5HP500-590 4139_751_627d[1]

HP 500 / HP 590

NBS

Stage 3

4139 751 627d

REPAIR MANUAL

005380

005380

Subject to modification

Copyright by ZF

These repair instructions are protected by copyright. Any reproduction and dissemination in whatever

form – also in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or

electronic reproduction or as a storage in data-processing equipment or data networks without approval

by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law.

Printed in Germany

Edition: 2000-02

4139 751 627d

Ecomat HP 500 / HP 590 Contents

1-1

Chapter Contents Page

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Important work safety notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Sectional view of transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -11

Adjustment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Table of springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

1. Placing transmission in assembly stand and removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.1 Placing transmission in assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.2 Removing transmission from assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2. Removal, installation, disassembly and assembly of retarder accumulator . . . . . . . . . . . . 2-4

2.1 Removal of retarder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.2 Removal of retarder accumulator from side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.3 Installation of retarder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.4 Installation of retarder accumulator on side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.5 Disassembly of retarder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.6 Disassembly of retarder accumulator for side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . 2-9

2.7 Assembly of retarder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.8 Assembly of retarder accumulator for side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 2-11

3. Removal, installation, disassembly and assembly of oil cooler . . . . . . . . . . . . . . . . . . . . . . 2-12

3.1 Removal of oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

3.2 Removal of side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

3.3 Installation of oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

3.4 Installation of side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

3.5 Disassembly of oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

4. Disassembly and assembly of connecting components for side-mounted oil cooler . . . . . 2-19

4.1 Disassembly of connecting components for side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . 2-19

4.2 Assembly of oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

4.3 Assembly of connecting components for side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . 2-22

5. Removal, installation, disassembly and assembly of converter . . . . . . . . . . . . . . . . . . . . . . 2-23

5.1 Removal of converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

5.2 Installation of converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

5.2.1 Measurement of converter end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

5.2.2 Measurement of installation dimensions of converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

5.3 Disassembly of converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

5.3.1 Disassembly of stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

5.3.2 Assembly of stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

5.3.3 Disassembly of turbine wheel and circuit cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

5.3.4 Assembly of circuit cover and turbine wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

5.4 Assembly of converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

5.4.1 Measurement and setting of end play for axial bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

5.4.1.1 New O-ring seal on HP 590 converter (ZFW 380-30) fitted during repairs . . . . . . . . . . . . . . . . 2-52

5.4.2 Check for converter leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

Contents Ecomat HP 500 / HP 590

1-2


6. Removal and installation of cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

6.1 Removal of cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

6.2 Installation of cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

7. Removal and installation of oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

7.1 Removal of oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

7.2 Installation of oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

8. Removal and installation of inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

8.1 Removal of inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

8.2 Installation of inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

9. Removal, installation, disassembly and assembly of hydraulic transmission control unit 2-67

9.1 Removal of hydraulic transmission control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

9.1.1 Retrofitting impurity collecting magnets on hydraulic control unit . . . . . . . . . . . . . . . . . . . . . . 2-68

9.2 Installation of hydraulic transmission control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

9.3 Disassembly of hydraulic transmission control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

9.3.1 Disassembly of throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

9.3.2 Assembly of throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

9.3.3 Disassembly of valve block for brake “F”, lock-up clutch and clutches “C” and “A” . . . . . . . 2-80

9.3.4 Disassembly of valve block for clutch “B” and brakes “E”, “D” and “G” . . . . . . . . . . . . . . . . 2-84

9.4 Assembly of hydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

9.4.1 Assembly of valve block for brake “F”, lock-up clutch and clutches “C” and “A” . . . . . . . . . 2-89

9.4.2 Assembly of valve block for clutch “B” and brakes “E”, “D” and “G” . . . . . . . . . . . . . . . . . . 2-95

10. Removal and installation of retarder valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

10.1 Removal of retarder valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

10.2 Installation of retarder valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103

11. Removal, installation, disassembly and assembly of output cover . . . . . . . . . . . . . . . . . . . 2-108

11.1 Removal of output cover/inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108

11.1.1 Installation of inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109

11.2 Installation of output cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115

11.2.1 Measurement of end play on sun gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116

11.3 Disassembly of output cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121

11.4 Assembly of output cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-126

11.4.1 Adjustment of tapered roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129

11.4.2 Setting of disc play for brake “F” (NBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136

Ecomat HP 500 / HP 590 Contents

1-3


12. Removal and installation of mechanical transmission section . . . . . . . . . . . . . . . . . . . . . . 2-141

12.1 Removal of mechanical transmission section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141

12.1.1 Disassembly of planetary carrier II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-144

12.1.2 Assembly of planetary carrier II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-147

12.1.3 Disassembly of planetary carrier I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-151

12.1.4 Assembly of planetary carrier I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153

12.1.5 Removal of sun gear from disc carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-159

12.1.6 Installation of sun gear in disc carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-159

12.2 Installation of mechanical transmission section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-163

12.2.1 Measurement and adjustment of inductive sensor ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-172

13. Removal, installation, disassembly and assembly of control unit . . . . . . . . . . . . . . . . . . . . 2-173

13.1 Removal of control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-173

13.2 Installation of control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-175

13.3 Disassembly of control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-178

13.3.1 Disassembly of control insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-179

13.3.2 Assembly of control insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-191

13.3.3 Disassembly of clutch carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-204

13.3.4 Assembly of clutch carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-212

13.3.5 Clutch carrier leakage test and functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-225

13.4 Assembly of control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-227

14. Removal and installation of D brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-230

14.1 Removal of D brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-230

14.2 Installation of D brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-232

Preface Ecomat HP 500 / HP 590

1-4

This manual is intended for skilled personnel who have been trained by ZF Friedrichshafen AG to carry out

maintenance and repair work on ZF products.

