Series TM

Transit Mixer Drive

System

Service Manual
 Series TM Transit Mixer Drive System
Service Manual
Contents

Functional General................................................................................................................................................................ 4
Description 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

Technical General Specifications.................................................................................................................................13

Specifications – Specific Data...................................................................................................................................................13
Axial Piston Pumps TMP Technical Data................................................................................................................................................13
Electrical Proportional Valves....................................................................................................................13
Circuit Diagram..............................................................................................................................................14
Determination of Nominal Pump Sizes.................................................................................................14

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

Axial Piston Pumps TMP

Technical General Specifications.................................................................................................................................18

Specifications – Specific Data...................................................................................................................................................18
Axial Piston Motors TMM Technical Data................................................................................................................................................18
Circuit Diagram..............................................................................................................................................19
Determination of Nominal Motor Sizes................................................................................................19

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

Axial Piston Motors TMM

Technical General Specifications.................................................................................................................................21

Specifications – Specific Data...................................................................................................................................................21
Gearbox TMG Technical Data................................................................................................................................................21

Dimensions – Gearbox Size 51.2..........................................................................................................................................22

Gearbox TMG 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

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

 Series TM Transit Mixer Drive System
Service Manual
Contents (continued)

Installation General..............................................................................................................................................................26
Instructions 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

Hydraulic Fluid Fluid Specification.........................................................................................................................................31

Hydraulic Fluid...............................................................................................................................................31
Cleanliness.......................................................................................................................................................31
Suction Filtration...........................................................................................................................................31

Pressure Required Tools................................................................................................................................................32

Measurement Port Location Pump......................................................................................................................................32
Port Location Motor.....................................................................................................................................32

Start-Up Procedure General..............................................................................................................................................................34

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

Maintenance Gearbox TMG..................................................................................................................................................36

Safety.................................................................................................................................................................36
Hydrostatic TMP and TMM.........................................................................................................................36

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

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

Discharging

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 Series TM Transit Mixer Drive System
Service Manual
Functional Description

General 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.

Transit The variable displacement pump TMP is designed to convert a mechanical input power
Mixer Pump – TMP into hydraulic power. The input shaft, driven by the engine PTO, turns the pump cylin-
der 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 propor-
tional control valves depending on the current value, which is generated by the TME
controller.

Variable Displacement Pump TMP

F300 691
F300 692

Cross Section – TMP

ACTUATING CYLINDER
ACTUATING PISTON
JOINT FLANGE

CYLINDER BLOCK

PISTON

CHARGE PUMP

INPUT SHAFT

VALVE PLATE

BEARING PLATE

P001 981E
SWASH PLATE

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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.
Cross Section

F300 691 P001 982

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.
Cross Section

Charge Relief
Valve

F300 691
P001 983

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.
Cross Section

HIGH PRESSURE RELIEF VALVE

SYSTEM CHECK VALVE

Multi Function
Valve

F300 691
HIGH PRESSURE
CHARGE PRESSURE P001 984E

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Functional Description

Input Shaft 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

F300 693 F300 688

Auxiliary Mounting Pads Auxiliary mounting pads are available in size ‘A‘ and ’B‘ to drive auxiliary hydraulic
pumps.
TMP with PTO ‘A’ Cross Section

F300 683
P001 985

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 Series TM Transit Mixer Drive System
Service Manual
Functional Description

Transit The fixed displacement motor TMM is designed to convert an input of hydraulic power
Mixer Motor – TMM 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

F000 857 F300 698

Cross Section – TMM

SHUTTLE SPOOL ORIFICED LOOP CYLINDER BLOCK
FLUSHING VALVE

OUTPUT SHAFT

BEARING PLATE PISTON

VALVE PLATE P001 953E

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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 loop-
flushing 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 “installa-
tion dirt“ is flushed out at the same time and can be picked up by the suction filtering
system.

Loop Flushing Device

X

F000 857 View “X”

F000 857

Cross Section

ORIFICED LOOP
FLUSHING VALVE

LOOP FLUSHING
SHUTTLE SPOOL P001 954E

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Functional Description

Transit The two-stage planetary gearbox has to turn and to carry one side of the drum of transit
Mixer Gearbox – TMG 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 DRUM FLANGE
DRIVE SHAFT
(90 degree turned)

MAIN BEARING

INPUT
SUN GEAR

CURVED TEETH
2-ND STAGE COUPLING
1-ST STAGE P001 986E

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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 Cross Section – Speed Sensor
and installed Speed Sensor

F000 861 P001 987

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Functional Description

Transit Mixer The controller constitutes a ready-to-install, operating unit, in dashboard design. The
Electronic – TME 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 estab-
lished, determines the reference motor speed at the input of the gearbox.
The speed sensor in the gearbox measures the actual speed as feedback for the control-
ler. The desired and actual values are compared and the pump 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 trans-
fered 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

Rotary Switch LED Rotary Switch LED

P001 956 P001 957

Touch Switch Touch Switch

Symbol used on the Controller

= Charging/Transport = Memory Switch “Stop/Start”

