfoss.com