This manual deals with the standard ZF product in accordance with the state of development on the date of

issue.

However, due to continuing development of the product, repair work might require work practices and test or

adjustment data which are not contained in this manual. We therefore recommend that work done on your ZF

product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on

a regular basis at our After-Sales Service training courses.

Service points equipped by ZF Friedrichshafen AG all over the world offer you:

1. Well-trained personnel

2. Specified equipment, e.g. specialized tools

3. Genuine ZF spares, to our latest specifications

All work performed in these service points is carried out conscientiously and with care.

Repair work carried out at ZF service points is guaranteed in accordance with the prevailing contractual

conditions.

Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner, together

with follow-on costs caused by such work, is excluded from the contractual warranty agreement. This also applies

where genuine ZF spares have not been used.

ZF FRIEDRICHSHAFEN AG

Friedrichshafen Division

After-Sales Service

Ecomat HP 500 / HP 590 General

1-5

General

The service manual deals with the ZF Ecomat HP500/HP590 4- and 5- speed version, including optional “Neutral

at Bus Stop” (NBS) function. The manual lists all the procedures required for disassembly and subsequent

assembly of the transmission.

When repairing the transmission, take extreme care with regard to cleanliness and workmanship. The transmission

should only be disassembled to replace damaged parts.

Cover and housing parts that are in contact with gaskets must be loosened by tapping with a plastic mallet once the

nuts or bolts have been loosened. Use suitable extraction devices to remove parts such as bearings, bearing races

etc., which are tightly fitted to the shafts.

Perform disassembly and assembly work in a clean working environment. Use the special tools which have been

specifically developed. Before reinstalling parts, clean the contact surfaces of the housing and cover to remove any

gasket residue. Remove any burrs or similar areas of roughness using an oil stone. Wash housings and the cover

plate with a suitable cleaning agent, paying particular attention to corners and angles. Renew damaged and severely

worn components. Expert personnel shall assess whether parts subject to normal wear, such as bearings, thrust

washers etc., should be reinstalled. Always renew parts such as sealing rings, fixing plates and split pins etc. Also

renew shaft sealing rings which have worn or torn sealing lips. Take particular care to ensure that no metal shavings

or other foreign bodies are left inside the housing. Check lubrication oil bores and grooves to ensure they are

perfectly clear.

Lubricate all bearings with oil before installing them.

NOTE: Only use an industrial oven or hot-air blower to heat up parts such as bearings, housings, etc.

CAUTION

When reassembling the transmission, observe the torques and adjustment data listed in the intructions exactly.

Unless otherwise stated, tighten bolts and nuts as listed in the standard table contained in this manual. Do not use

liquid sealant compounds in this transmission, because they can cause malfunctions in the control section.

Never use molycote grease.

Never wash lined disks. Only clean discs using a leather cloth.

DANGER

Observe the manufacturer’s instructions when using cleaning agents.

!

General Ecomat HP 500 / HP 590

1-6

Layout of the service manual

The layout of this manual corresponds to the order of working steps required to completely strip down a

transmission that has already been removed. Each section describes the removal and installation of a subassembly

and gives details of how to disassemble and reassemble that subassembly.

The start of each section also gives the preliminary work which must be performed if only the subassembly being

discussed in that particular section needs to be removed.

A list of special tools required for carrying out repair work are listed under the section headed „Special Tools“.

Important work safety notice:

Companies who repair ZF units are responsible for their own work safety.

To avoid injury to personnel and damage to products, all safety regulations and legal requirements which

apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize

themselves with these regulations.

Personnel required to carry out repairs on these ZF products must receive appropriate training in advance. It isnce.

It is the responsibility of each company to ensure that their repair staff is properly trained.

The following safety instructions appear in this manual:

NOTE: Refers to special processes, techniques, data, use

of auxiliary equipment, etc.

CAUTION This is used when incorrect, unprofessional

working practices could damage the product.

This is used when lack of care could lead to

personal injury or death.

NOTE: Read this manual carefully before starting any tests or repair work.

CAUTION

Pictures, drawings and components do not always represent the original object, but are used to illustrate working

procedures.

Pictures, drawings and components are not to scale and no information about size and weight should be inferred

(even within a complete illustration).

Always follow the working steps as described in the text.

NOTE: After completion of repair work and testing, skilled staff must satisfy themselves that the product is

functioning correctly.

DANGER!

General Ecomat HP 500 / HP 590

1-7

1 Input

2 Cover plate

4 Control insert

5 Oil feed flange

6 Clutch “A”

7 Clutch “B”

9 Housing

10 Planetary gear set I

11 Planetary gear set II

12 Planetary gear set III

13 Output

14 Inductive sensor “output”

15 Brake “F”

16 Brake “E”

17 Brake “D”

18 Control unit

19 Inductive sensor “turbine”

20 Oil pan

21 Retarder

22 Primary pump

23 Torque converter

24 Lock-up clutch “WK”

25 Turbine shaft

1-8

Sectional view of transmission Ecomat HP 500 / HP 590

Sectional view of the ECOMAT 4-speed version

004 250

1 2 4 5 6 7 9 10 11 12 13

25 24 23 22 21 20 19 18 17 16 15 14

004250

1-9

Ecomat HP 500 / HP 590 Sectional view of transmission

1 Input

2 Cover plate

3 Drive gears for PTO

4 Control insert

5 Oil feed flange

6 Clutch “A”

7 Clutch “B”

8 Clutch “C”

9 Housing

10 Planetary gear set I

11 Planetary gear set II

12 Planetary gear set III

13 Output

14 Inductive sensor “output”

15 Brake “F”

16 Brake “E”

17 Brake “D”

18 Control unit

19 Inductive sensor “turbine”

20 Oil pan

21 Retarder

22 Primary pump

23 Torque converter

24 Lock-up clutch “WK”

25 Turbine shaft

Sectional view of the ECOMAT 5-speed version

004 251

1 2 3 4 5 6 7 8 9 10 11 12 13

004251

25 24 23 22 21 20 19 18 17 16 15 14

1-10

Tightening torques Ecomat HP 500 / HP 590

1-11

Tightening torques for bolts and nuts from ZFN 148

This Standard applies for bolts as per DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and nuts as per DIN 934.