P001 958
Remote Station
P001 960

= Discharging
P001 959
= Changeover Switch
Cabin Station
P001
961

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Functional Description

Transit Mixer Drive In accordance with the rotary switch position on the TME controller unit (13), a current
System – TM set point is generated and provides to the electrical proportional valve (6) of the TMP
main pump (2) with a PWM signal. The necessary control oil supply is provided by the
feed circuit of the charge pump (3) and is delivered to the actuating cylinder (7) via the
electrical proportional valve (6). Depending on the current value, a proportional actuat-
ing pressure is established on the actuating cylinder (7) and therefore a stroke, which
adjusts the swash plate angle and 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 pre-
selected set point of the drum speed and controls the current to the electrical propor-
tional valves (6) which sets the swashplate of the pump to the appropriate 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 TMM TMG

6 13

L1 M1 L1 M1 10
6 N
n
M3
A 8 A 14
M5
M4 5
2 3

1 9
4 5
7 8 11
B B
M10 S L2 M2 L2 M3 M2
12
15
P001 962

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Technical Specifications – Axial Piston Pumps TMP

General Specifications for axial piston variable displacement pump are listed on these pages.
Specifications For definitions of the various specifications, see the related pages in this publication.

Pump type
Direction of rotation
Istallation position
Other system requirements
General Specifications
Axial piston pump with variable displacement swashplate axial piston design
Clockwise or counter-clockwise
Discretionary, the housing must always be filled with hydraulic fluid
Circuit overpressure protection, suitable reservoir

Specific Data Specific Data

Frame size
Dimension
070 089
cm3 70 89
Displacement Vg
[in3] [4.27] [5.43]
l/min 203 258
Maximum flow Qmax
[US gal/min] [54] [68]
kW 142 180
Maximum corner power p cornermax
[hp] [190] [242]
kg 61
Weight m
[lb] [134]
Mass moment of inertia kgm2 0.01777
J
of the internal rotation parts [lbf•ft2] [0.42]
Type of mounting Four (4) bolt flange, SAE flange configuration
Main pressure ports: SAE flange
Pipe connections
Remaining ports: SAE straight thread O-ring boss
Shaft configuration 100 mm [3.94 in] joint flange (DIN/ISO) or Splined ANSI

Technical Data Case Pressure Speed Limits

bar [psi] min-1 (rpm)
Frame size
Rated pressure 3 [44.0] 070 089
Maximum pressure (cold start) 5 [73.0] Minimum speed 500
Rated speed 2500
Maximum speed 2900

Theoretical Torque System Pressure Range, Input

Frame size 070 089 bar [psi]
At. maximum Nm/bar 1.11 1.42 Maximum delta pressure 420 [6090]
displacement [lbf•in/1000 psi] [680] [864]

Electrical General Data

Proportional Valves • Protection class: DIN VDE 0470: IP65/IPX7
• Electrical connections: AMP Junior Power Timer
• Supply pressure pPmax: 50 bar [725 psi]

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

Electrical Data
Voltage 12 V 24 V
R20 in Ω 5.3±5 % 21.2±5 %
I1 in mA 600±10 300±10
I2 in mA 1500±10 750±10

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Service Manual
Technical Specifications – Axial Piston Pumps TMP

Circuit Diagram
CB Ports:
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 M1 M10 = Gage port charge pump inlet
pressure
A
S = Charge pump inlet
M3
CA, CB = Electrical proportional valve
M5

M4

M10 S L2 M2
P001955E

Determination of
Nominal Pump Sizes Metric System Inch System
Vg • n • ηv Vg • n • η
Output flow: Qe = __________ l/min Qe = __________v [US gal/min]
1000 231
Vg • ∆p Vg • ∆p
Input torque: Me = ___________ Nm Me = __________ [lbf•in]
20 • π • ηmh 2 • π • ηmh

Me • n Qe • ∆p Vg • n • ∆p
Input power: Pe = _______ = _______ kW Pe = ____________ [hp]
9550 600 • ηt 396 000 • ηt

Qe • 1000 • ηv Qe • 231 • ηv
Input Speed: n = ______________ min-1 n = ____________ min-1 (rpm)
Vg Vg

Vg = Pump displacement per rev. cm3 [in3]

∆p = pHD - pND bar [psid]
ηv = Pump volumetric efficiency
ηmh = Pump mechanical-hydraulic
(Torque) efficiency
ηt = Pump overall efficiency
pHD = High pressure bar [psid]
pND = Low pressure bar [psid]

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Dimensions – Axial Piston Pumps TMP

Axial Piston Pumps mm

– Size 070 and 089 106.0 Split flange boss
[in]
Size and rotation direction
[4.175] are machinde beside the DN 25 Typ I 40MPa series
Case drain port L1 name plate; as example per ISO 6162
use highest port as outlet Ø12.0
[0.472] • 7L for 70 cc, left hand. 4 Thread: M12
Connector CA 49.0 M22x1.5 21 [0.83]
AMP Junior Power Timer [1.92] 11.0 min. [0.433] depth 54.8 17.0 full thread depth
[2.157] [0.679]
12.4
Ø15.0 +0.8 [0.49]
-0.3
2.3
[0.591+0.31] [0.091]
-0.12
8.5

[1.09]
27.8
57.2
[0.335] [2.25]

[3.56]

[4.33]
110.0
90.0
[3.73]
Ø60.0
(CCW) (CW) 95.0 [2.362]
[2.25]
57.25

Ø126.975±0.025

Ø100.0±0.3
[3.94±0.01]
[6.44]
163.0

X
[4.508]
114.5

[11.5]
292.0
Ø84.0
[3.31]
[5.0]

