Moxy DA30 New pump and transmission with center mounted PTO

PROCEDURE & WARRANTY GUIDELINES

* Applicable when it is a Field Campaign Bulletin.

** When submitting warranty claim, please input the warranty code under phenomena field (Doobiz / Warranty claim submittal).

ISSUE

New improved transmission version with ZF part no.4662.028.020 will be introduced as aftermarket spare part.

To simplify the aftermarket spare parts stock, the exchange transmission with zf part no. 4662.028.007 and 4662.028.015 will be replaced with the new -020version.

The -020 transmission will be available with only 1 center mounted PTO flange, this affects the PTO direction of rotation. Direction of rotation has changed from CCW (counter clockwise) to CW (Clockwise).

This means that the hydraulic pump must be replaced together with the transmission to suit the new direction of rotation on the PTO if the transmission does not have center mounted PTO.

CORRECTION

An aftermarket kit with a new pump and connecting hoses has been made for aftermarket use. This must be ordered together with the new type transmission.

MX534255- Modification kit 2PTO to 1PTO

AFFECTED MACHINES

APPLICATION

Introduction at DIN from:

DA30

7X1090; Transmission with center mounted PTO introduced into production; DA30

7X1243; Improved transmission (-020) introduced into production;

Parts replacement overwiew:

Old design with two PTO’s. From machine no. 7X0001 to 7X1089

New design with one PTO. From machine no. 7X1090

Part Information

Tool Information

Tool name / description

Wrench 14mm, 17mm, 18mm, 21mm, 32mm, 36mm

Wrench reversible

Socket set 18mm, 21mm

Allen wrench/socket 8mm, 14mm

Thread locking fluid Loctite 245

Safety Procedure

1. Place the machine on a flat and level surface.
Apply the parking brake and secure the machine from rolling with wheel chocks.

2. Lift the body and secure it on the body support strut.

3. Turn the ignition to OFF and remove the key.
After turning the ignition “OFF”, wait 3 minutes before pressing the emergency stop button and to position the battery main switch to "OFF";

4. WARNING!
Brake Accumulators contain oil under high pressure!

Always empty the accumulators before working on or opening the hydraulic system.

Procedure:
•Stop the engine.
•Operate the brake pedal repeatedly. until the Service brake accumulators are empty.

Operate the parking brake switch until the parking brake accumulator is empty.
•Accumulators can also be emptied through the accumulator test point connections.

Be aware that the accumulators will be recharged with oil when the engine is started again!

Repair Procedure

Install the new bracket for the transmission dipstick.
Tightening torque: 65Nm
Re-use the clamp and screw.
Tightening torque: 10Nm

Install the hydraulic main pump to the transmission PTO flange.
Apply a thin Coat of oil to the O-ring.
Tightening torque. 330Nm

Mount the suction hose between the pump and tank.
Apply a thin coat of oil to the O-rings.
Re-use the flange half's previously mounted on the old pump.
Re-use the screws and flanges on the tank.
Tightening torque. 98Nm

Make sure there is clearance between the hose and steering valve bracket.

On the hydraulic tank.
Remove the old connector for the bleed line and install the new one.
Tightening torque: 180Nm

Mount the connector for the hose between the main pump and main valve.
Tightening torque: 140Nm

Install the new pump bleed line from the pump to the hydraulic tank.
Mount the hose between the tank and pump.
Tightening torque. 116Nm

Tie the drain hose to the suction hose with cable ties and straps.

Remove the old hose and install the new hose between the main pump and main valve.
Install the new O-ring to bot ends hose flanges.
Re-use the flange half's on the main valve Tightening torque: 45Nm
Re-use the flange half's from the previous pump.
Tightening torque: 130Nm

Note!
Make sure that the transmission dipstick tube is not crossing over the pressure hose from the pump.

Mount the connector to the LS port on the pump.
Point the connector against the lifting eye on the pump.
Use Loctite 245 to secure the connector lock nut
Tightening torque: 12Nm

Remove the old LS hose from the “LSP1” 11 outlet on the main valve.
Install the new LS hose between the pump and main valve
Tightening torque: 16Nm

On the Main valve.
Remove the valve on pos.23
Install the new fan pressure reduction valve.
Tightening torque: 40Nm

Tie the hydraulic hoses back together 13 with the straps previously removed. Make sure that none of the hoses can chafe against the transmission during operation

Checking and adjusting fan drive pressure 
After the rework, the new pressure reduction valve must be checked and adjusted to make sure the fan pressure is correct.
1.Lift the body and place it on the safety stand.
2.Put the cabin in service position on the safety stand.

3.Connect a pressure gauge to the FDM test port located on the hydraulic tank.

4.On top of the main hydraulic valve; Disconnect the electrical connector from the fan drive proportional valve to activate the cooling fan.
5.Start the engine.

6.Read out the max. fan drive pressure.
7.Loosen the lock nut and turn the adjustment screw on the relief valve to adjust the pressure.
Max fan pressure: 250bar
When the correct pressure is reached make sure to lock the adjustment screw again with the lock nut.
8.Turn off the engine and reattach the electrical connector to the proportional valve.