This Standard contains data on tightening torques (MA) for bolts in strength categories 8.8, 10.9 and 12.9 and nuts

in strength categories 8, 10 and 12.

Surface condition of bolts: heat-treated blackened finish and oiled; galvanized and oiled; galvanized, chrome-plated

and oiled.

Tighten screws using a calibrated signal or pointer-type torque wrench.

Edition: August 1991

Metric coarse pitch thread Metric fine pitch thread

Size Tightening torque Size Tightening torque

MA (Nm) for MA (Nm) for

Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9

Nut 8 10 12 Nut 8 10 12

M 4 2.8 4.1 4.8 M 8 x 1 24 36 43

M 5 5.5 8.1 9.5 M 9 x 1 36 53 62

M 6 9.5 14 16.5 M 10 x 1 52 76 89

M 7 15 23 28 M 10 x 1.25 49 72 84

M 8 23 34 40 M 12 x 1.25 87 125 150

M 10 46 68 79 M 12 x 1.5 83 122 145

M 12 79 115 135 M 14 x 1.5 135 200 235

M 14 125 185 215 M 16 x 1.5 205 300 360

M 16 195 280 330 M 18 x 1.5 310 440 520

M 18 280 390 460 M 18 x 2 290 420 490

M 20 390 560 650 M 20 x 1.5 430 620 720

M 22 530 750 880 M 22 x 1.5 580 820 960

M 24 670 960 1100 M 24 x 1.5 760 1100 1250

M 27 1000 1400 1650 M 24 x 2 730 1050 1200

M 30 1350 1900 2250 M 27 x 1.5 1100 1600 1850

M 27 x 2 1050 1500 1800

M 30 x 1.5 1550 2200 2550

M 30 x 2 1500 2100 2500

Description Data Measuring device Remarks

1-12

Ecomat HP 500 / HP 590Adjustment data

Converter

01. Installation dimension of

converter (depending on

version)

02. Converter end play be-

tween face end of inner race on

converter freewheel and spacer

ring on stator quill shaft.

03. Disc play of lock-up clutch

in converter.

04. End play of axial bearing

in converter

05. Maximum pressure for

converter leak test

06. Tightening torque of cap

screws on converter

HP 500 (M8)

HP 590 (M10)

07. Tightening torque of M16

cap screw in turbine shaft

08. Tightening torque of

M33x2 screw plug in converter

2.81 ± 0.02"

(71.25 ± 0.5 mm)

3.01 ± 0.02"

(77.00 ± 0.5 mm)

3.20 ± 0.02"

(81.25 ± 0.5 mm)

3.40 ± 0.02"

(86.25 ± 0.5 mm)

0.01 to 0.016"

(0.3 to 0.4 mm)

0.02 to 0.043"

(0.5 to 1.1 mm)

0.004 to 0.01"

(0.1 to 0.3 mm)

36 + 7 psi

(2.5 +0.5 bar)

= 26 ft-lbs (35 Nm)

= 44 ft-lbs (60 Nm)

133 to 140 ft-lbs

(180 to 190 Nm)

140 to 155 ft-lbs

(190 to 210 Nm)

Depth gauge

Depth gauge

Feeler gauge

Measurement bars and

depth gauge

Forcing device

1X56 137 129,

compressed air unit

1X56 137 130 and

water container

Torque wrench

Torque wrench and

supporting fixture

1X56 137 158

Torque wrench

Installation dimension

measured from flange face on

converter to flange face on

transmission housing.

Installation dimension can be

adjusted by placing one or

more spacer rings on stator

quill shaft.

End play can be adjusted by

adding shims to face end of

turbine shaft.

Measure disc play between

end disc and inner disc

Adjust by fitting spacer discs

between housing and turbine

flange

Check converter underwater

using air

Lock the converter using

brace bracket 1X56 137 658

Insert new copper sealing

washer.

Lock the converter using

brace bracket 1X56 137 658


1-13

Adjustment dataEcomat HP 500 / HP 590

Output

09. Specified distance between

contact face of inductive

sensor (in output cover) and

face of toothed disc (impulse

sensor)

10. End play of speedo shaft

11. Tooth backlash of speedo

shaft


shaft seal in output cover

13. Pre-load of taper roller

bearing in output cover when

cold (approx. 20 ºC)

14. Total end play between sun

gear and output


needle bearing in planetary

carrier III

16. End play of planetary gears

in planetary carrier III

0.02 to 0.027"

(0.5 to 0.7 mm)

0.004 to 0.01"

(0.1 to 0.3 mm)

0.004 to 0.008

(0.1 to 0.2 mm)

0.60 -0.04"

(15 -1 mm)

0.002 to 0.006"

(0.05 to 0.15 mm)

preload

1.8 to 6.4 Nm

Drag torque

0.02 to 0.03"

(0.6 to 0,8 mm)

0.10 + 0.04"

(2.5 +1 mm)

0.02 to 0.05"

(0.5 to 1.2 mm)

Depth gauge, measure-

ment rule 1P01 137 833

Depth gauge

Experience

Depth gauge

Setting device

1P01 136 816, dial

gauge and tension

balance

Measurement bars and

depth gauge

Depth gauge

Feeler gauge

Adjust distance using shims.