M42x2
[2.244-0.001] 20.0 [0.79] depth

[0.315]
Ø57.0-0.019

Ø8.0

Connector CB 149.0
AMP Junior 57.25 Case drain port L2 [5.86]
Power Timer [2.25] M22x1.5 254.0
11.0 min. [0.433] depth [9.98]
114.5 262.0
[4.51] [10.32]
146.0 304.0
[5.75] [11.96]
216.0 313.0
[8.50] [12.32] P001 988E

Direction of Rotation
NFPE
Port "A" Port "B"
valve
Clockwise
Output Input CA
(cw)
Counterclockwise
Input Output CB
(ccw)

X
105.00
[4.13]
89.00 Gage port M4
[3.50] Servo pressure
M12x1.5

Gage port M1 High pressure

System pressure port "A" relief valve port A
M12x1.5
12.7 [0.5] min. depth
Charge pressure
relief valve

Charge pump inlet S High pressure

relief valve port B

Gage port M10 Gage port M3

Charge pump Charge pressure
inlet pressure M12x1.5
M12x1.5 12.7 [0.5] min. depth
12.7 [0.5] min. depth
Gage port M5
Servo pressure
Gage port M2 M12x1.5
System pressure port "B"
M12x1.5
12.7 [0.5] min. depth P001 989E

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Dimensions – Axial Piston Pumps TMP

Option Spline Shaft – Size 070 Option Spline Shaft – Size 089
Axial Piston Pumps
– Size 070 and 089 mm
(continued) [in]
56.00 56.00
[2.207] [2.207]
45.00 max 45.00 max
[1.772] [1.772]
33.00 [1.31] 33.00 [1.31]
Full spline lenght Full spline lenght

-0.17

-0.007 ]

Ø37.60±0.09
[1.48±0.004]
Ø34.5 0

[1.358 0
R6 R6
[0.24] [0.24]
Ø80.00 max

Ø80.00 max
[3.15]

[3.15]
M10

M10
Ø29.00

Ø32.00
[1.13]

[1.26]
Spline data Spline data
Pitch dia : 33.338 Pitch dia : 36.513
[1.313] [1.438]
Pressure angle : 30˚ 20.00 Pressure angle : 30˚ 20.00
[0.792] [0.792]
Number of teeth : 21 Number of teeth : 23
Pitch : 16/32 28.50 max Pitch : 16/32 28.50 max
ANSI B92.1-1970 class 5 [1.122] [1.122]
ANSI B92.1-1970 class 5
fillet root side fit 51.00 fillet root side fit 51.00
[2.00] P001 990E [2.00] P001 991E

Option Auxiliary Pad SAE ”A” – Size 070 and 089

331.00
[13.05]
317.00
[12.49] 15.00
[0.591] Thread (2x)
10.50 M10,
[0.41] 19.0 [0.748] deep
1.20
[0.05]
[3.25 +0.005]
Ø82.6 +0.13

Ø87.12

106.375
0

[3.43]

[4.188]
0

for O-ring
1.78x82.3
[0.07x3.24]

Spline data
Pitch dia : 14.288
[0.563]
Pressure angle : 30˚ 106.375
Number of teeth : 9 [4.188]
Pitch : 16/32
ANSI B92.1-1970 class 6
fillet root side fit
Full spline lenght : 17.0
[0.669] P001 992E

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Dimensions – Axial Piston Pumps TMP

Option Auxiliary Pad SAE ”B” – Size 070 and 089

Axial Piston Pumps
– Size 070 and 089 mm
(continued) [in]

334.00
[13.15]
317.00
[12.49]
15.00
[0.591] Thread M12 (2x)
deep min.
10.50 [0.787]
[0.41]
1.20
[0.05]

[4.002 +0.005]
Ø101.65 +0.13

Ø106.80
0

146.00
[5.75]
0

for O-ring [4.2]

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] P001993E

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Technical Specifications – Axial Piston Motors TMM

General Specifications for axial piston fixed displacement motors are listed on these pages.
Specifications

Motor type
Direction of rotation
Istallation position
Other system requirements
General Specifications
Axial piston motor with fixed displacement swashplate axial piston design
Clockwise or counter-clockwise (bi-directional)
Discretionary, the housing must always be filled with hydraulic fluid
Circuit overpressure protection, suitable reservoir

Specific Data
Specific Data
Frame size
Dimension
070 089
cm3 70 89
Displacement Vg
[in3] [4.27] [5.43]
l/min 203 258
Maximum flow Qmax
[US gal/min] [54] [68]
kW 142 180
Maximum corner power p cornermax
[hp] [190] [242]
kg 35
Weight m
[lb] [77]
Mass moment of inertia kgm2 0.01777
J
of the internal rotation parts [lbf•ft2] [0.42]
Type of mounting Four (4) bold flange, SAE flange configuration
Main pressure ports: SAE flange
Pipe connections
Remaining ports: SAE straight thread O-ring boss
Shaft configuration Splined ANSI

Technical Data
Case Pressure Speed Limits
bar [psi] min-1 (rpm)
Frame size
Rated pressure 3 [44.0] 070 089
Maximum pressure (cold start) 5 [73.0] Rated speed 2500
Maximum speed 2900