Can also be checked by hand

(touch)

Backlash is fixed, check by

hand (touch)

Adjust installation dimension

from end of tapered roller

bearing inner race to end face

of sealing ring using inserter

1X56 136 824. Double-check.

Set to 1.3 ft-lbs to 4.7 ft-lbs

(1.8 - 6.4 Nm) drag torque of

taper roller bearing. The

adjustment is made using

spacing washers. Difference

between speedometer worm

and setting ring = dimension

“C”.

Thickness "S" of spacing

washer =

C + 0.002" (0.05 mm).

Fit shims to output to obtain

correct setting.

Measured from thrust face of

shim to edge of needle

bearing. Use rod

1X56 137 101 to set the

correct installation

dimension.

End play is fixed, double-

check


1-14



stud bolts on output cover


hex nuts on output cover


inductive sensor (output speed)


hex bolts on output flange


speedo connection piece

3.7 to 5.6 ft-lbs

(5 to 7.5 Nm)

5 ft-lbs

6 Nm

max. 37 ft-lbs

(50 Nm)

44 ft-lbs

(60 Nm)

approx. 88 ft-lbs

(120 Nm)

Torque wrench

Torque wrench

Torque wrench

Torque wrench

Torque wrench

Do not exceed stated value

Secure with tab washer.

Use punch 1X56 136 471

Fit new copper sealing

washer

22. Separate check of primary

pump delivery volume

(theoretical value)

23. Clearance between spring

guide and guide bolt of stator

ring

approx. 18.5 gal/min

(60 l/min)

0.06 + 0.02"

(1.6 +0.5 mm)

Measuring container

and stopwatch

Vernier callipers

Measured at pump speed of

n = 1500 rpm. SAE 10 W oil

at 80°C. Primary pump is a

complete assembly.

Adjust by removing or

installing cup springs used for

installation. Measure with

cup springs in unloaded

condition.

24. Test pressure for pistons of

clutches “A”, “B” and “C”.

25. Disc play of clutch “A”

36 + 7 psi

(2.5 +0.5 bar)

0.13 to 0.15"

(3.2 to 3.7 mm)

Insertion bush

1X56 137 128,

Compressed air unit

1X56 137 130

Depth gauge

Pressure test for leakage:

Pressure drop of 36 + 7 psi to

20 psi (2.5 + 0.5 bar to 1.4

bar) after cut-off = 10 sec.

Deviations can be corrected

by installing steel discs of

differing thicknesses or a

different “A” piston

Control insert

Clutch carrier


1-15


26. Disc play of clutch “B”

27. Disc play of clutch “C”

28. Run-out of inductive sensor

ring when installed


hex nuts on rotor (retarder)

0.06 to 0.082"

(1.6 to 2.1 mm)

(HP 500)

0.08 to 0.10"

(2.0 to 2.5 mm)

(HP 590)

0.05 to 0.06"

(1.2 to 1.7 mm)

(HP 500)

0.06 to 0.082"

(1.6 to 2.1 mm)

(HP 590)

+ 0.008" (+ 0.2 mm)

26 ft-lbs (35 Nm)

Feeler gauge

Feeler gauge

Dial gauge

Torque wrench

Measure by inserting feeler

gauge between end disc and

outer disc. Correct deviations

by installing steel discs of

differing thicknesses or a

different “B” piston


gauge between reverse gear

„pot“ and outer disc. Correct

deviations by installing steel

discs of differing thicknesses

or a different “C” piston

Measure from the raised point

on the inductive sensor ring.

Correct by tapping lightly

with a plastic mallet.


in planetary carrier I

31. Disk play of brake “D”


needle bearing in input shaft


in planetary carrier III

0.02 to 0.05"

(0.5 to 1.2 mm)

0.06 to 0.082"

(1.6 to 2.1 mm)

0.16 + 0.04"

(4 +1 mm)

0.02 to 0.05"

(0.5 to 1.2 mm)

Feeler gauge

Feeler gauge

Depth gauge

Feeler gauge


check


gauge between end disc and

outer disc. Correct deviations

by adding or removing outer

discs.

Measured from thrust face of

thrust disc to edge of needle

bearing. If rod 1X56 137 101

is used, the installation

dimension will be correct.


check

Mechanical transmission

section


1-16


34. Disc play of brake “E”

35. Disc play of brake “F”

0.10 to 0.12"

(2.5 to 3.0 mm)

(HP 500)

0.12 to 0.14"

(3.0 to 3.5 mm)

(HP 590)

0.13 to 0.15"

(3.2 to 3.7 mm)

Feeler gauge

Depth gauge


gauge between sealing ring

and outer disc. Correct

deviations by adding outer

discs

Correct deviations by

inserting discs of differing

thicknesses or a different “F”

piston

36. Specific clearance between

contact face of inductive

sensor (in duct plate) and

raised areas around rim of

inductive sensor ring (impulse

sensor)


inductive sensor (turbine

speed)


M42x2 screw plug (tapered in

duct plate)

0.02 to 0.03"

(0.6 to 0.8 mm)

max. 37 ft-lbs

(50 Nm)

60 to 74 ft-lbs

(80 to 100 Nm)

Depth gauge,

measurement rule

1P01 137 833

Torque wrench

Torque wrench

Adjust clearance using shims

Do not exceed stated value


stud bolts on rear cover of

retarder accumulator


lock nuts on retarder

accumulator cover


M12x1.5 screw plug in

solenoid valve

5.6 to 7.4 ft-lbs

(7.5 to 10 Nm)

11 ft-lbs (15 Nm)

18 ft-lbs (25 Nm)

Torque wrench

Torque wrench

Torque wrench

Only replace stud bolts with

new ones if damaged

Fit washers


washer

Hydraulic control unit

Retarder accumulator


1-17



oil filler pipe


M30x1.5 slotted nut on oil

filler pipe


M22x1.5 oil drain plug in oil

pan


M10x1 screw plug on pressure

measuring ports


M10x1 union screws in cover

plate

1.57 + 0.04"

(40 +1.0 mm)

approx. 60 ft-lbs

(80 Nm)

37 ft-lbs

(50 Nm)

9 ft-lbs

(12 Nm)

approx. 15 ft-lbs

(20 Nm)

Depth gauge

Experience

Torque wrench

Torque wrench

Torque wrench

Measurement from sealing

face of transmission housing

(oil pan connection) to end of

filler pipe.

(Use sealing tape on thread)


washer


washer


washer

Other transmission data

Table of springs Ecomat HP 500 / HP 590

External

Order number Installation position No. of coils Wire dia spring dia Length (untensioned)

0732 041 934 Control insert - 13.50 0.055" 0.4" 2.21"

Stator ring (1.40 mm) (16.35 mm) (56.20 mm)

0732 041 718 Control insert - 14.50 0.095" 0.57" 2.42"

Main pressure valve P1 (2.40 mm) (14.58 mm) (61.60 mm)

0732 041 719 Control insert - 10.50 0.138" 0.90" 2.57"

Main pressure valve P1 (3.50 mm) (22.84 mm) (65.30 mm)

0732 042 113 Control insert - 17.50 0.110" 0.61" 2.93"

Main press. valve P2/P3.1 (2.80 mm) (15.66 mm) (74,56 mm)

0732 042 114 Control insert - 11.50 0.118" 0.90" 2.79"

Main press. valve P2/P3.1 (3.00 mm) (22.9 mm) (71.14 mm)

0732 041 125 Control insert - 4.50 0.098" 0.91" 0.89"

Lubrication pressure valve (2.50 mm) (22.94 mm) (22.70 mm)

0732 041 654 Control insert - Converter 10.50 0.110" 0.72" 1.90"

pressure back-up valve (2.80 mm) (18.40 mm) (48.50 mm)

0732 040 786 Control insert - 14.50 0.098" 0.69" 2.65"

Cooler change-over valve (2.50 mm) (17.54 mm) (67.40 mm)

0732 041 269 Clutch carrier 28.50 0.070" 0.45" 3.43"

B clutch (1.80 mm) (11.50 mm) (87.20 mm)

0732 041 373 Gearshift control - 27.50 0.035" 0.21" 1.51"

Valve blocks (0.90 mm) (5.40 mm) (38.40 mm)











1-18

1-19

Ecomat HP 500 / HP 590 Table of springs

External

Order number Installation position No. of coils Wire dia spring dia Length (untensioned)






Pre-control valve (2.25 mm) (11.81 mm) (63.40 mm)

0732 041 098 Retarder 12.50 0.055" 0.43" 1.43"

control valve (1.40 mm) (11.16 mm) (36.40 mm)

0732 041 142 Retarder 31.50 0.049" 0.36" 2.85"

control valve (1.25 mm) (9.21 mm) (72.50 mm)

0732 041 322 Retarder 9.50 0.098" 0.58" 2.31"-0.01

control valve (2.50 mm) (14.86 mm) (58.90 -0.03 mm)

0732 041 847 Disc brake “D” 10.50 0.062" 0.39" 1.09"

(1.60 mm) (10.10 mm) (27.80 mm)

0732 041 409 Disc brakes “E” and “F” 50.50 0.062" 0.33" 4.84"

(1.60 mm) (8.60 mm) (123.00 mm)

0732 042 334 Disc brakes “E” and “F” 22.50 0.05" 0.35" 2.44"

with "NBS" (1.50 mm) (8.96 mm) (62.36 mm)

0732 041 421 Clutch carrier - 24.50 0.07" 0.45" 3.10"

Reverse gear „pot“ (2.00 mm) (11.60 mm) (79.10 mm)

Ecomat HP 500 / HP 590Special tools

Fig. Illustration Order No. Application Qty. Remarks

No.

1X56 097 775

Assembly hooks

for lifting planetary carrier out of

housing

2

1

1X56 100 632

Adapter with taper

for shaft sealing ring (10 x 15 x 3) in

speedo connection piece

1

2

1X56 122 205

Internal extractor

for needle bearing (18 x 24 x 16) in

planetary carrier II and in input shaft

(use with 1X56 122 227)

1

3

1X56 122 208

Internal extractor

for needle bearing (45 x 52 x 16)

(use with 1X56 122 227)

1

4

1X56 122 227

Counter bracket

use with internal extractors

1X56 122 205 and 1X56 122 208

1

5

1-20

Special toolsEcomat HP 500 / HP 590


No.

1X56 122 306

Base tool

use with grip 1X56 136 706

1

6

1X56 122 322

Extractor

for grooved ball bearing

(0635 331 232) in control insert

1

7

1X56 124 659

Extractor plate

for bearing inner race on stator quill

shaft

1

8

1X56 126 464

Extractor

for speedo worm

1

9

1X56 136 260

Lifting device

for complete output

1

10

1-21



No.