Theoretical Torque System Pressure Range, Input

Frame size 070 089 bar [psi]
At. maximum Nm/bar 1.11 1.42 Maximum delta pressure 420 [6090]
displacement [lbf•in/1000 psi] [680] [864]

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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

L2 M3 M2 P003 021

Determination of
nominal motor sizes Metric System Inch System
Vg • n Vg • n
Input flow: Qe = _________ l/min Qe = ________ [US gal/min]
1000 • ηv 231• ηv
Vg • ∆p • ηmh Vg • ∆p • ηmh
Output torque: Me = ____________ Nm Me = ____________ [lbf-in]
20 • π 2•π

Me • n Qe • ∆p • ηt Vg • n • ∆p • ηt
Output power: Pe = _______ = ___________ kW Pe = _____________ [hp]
9550 600 396 000

Qe • 1000 • ηv Qe • 231 • ηv
Output Speed: n = ______________ min-1 n = ____________ min-1 (rpm)
Vg Vg

Vg = Motor displacement per rev. cm3 [in3]

∆p = pHD - pND bar [psid]
ηv = Motor volumetric efficiency
ηmh = Motor mechanical-hydraulic
(Torque) efficiency
ηt = Motor overall efficiency
pHD = High pressure bar [psid]
pND = Low pressure bar [psid]

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 Series TM Transit Mixer Drive System
Service Manual
Dimensions – Axial Piston Motors TMM

Axial Piston Motors –

Size 070 and 089 mm
[in]
249.00
[9.803]
207.00
[8.150]
118.00
[4.650]

Size identification Case drain port L2

are machined here : use highest port as outlet
7 for 70 cc M22x1.5
9 for 89 cc 12.40
[0.490]
12.00 Orificed loop
[0.470] 31.20 Full spline lenght flushing valve
L2 [1.228]
Ø15.00 +0.8
-0.3
[0.591 +0.031
[3.346] -0.012]
85.00

Ø127.00-0.05

[4.999-0.002 ]
Ø66.50 max.

L R
[2.618]

[7.492]

[4.508]

[6.457]
190.30

114.50

164.00
(ccw) (cw)
[3.346]
[3.740]

85.00
95.00

L1
72.00 46.30 max. 114.50
Case drain port L1 Spline data [4.508]
[2.835] [1.823]
M22x1.5 Pitch dia : 33.338
146.00
122.00 55.00 [1.313] [5.748]
[4.803] [2.169] Pressure angle : 30˚
Number of teeth : 21
218.00
[8.583] Pitch : 16/32
251.00 ANSI B92.1-1970, class 5
[9.882] fillet root side fit

Direction of Rotation
Port "A" Port "B"
Clockwise (cw) Output Input
Counterclockwise (ccw) Input Output

Gage port M2 Gage port M1

System pressure port B System pressure port A
M12x1.5 M12x1.5
Loop flushing A
shuttle spool Split flange boss
DN 25 Typ I 40MPa series
per ISO 6162
4 Thread: M12
21 [0.83]
full thread depth 41.60
[1.64]
[1.09]
27.80

Gage port M3
Loop flushing pressure

57.20
164.00 [2.250]
[6.460]

P001 996E
A

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 Series TM Transit Mixer Drive System
Service Manual
Technical Specifications – Gearbox TMG

General
Specifications
General Specifications
Size 51.2 and 61.2: Two-stage planetary
Gearbox
Size 71.2 : Two-stage planetary with initial spur gear stage
Direction of rotation Clockwise and counterclockwise
Purpose Drive the drum, carry the torque forces and a part of the drum weight
Options 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 i 101.9 111.5 131.3
Gearbox efficiency 0.96 0.96 0.95
Max. dynamic swivel angle of the drum flange ˚ ±6˚ ±7˚ ±7˚
Slope of the gearbox main shaft (design) ˚ 15˚ 15˚ 15˚
up to 7 m3 : max. 15˚
Max. drum installation angle 8 and 9 m3 : max. 12˚
˚
(adjusted through frame support) 10 m3 : max. 11˚
12 m3 : max. 11˚
kg 253 325 333
Weight
[lb] [558] [717] [735]
l/min 12 16 16
Lubricant volume
[US gal/min] [3.2] [4.2] [4.2]
Lubricant type EP-Gear lubricant 1)
API-class GL-5
FZG powerstage acc. to DIN 51 354 >12
Vicosity grade SAE 90
1)
Attention: Gear lubricant w/o EP-Additives reduce the life by 80 %.