1X56 136 471

Punch

for tab washer on output flange

1

11

1X56 136 513 (220V) Optional

1X56 137 575 (110V)

Hot-air blower

for heating various components

1

12

1X56 136 594

Adapter (LH)

for supporting the transmission (use

with assembly stand 1X56 137 450)

1

13

1X56 136 595

Adapter (RH)

for supporting the transmission (use

with assembly stand 1X56 137 450)

1

14

1X56 136 605

Punch

for shaft sealing ring

(125 x 150 x 10) behind torque

converter

1

15

1-22



No.

1X56 136 612

M8 Hook

for lifting control insert off clutch

carrier

2

16

1P01 137 833

Measurement rod

for measuring inductive sensor

clearance

1

17

1X56 136 706

Grip

for tapered roller bearing

(0635 370 006) on output

1

18

1X56 136 815

Extractor

for cover plate behind torque

converter

3

19

1P01 136 816

Adjustment device

for tapered roller bearing on output

1

20

1-23



No.

1X56 136 818

Support

for oil feed flange when fitting

control insert

1

21

1X56 136 820

Punch

for removal of bush in stator quill

shaft

1

22

1X56 136 821

M8 guide bolts

for installation of control insert and

primary pump

2

23

1X56 136 824

Inserter

for shaft sealing ring (90 x 125 x 10)

on output and bearing outer race in

output cover

1

24

1X56 136 862

Lifting device

for converter

1

25

1-24



No.

1X56 137 101

Rod


planetary carrier III and input shaft

1

26

1X56 137 103

Rod


clutch body hub

1

27

1X56 137 104

Pressure piece

for pulling off grooved ball bearing

in control insert

(use with 1X56 122 322)

1

28

1X56 137 105

Pressure piece

for inserting securing rings in front

of “A” piston cup springs

1

29

1X56 137 107

1X56 137 107

Device

for inserting spacer rings

4139 310 018 in control insert

1

30

1-25



No.

1X56 137 108

Clamping device

for removal and installation of main

pressure valve and lubricating

pressure valve and/or converter

pressure back-up valve in control

insert

1

31

1X56 137 109

Rod

for separating clutch carrier from

control insert

1

32

1X56 137 126

Lifting device

for Ecomat transmissions

1

33

1X56 137 127

Clamping device

for inductive sensor ring

1

34

1X56 137 128

Insertion bush

for leakage check of clutches in

clutch carrier

1

35

1-26



No.

1X56 137 129

Forcing device

for converter leak test

1

36

1X56 137 130

Compressed air unit

for leak test of converter and clutch

carrier. Use with insertion bush

1X56 137 128 and forcing device

1X56 137 129

1

37

1X56 137 151

Punch

for knocking in and peening the

pressure control unit orifices

1

38

1X56 137 152

Support

for stator bearing

2

39

1X56 137 153

Insert

for cleaning oil cooler

2

40

1-27



No.

1X56 137 156

Punch

for knocking out orifices

1

41

1X56 137 158

Holding device

for loosening and tightening M16

cap screw in converter

1

42

1P01 137 173

Plug gauge

range 0.03 to 0.12” (0.7 to 3.0 mm),

for measuring orifices

1

43

1X56 137 213

Lifting device

for turbine shaft

1

44

1X56 137 273

Internal hex head driver

for cap screws on control insert

1

45

1-28



No.

1X56 137 432

Extractor

for pressing off piston ring carrier

from stator quill shaft

1

46

1X56 137 450

Assembly stand

can be swivelled/pivoted

1

47

1X56 137 464

Support

for securing planetary gear pins

1

48

1X56 137 465

Punch

for closing in the planetary gear pins

of planetary carrier I

1

49

1X56 137 466

Punch

for closing in the planetary gear pins

of planetary carriers II and III

1

50

1-29

Special tools


No.

1X56 137 658

Brace bracket

for loosening and tightening screw

plugs in converter

1

51

1X56 150 111

M6 threaded pin

for control unit

2

52

1P01 137 906

Adjustment device

for setting NBS (Neutral at bus stop)

1

53

1-30

Ecomat HP 500 / HP 590

Ecomat HP 500 / HP 590 Special tools

1-31

“Make your own” auxiliary tools

Auxiliary punch for centring planetary gears

4139 333 041 4139 233 049 / 4139 333 667

ø 1 0.9834 - 0.002” 1.1803 - 0.002”

24.98 - 0.05 mm 29.98 - 0.05 mm

ø 2 0.5897 - 0.002” 0.7866 - 0.002”

14.98 - 0.05 mm 19.98 - 0.05 mm

L 1 3.15” 3.15”

80 mm 80 mm

L2 0.315” 0.315”

8 mm 8 mm

ø 1

ø 2

L 1

L 2

000786

008380

008381

1 Placing transmission in assembly stand and

removing.

1.1 Placing transmission in assembly stand.

1 Secure adapters (1/2) on the transmission assembly

stand.

2 Tighten M10 hex nuts and bolts;

Tightening torque: 34 ft-lbs (46 Nm).

3 Unscrew cap screws (4).

4 Set distance “A” to approx. 21.65” (550 mm) by

moving the center cross-beam.

5 Tighten cap screws (4).

6 Attach lifting device 1X56 137 126 to output cover

(1).

7 Screw in four M16x1.5 hex bolts;


8 Unscrew shackle (1) and insert it and ring (2) into

the correct bore. Tighten the shackle.

9 Attach ring (2) to the crane hook. Move the

transmission over the assembly stand, center it

between the adapters and lower it into the assembly

stand.

DANGER

Insert the shackle carefully.

See the instruction plate on the lifting device.

2-1

Ecomat HP 500 / HP 590 Assembly stand

!