Technical Data
Technical Data
Gearbox size 51.2 61.2 71.2
Nm 51 000 61 000 71 000
Max. output torque
[lb-ft] [37 600] [45 000] [52 350]
t 21.5 32 32
Permissible weight of the full drum
[lb] [47 410] [70 563] [70 563]
Permissible static radial load to the drum kN 130 180 180
flange [lbf ] [29 224] [40 464] [40 464]
Permissible dynamic radial load to the drum kN 265 350 350
flange (intermittent) [lbf ] [59 572] [78 680] [78 680]
Permissible static axial load to the drum kN 50 65 65
flange [lbf ] [11 240] [14 612] [14 612]
Permissible dynamic axial load to the drum kN 160 230 230
flange (intermittent) [lbf ] [35 968] [51 704] [51 704]
Output speed TM-performance min-1 (rpm) 15 14 14
Max. output speed w/o water pump drive min-1 (rpm) 18 18 16
Max. output speed with water pump drive min-1 (rpm) 18 16 16
˚C
Min./max. operating temperature -20 [-4] up to +85 [+185]
[˚F]

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 Series TM Transit Mixer Drive System
Service Manual
Dimensions – Gearbox TMG

Gearbox Size 51.2

458.0 mm
[18.03]
200.0 200.0 [in]
[7.87] [7.87]
12 x 30˚ Cover for speed sensor Oil dip stick
159.0 connection and oil inlet
30˚
[6.260]

˚
114.6 60
[4.51] 6x
6 0˚

Ø120.0
[4.72]
[4.51]
114.6

M8
16.0 [0.63]
deep
M12
20.0
[0.79] deep

Connection for
waterpump 194.5
70.0 i = 0.41 [7.66] 0
75.0 -5.0
[2.756]
20.0 max.

0 ]
[2.953-0.2
200.0 200.0
[0.787]
[1.02]
26.0

[0.20]
[0.51]

[7.87] [7.87]
13.0

5.0

Lubrication oil outlet

Parallel key 0
A 6x6x20 DIN6885 Ø18.0 -0.011 (h6)
[0.7087 0
Cover for water-pump-connection -0.0004 ]

Ø100.0 +0.054
0 (H8)
[3.937 +0.0021
0 ]

198.0
[7.78 Securing device during transport
]
110.0 Displayed position turned 62.5˚
Air breather
[4.43
]
Ø17.0
[0.67]

10.0
+3.0
]

[0.39
15.0

0 2]
[0.59

]
0
+0.1

Variation of
21.0
[0.84

drum flange
14.0
R225.0

Dynamic swivel
[8.86]
Ø426.0
[16.77]

[0.55] Ø22.0 41.0

[1.63 angle max.
[0.87 ]
]
Ø31.5
O-ring 124x4 [1.24
[4.88x0.16] NBR 70 ]
(h9)

Ø40.0 105.0
]
[19.685 ±0.008]

[20.87 -0.0061
(H7)

[1.57 [4.13]
Ø500.0 ±0.2
.0

Ø530.0 -0.155
4]

]
R168
]

6˚

[6.61

0
+0.002

0
Ø127.0 +0.04
0
0

[5.00

15˚
6˚

Ø40.0
74.5
400.0
5]

Spline data [1.57

[15.7

] [2.93 18.0
Pitch dia : 33.34 ]
50.0

[0.71]
]
[1.97

[1.313] Ø22.0
Pressure angle : 30˚ [0.87
246.3
]

]
[9.70

Number of teeth : 21
Pitch : 16/32
ANSI B92.1-1970, class 6
17.0
]

fillet root side fit 57.0

[0.67

53.0
[2.24] [2.09 67.0
] [2.64
205.0 ]
30.0
[8.06] 10.5
[1.18
188.0 ] [0.41]
[7.4] 55.0
[2.165]
454.0 P001 997E
[17.87]

22 520L0482 • Rev BC • Dec 2010

 Series TM Transit Mixer Drive System
Service Manual
Dimensions – Gearbox TMG

Gearbox Size 61.2

458.0
mm
200.0
[18.03]
200.0
[in]
[7.87] [7.87]
24x Cover for speed sensor
147.5 7.5˚ 15˚
15˚ connection
[5.81]
81.5 Oil dip stick
[3.209] and oil inlet

114.6
˚
[4.51] 60
6x
˚
60

Ø120.0
[4.51]

[4.72]
114.6

M8
16.0 [0.63]
deep
M12
20.0 [0.79]
deep

Connection for
waterpump
215.0 0
75.0 -5.0
70.0 i = 0.41
[8.5]
0 ]
[2.953-0.2
[2.76]
20.0 max.
[0.51]
[1.02]

[0.787]
26.0

[0.2]
13.0

200.0 200.0
5.0

Lubrication oil outlet

[7.87] [7.87]

Parallel key 0
Ø18.0 -0.011 (h6)
A 6x6x20 DIN6885
[0.7087 0
-0.0004 ]
Cover for water-pump-connection
Ø100.0 +0.054
0 (H8)
[3.937 +0.0021
0 ]
192.0 Securing device during transport
Air breather [7.57
7] Displayed position turned 62.5˚
110.0
[0.67±0.01]
Ø17.0±0.2

[4.33
]
35.0
[1.37
9]
6.0
[0.23
6]
1˚30'
[18.31]
Ø465.0
R245.0
[9.65]

[9.488]

14.0
241.0

Variation of
17.3

Ø22.0
[0.68

[0.55] [0.87 drum flange

]
Ø40.0 12.0 Dynamic swivel
O-ring 124x4
[1.57 [0.48 angle max.
[4.88x0.16] NBR 70 ] 4]
Ø419.0
[16.5]

(h9)

129.0
(H7)

[19.685 ±0.008]

]
Ø500.0 ±0.2

[20.87 -0.0061

[5.08]
7˚
]

Ø530.0 -0.155
[5.00 +0.002
Ø127.0 +0.04

0
0
0
0

15˚
7˚

18.5
Ø40.0
400.0
5]