12

3

4

4

5

008382

008383

008384

10 Tighten the RH adapter on the transmission. Screw

in hex bolts (1);

Tightening torque: 166.4 ft-lbs (225 Nm).

11 Pivot the LH adapter (1) upwards and fasten it to

the transmission with M16x1.5 hex bolts;


12 Remove the crane hooks and the lifting device.

13 Release the assembly stand and pivot the

transmission into the desired position.

2-2

Assembly stand Ecomat HP 500 / HP 590

DANGER

Avoid knocking or hitting the transmission

outside of its axis of rotation.

!

DANGER

Stand clear when pivoting the transmission.

Lock the assembly stand with a pin after

pivoting the transmission. Secure pin (1) with

lock screw (2).

!

008385

008386

008387

1.2 Removing transmission from assembly stand.

1 Place lifting device 1X156 137 126 against the

output cover. Screw in four hex bolts;

Tightening torque: 81 ft-lbs (110 Nm)

2 Attach a crane hook to ring (1).

3 Using lifting equipment, lift until ring (1) is under

slight tension.

4 Unscrew the hex bolts from the adapters.

5 Remove the transmission from the assembly stand.

2-3

Ecomat HP 500 / HP 590 Assembly stand

DANGER

Do not lift the assembly stand.

!

DANGER

Secure the LH adapter to stop it swinging down.

!

DANGER

The transmission may drop slightly - take care

not to get trapped.

!

008388

008389

008390

2 Removal, installation, disassembly and assembly

of retarder accumulator.

2.1 Removal of retarder accumulator.

1 Unscrew and remove M8 hex bolts (1). Remove

solenoid valve (2) from the accumulator.

2 Unscrew and remove M10 hex bolts (1) from the

output cover.

3 Unscrew and remove M8 cap screws (1). Remove

the retarder accumulator from connection (2).

2-4

Retarder accumulator Ecomat HP 500 / HP 590

001558

001558

001565

001565

2.2 Removal of retarder accumulator from side-

mounted oil cooler.

1 Unscrew M8 hex bolts and remove solenoid valve

(2) with O-ring (3) from the accumulator.

2 Unscrew hex bolts (1) and remove retarder

accumulator (2) with gaskets (3) from oil cooler

(4).

2-5

Ecomat HP 500 / HP 590 Retarder accumulator

1

2

3

1

2

3

4

3

008393

008391

008392

2.3 Installation of retarder accumulator

1 Insert new O-ring (1) in the accumulator cover.

NOTE: Coat the O-ring with Vaseline.

2 Push the retarder accumulator against the

connection. Fit one washer to each M8x2.5 cap

screw (1) and bolt the retarder accumulator onto the

connection;


3 Fit a washer to each M10 hex bolt (1) and bolt the

bracket onto the output cover;

Tightening torque: 34 ft-lbs (46 Nm)).

NOTE: Ensure the accumulator is not placed under

tension due to the bracket. Use washers to correct if

necessary.

2-6


008394

008395

001573

001573

4 Coat new O-ring (1) with Vaseline and insert it in

the solenoid valve.

5 Hold solenoid valve (1) against the accumulator.

6 Fit one washer to each M8x55 hex bolt (2) and

screw them into the solenoid valve;


NOTE: Fit the solenoid valve with the electrical

connection pointing upwards (3).

2.4 Installation of retarder accumulator on

side-mounted oil cooler.

1 Hold retarder accumulator (1) and gaskets (2)

against oil cooler (3).

2 Fit washers to six hex bolts (4) and screw on the oil

accumulator;


3 Coat new O-ring (5) with Vaseline and insert it into

the solenoid valve.

4 Hold solenoid valve (6) against the accumulator.

Screw it on using two hex bolts (7) and washers;


2-7


1

2

3

4

5

67

008396

008398

008397

2.5 Disassembly of retarder accumulator.

1 Remove M8 lock nuts (1) and washers.

2 Remove connection plate (2).

3 Remove rear cover (1).

4 Slide complete piston (2) out of tube (3).

5 Use a suitable tool to remove grooved rings (1)

from piston.

6 Remove piston guide ring (2) from piston.

2-8


008399

001574

001574

7 If any of the threaded pins (1) are damaged, use a

bolt drawer or bolt punch to remove it from the rear

cover.

8 Screw in a new threaded pin if required;

Tightening torque: 5.6 to 7.4 ft-lbs (7.5 to 10 Nm).

2.6 Disassembly of retarder accumulator for


1 Disassemble the retarder accumulator as described

in 2.5.

NOTE: The retarder accumulator connection plates (1)

and (2) are different.

2-9


1

2

008400

008401

008402

2.7 Assembly of retarder accumulator.

NOTE: Clean all parts thoroughly before assembly.

Always renew slotted rings, O-rings, piston guide rings,

cap collars etc.

1 Insert new slotted rings (1) into the piston ring

groove.

2 Insert new piston guide ring (2) onto the piston.

CAUTION

Insert slotted rings with their open side facing outwards.

3 Coat the outside of the piston and the inside of the

pipe with grease MIL-G-24 139. (Grease quantity

1/8 - 1/4 cubic inch (2 cc to 4 cc).

4 Insert piston (1) into pipe (2).

CAUTION

Do not damage the slotted rings when inserting them.

5 Slide new O-ring (1) onto rear cover (2) and coat

with Vaseline.

6 Slide pipe (3) and piston onto the rear cover.

CAUTION

Slide on the pipe so that the stamped number on the

piston faces towards the rear cover.

2-10


008403

008404

001574

001574

7 Coat new O-ring (1) with Vaseline and place it on

the connection plate.