Spline data [0.73]

[15.7

[1.57 94.0
Pitch dia : 33.34 ]
[3.68
[1.313] 9]
241.7
6]

Ø22.0
[9.51

Pressure angle : 30˚ [0.87

50.0
]
[1.97

Number of teeth : 21 ]
Pitch : 16/32
ANSI B92.1-1970, class 6
fillet root side fit 57.0
]
17.0
[0.67

[2.24] 53.0
[2.09 67.0
252.0 ] [2.64
[9.92] ] 18.0
32.6
[1.28 [0.71]
]
190.0
[7.48 66.0 P001 998E
] [2.6]
505.0
[19.88]

520L0482 • Rev BC • Dec 2010 23

 Series TM Transit Mixer Drive System
Service Manual
Dimensions – Gearbox TMG

Gearbox Size 71.2

458.0 mm
200.0
[18.03]
200.0
[in]
[7.87] [7.87]
24x1 Cover for speed sensor
154.0 7.5˚ 5˚
15˚ connection Oil dip stick
[6.063]
and oil inlet

114.6 ˚
60
[4.51] 6x ˚
60

Ø120.0
[4.51]

[4.72]
114.6

M8
16.0 [0.63]
deep
M12
20.0 [0.79]
deep

Connection for
waterpump
200.0 123.5 70.0 i=0.41 215.0
0
[8.5] 75.0 -5.0
[7.87] [4.86] [2.76]
20.0 max.

0 ]
[1.02]

[2.953-0.2
[0.51]

[0.787]
26.0

13.0

[0.2]

215.0 200.0
5.0

[8.5] [7.87] Lubrication oil outlet

Parallel key 0
A 6x6x20 DIN6885 Ø18.0 -0.011 (h6)
[0.7087 0
Cover for water-pump connection -0.0004 ]

+0.054
Ø100.0 0 (H8)
[3.937 +0.0021
0 ]
192.0 Securing device during transport
Air breather [7.57 Displayed position turned 61.5˚
7]
[0.67±0.01]
Ø17.0±0.2

110.0
[4.33
]
6.0
[0.23
6]
1.5˚

14.0
Ø465.0
[18.31]

35.0
R245.0

[0.55]
[9.65]

[9.488]
241.0

[1.37 Variation of
17.3
]

9]
[0.68

Ø22.0 drum flange

[0.87 Dynamic swivel
]
O-ring 124x4 12.0 angle max.
[4.88x0.16] NBR 70 Ø40.0 [0.48
[1.57 4]
] 129.0
Ø419.0
[16.5]
(H7)

[5.08]
(h9)
]

7˚

[19.685 ±0.008]

]
[5.00 +0.002

[20.87 -0.0061
Ø500.0 ±0.2
Ø127.0 +0.04

Ø530.0 -0.155
0
0

0
0
15˚
7˚

Ø40.0
Spline data [1.57 94.0
400.0
5]

] [3.68
Pitch dia : 33.34
[15.7

9]
[1.313] Ø22.0
241.7
6]

Pressure angle : 30˚ [0.87

50.0
]

[9.51
[1.97

]
Number of teeth : 21
18.5
Pitch : 16/32
[0.73]
ANSI B92.1-1970, class 6
17.0
]

53.0
[0.67

fillet root side fit 57.0

[2.09 67.0
[2.24] ] [2.64
]
252.0 32.6
[1.28 18.0
[9.92] ]
190.0 [0.71]
[7.48 66.0
] [2.6] P001 999E
505.0
[19.88]

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Series TM Transit Mixer Drive System
Service Manual
Notes

520L0482 • Rev BC • Dec 2010 25

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

Mounting the Gearbox mounting must be on a solid, distortion free, and flat support face.
Gearbox 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

0.15 A
GEARBOX FOOT
3.2

MIXER FRAME

10+5x70 (Stops)

STOPS (REAR DISCHARGE) P001 497E

Mounting the A water tank with max. 1500 l [396 US gal] volume can be attached to the upper part of
Water Tank 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]
500.0 max.

WATER TANK
[19.7]

0,3

P001 498E

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 Series TM Transit Mixer Drive System
Service Manual
Installation Instructions

Mounting the Unit will be shipped with the flange locked in the zero degree position.
Drum Flange 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 1 A

removed until adjusting 1.5 max. x 45˚

the drum [0.6]

6.3
DRUM FLANGE

6.3
530.1+0.6 Drum flange dia

140.0 max. Drum flange dia

[20.87+0.024]

[5.51]

GEARBOX OUTPUT FLANGE

Drum flange A

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 com-
TMG 51.2 TMG 61.2 / 71.2
ponent life.

18.5
10.5
P003 002 [0.73] P003 003
[0.41]

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

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 Series TM Transit Mixer Drive System
Service Manual
Installation Instructions

Mounting Machine wiring, see guidelines below:

Controller TME
• 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
Warning pumps from control wires. 
Separate high current • Run wires along the inside of, or close to, metal machine frame surface, where pos-
wires from speed sensor sible. This simulates a shield, which will help minimize the effects of EMI/RFI radiation.
wire. • 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 con-
nectors:

• Crimp Tool for Micro Timer - AMP/2-pin: Id. No. 515 895
• Die Set for 515 895: Id. No. 515 896
• Contact Extraction Tool for Micro Timer: Id. No. 517 023

The wiring diagram is on the next page.

520L0482 • Rev BC • Dec 2010 29

 Series TM Transit Mixer Drive System
Service Manual
Installation Instructions

Wiring Diagram – TME

F
4A + -
External Batt.
stop switch 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 10 VCC/2
(+)
PPU signal 11 PPU (2-wire) 11
GND 12 12 GND
Option: Safety function can be
Disable lost of feedback 13 13
invalidate by connecting.
Ext. Stop 14 14
Valve 0 (+) 15 15
Proportional valve 0
Valve 1 (+) 16 CHARGE 16

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

Proportional valve 1
DISCHARGE
P003 022E

Installation In order to accommodate the TME in the customer-specific housing, it is necessary to

Space – TME produce a cutout as illustrated below.
Tightening torque max. 1 Nm [0.7 lbf•ft].

mm
[in]
max. 5
[0.20] min. 50
72.4 ± 0.3 min. 1 [1.97]
[2.85 ±0.01] [0.04]
[3.68 ±0.01]
93.4 ±0.3

R3 ±0.1
[0.12 ±0.004]

P001 937E P001 938

30 520L0482 • Rev BC • Dec 2010

 Series TM Transit Mixer Drive System
Service Manual
Hydraulic Fluid

Fluid Specification Temperature Range1) Viscosity

˚C [˚F] mm2/s [SUS]
Minimum -40 [-40] intermittent, cold start Minimum 7 [49] intermittent
Rated 104 [220] Recommended
12-80 [70-370]
Maximum 115 [240] intermittent operating range
1)
At the hottest point, intermittent
Maximum 1600 [7500]
normally the motor case drain port. cold start

Cleanliness Level and βx-Ratio

Required fluid cleanliness
ISO 4406 Class 18/13
level
Recommended βx-ratio
β35-45=75 (β10≥2)
for suction filtration

Hydraulic Fluid 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).

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.
MANO-
VACUUMMETER
Improper filter selection
can cause charge pump
cavitation. HYDRAULIC FLUID RESERVOIR

CHARGE PUMP FILTER

ADJUSTABLE
TO LOW CHARGE PRESSURE RELIEF VALVE
PRESSURE
SIDE AND
CONTROL TO PUMP CASE P000 797E

Recommended β-ratio can be found on cleanliness level table.

520L0482 • Rev BC • Dec 2010 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 M12x1.5 O-ring boss
L1+L2 Case pressure or drain ports 10 bar [100 psi] M22x1.5 O-ring boss
S Charge pump inlet M42x2 O-ring boss

X
L1 M4

M1 A

S B
X
M10

M2 M3

M5 P003 004
L2

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 Loop flushing pressure 60 bar [1000 psi] M12x1.5 O-ring boss
L1+L2 Case pressure or drain ports 10 bar [100 psi] M22x1.5 O-ring boss

X
L2 M2 M1

X
M3

P003 007
L1

32 520L0482 • Rev BC • Dec 2010

Series TM Transit Mixer Drive System
Service Manual
Notes

520L0482 • Rev BC • Dec 2010 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 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
The pump must be in zero pump.
position. • 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 pres-
sure 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 dis-
Check and make sure that placement pump.
the rotary switch on the • Restart the engine, check the pump should remain in the neutral position (no drum
controller - Remote and rotation).
Cabin - are in neutral posi- With engine at normal operating speed, app. 1500-1600 min-1 (rpm), select the lowest
tion 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

34 520L0482 • Rev BC • Dec 2010

 Series TM Transit Mixer Drive System
Service Manual
Start-Up Procedure

Hydrostatics be constant at 2 min-1 (rpm).

(continued) • 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 neces-
Tighten up any leaking sary.
joints and other connec-
tions while system is not The transmission is now ready for operation!
under pressure.

520L0482 • Rev BC • Dec 2010 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 (Hydrau-
pressure 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 recti-
this 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 opera-
tion and the highest level of technology. However, there are certain dangers inherent
if they are improperly operated or if they are used for other purposes than they were
intended, for example, by unskilled personnel.

This may result in
• dangers for life and limb
• dangers for machines and other company assests
• adverse effects on the 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 The filter must be also changed if the inlet vacuum pressure is less than 0.7 bar absolute
TMP and TMM [-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 reduc-
tion 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 connec-
tions while system is not
under pressure.
Replace defective seals.

36 520L0482 • Rev BC • Dec 2010


Hydrostatic
TMP and TMM
(continued)
Without this safety pre-
cautions there could be
danger for body and life
e. g. danger for machines
and property.
Use only recommended
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 specifica-
tions. When reassembling do not exchange connection ports of pipes and hoses.
When exchanging system pressure ports, the direction of drum rotation will be changed.
Make certain that the oil 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
 Series TM Transit Mixer Drive System
Service Manual
Troubleshooting
Drum Speed doesn‘t Check
Reached Maximum
Speed 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.
System Operating Hot Oil cooler.
Electrical fan drive.
Electrical fan drive.
38 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 influ-
ence 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 mea-
sure the pressure in neutral.
If the pressure is low, turn
the screw clockwise to the
correct value. If not, please
check and change the relief
valve.
Stop the engine.
Disconnect the speed
sensor, install gage port in
M4 (M5) Start the engine.
Select maximum position
on the TME rotary switch.
If the control pressure is less
than 20 ± 1 bar
[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.
 Series TM Transit Mixer Drive System
Service Manual
Troubleshooting

Drum Speed Droops Check Description Action

Down Depending on
Increased Load Charge pump pressure in Drum speed will be go Change the transmission,
neutral Values: 21.5±1bar slower if the load increases pump and motor.
[312±14.5 psi // and charge pressure droops
1500 rev/min // suction line too low.
temperature 50±3 °C
[122±37 °F //
Gage Port M3.

Drum Rotating in One Loop flushing shuttle spool. Pre-selected direction and Check loop flushing shuttle
Direction Only speed but the drum spool which maybe “stick-
doesn‘ t turn. ing” in one direction Check
the springs of the shuttle
spool, too.

Pump displacement control. Electrical proportional valve Make cross-check with both
is operating improperly. 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.

Multifunction valve. Interchanging the valve to If the problem changes

see and how the failure is direction, replace the valve.
related to the valve func-
tion.

Drum doesn‘t Stop if the Stop the engine immedi- Proportional valve is stick- Using the “Emergeny Tool
Rotary Switch Turned to ately! ing from contamination. Kit”1) for discharging and
Neutral later on, replace the propor-
tional valve.

Light on signalls active

Remote Station in Set the rotary switch to
“Stand by”; Signalled by neutral; touch the yellow
Flashing LED switch; confirmed by lights
up LED.
status. Replace the Remote Station.
If not, this means con-
tinuously flashing and the
switch operating improp-
erly.
Description

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

520L0482 • Rev BC • Dec 2010 39

 Series TM Transit Mixer Drive System
Service Manual
Troubleshooting

Cabin Station Active; Check Action

Signalled by Lights Up
LED Set the rotary switch to
neutral; touch the yellow
switch; confirmed by off
LED.
Means, function transfer to
LED still on, the switch is
operating improperly.
If not, the required supply

Drum Stopped During Active controller signalled voltage is not present. Check the fuse in the supply
Operation through lighted LED. LED indicats active status. wire.
If destroyed, replace the
fuse and check the reason
for the short circuit.

How to Replace the

TME-Controller

Red fixture

Screw driver

P001 938 F000 873

• 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 Disconnect the speed

through lighted LED. 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.

40 520L0482 • Rev BC • Dec 2010


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:
Rear Cover
Actuating cylinder “A”
Main pressure port “A”
Main pressure port “B”
Actuating cylinder “B”
F000 876 F300 684
• Remove plug M12x1.5 from the actu-
ating cylinder “B” 1)
F000 875
TMM, main
ports show
P001
TMP,963 F300 689
right hand rotation F300 685
downwards 1)
• Install screw M12x1.5 with seal lock
nut into the actuating cylinder until
(appr. 80mm [3.15 in]) you feel notice-
able resistance, (when the screw
comes in contact with actuating
piston).
F300 686
F300 690
• Start truck engine (low idle is recom-
manded for slow discharge).
• Turn screw clockwise against actuat-
ing piston so the pump displacement
increases and the drum turns in
discharge direction at desired speed.
• Tighten lock nut to prevent external
leakage during operation.
F300 687
This description concerns to our recommended standard installation. If drums turns with the tool on servo
1)
cylinder “B” in wrong direction, change the tool to servo cylinder “A”.
520L0482 • Rev BC • Dec 2010 41
 Series TM Transit Mixer Drive System
Service Manual
Notes

42 520L0482 • Rev BC • Dec 2010

Series TM Transit Mixer Drive System
Service Manual
Notes

520L0482 • Rev BC • Dec 2010 43

Products we offer:
• 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 high-
quality hydraulic and electronic components. We specialize in
providing state-of-the-art technology and solutions that excel in
the harsh operating conditions of the mobile off-highway market.
Building on our extensive applications expertise, we work closely
with our customers to ensure exceptional performance for a broad
range of off-highway vehicles.
We help OEMs around the world speed up system development,
reduce costs and bring vehicles to market faster.
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 offer expert worldwide support for our customers, ensuring
the best possible solutions for outstanding performance. And with
an extensive network of Global Service Partners, we also provide
comprehensive global service for all of our components.
Please contact the Sauer-Danfoss representative nearest you.
local address:
Sauer-Danfoss (uS) Company Sauer-Danfoss ApS
2800 East 13th Street DK-6430 Nordborg, Denmark
Ames, IA 50010, uSA Phone: +45 7488 4444
Phone: +1 515 239 6000 Fax: +45 7488 4400
Fax: +1 515 239 6618
Sauer-Danfoss GmbH & Co. OHG Sauer-Danfoss-Daikin lTD.
Postfach 2460, D-24531 Neumünster Shin-Osaka TERASAKI 3rd Bldg. 6F
Krokamp 35, D-24539 Neumünster, Germany 1-5-28 Nishimiyahara, yodogawa-ku
Phone: +49 4321 871 0 Osaka 532-0004, Japan
Fax: +49 4321 871 122 Phone: +81 6 6395 6066
Fax: +81 6 6395 8585
www.sauer-danfoss.com