8 Slide connection plate (2) onto threaded pin (3).

NOTE: Make sure the extension piece of the connection

plate faces the bracket on the rear cover.

9 Screw on M8 lock nuts (1) and washers;


NOTE: Use new lock nuts.

2.8 Assembly of retarder accumulator on


1 Assemble the retarder accumulator as described in

2.7.

NOTE: The retarder accumulator connection plates (1)

and (2) are different. Ensure the connection plates are

positioned correctly. Assemble the retarder accumulator

on a flat surface plate.

2-11


2

1

001575

001575

001577

001577


of oil cooler.

3.1 Removal of oil cooler.

1 Unscrew and remove hex bolts (1) from the

connection.

2 Using a plastic mallet, knock the connection down

off the oil pipes.

3 Remove gaskets (2) from the connection and/or

transmission.

4 Remove inserts (3) and O-rings (4) from housing

bores.

NOTE: Step 4 only applies for the version with new

housing (from transmission no. 96173; modification

no.: 65556).

5 Pull oil pipes (1) and O-rings (2) out of the bores in

the oil cooler.

2-12

Oil cooler Ecomat HP 500 / HP 590

1

2

1

005576

1

2

3

4

008405

008406

008407

6 Unscrew M18x1.5 screw plug (1) and drain the

water from the oil cooler.

7 Remove sealant from oil drain plugs (1) with a

triangular scraper.

8 Unscrew and remove M12x1.5 oil drain plugs (2)

from the oil cooler and drain the oil.

NOTE: Oil drain plugs may or may not be fitted,

depending on the version.

9 Unscrew M10 hex nuts (1) from the bottom of the

oil cooler.

Remove the washers.

2-13

Ecomat HP 500 / HP 590 Oil cooler

008408

001562

10 Unscrew M10 hex nuts (1).

Remove the washers.

11 Remove (lift) oil cooler (2).

NOTE: If necessary, separate the oil cooler from the

connection pipes by tapping it lightly with a plastic

mallet.

3.2 Removal of side-mounted oil cooler.

1 Unscrew and remove M8 hex bolts (2) from the

connection.

2 Unscrew and remove hex bolts (3) from retaining

brackets (4) and (5).

3 Remove (lift) the oil cooler and gasket (6).

CAUTION

Remove and transport the oil cooler carefully.

2-14


DANGER

The oil cooler weighs approx. 50 lbs (25 kg).

Take extra care when lifting and transporting it.

!

001561

001562/001561

3

34

56

2

1

008410

008409

3.3 Installation of oil cooler.

1 Coat O-rings (4) with vaseline and place in bores

on housing.

2 Place bushes (3) in bores.

NOTE: Steps 1 and 1 only apply for the version with

new housing (from transmission no.: 96173;

modification no.: 65556).

3 Place connecting piece (1) with gasket (2) on

transmission. Screw in hex bolts;


4 Coat O-rings (1) with vaseline and push onto both

ends of the oil pipes. Place oil pipes (2) in

connecting piece.

5 Place oil cooler (1) onto the mounting threads and

push connection pipes into the oil cooler.

6 Screw on hex nuts (2) and washers until hand-tight.

2-15


005576

1

2

3

4

8 Thoroughly clean M12x1.5 oil drain plugs (1) and

seats (2).

9 Tighten oil drain plugs;


10 Fit the water drain plug with a new M18x1.5

sealing ring (3) and screw it in;


11 Seal oil drain plugs with silicon paste (if oil drain

plugs fitted).

NOTE: Oil drain plugs may or may not be fitted,

depending on version.

008411

008412

7 Screw on M10 hex nuts (1) and washers;


2-16


DANGER

See special safety regulations for cleaning

agents.

!

001561

001561

3.4 Installation of side-mounted oil cooler.

1 Attach the retaining bracket to the transmission.

2 Attach the oil cooler to the fixing plate.

3 Coat gaskets (1, 2) with Vaseline and position them

on the transmission and oil cooler.

4 Screw the pre-assembled connection with inserted

oil pipes onto the oil cooler;


5 Screw hex bolts (3) and washers into the

connection;


6 Tighten M10 hex bolts on the retaining bracket;


2-17


1

2

3

008413

008415

008414

3.5 Disassembly of oil cooler.

1 Unscrew seven M8 cap screws (1).

2 Unscrew M8 (1) and M6 (2) cap screws from the

rear of the oil cooler.

3 Unscrew M8 cap screws (1).

4 Drive out the clamping pins.

5 Remove cover (3) from the oil cooler

2-18


008416

001563

001563

008417

6 Remove gasket (1) from the oil cooler housing.

7 Remove gaskets (2) from the heat exchanger.

8 Pull heat exchanger (3) out of the oil cooler housing

and remove silicone partition (4).

NOTE: Because of the O-ring, the heat exchanger is

quite firmly located in the oil cooler housing.

4 Disassembly and assembly of connection

components for side-mounted oil cooler.

4.1 Disassembly of connection components for


1 Unscrew hex bolts (1) from pipes (2) and (3) and

remove the pipes and gaskets (4) from the oil

cooler.

2 Pull oil pipes (2) and (3) out of the connection and

slide O-rings (5) off the oil pipes.

4.2 Assembly of oil cooler.

1 Check the heat exchanger for damage and renew it

if necessary.

2 If re-using the same heat exchanger, renew O-ring

(1).

2-19


1

3

2

45

5

1

008420

008419

008418

3 Insert both heat exchangers (1) one after the other

into the oil cooler housing.

4 Insert silicone partition (2) between the two heat

exchangers.

NOTE Clean the metal sealing faces before installing

the gaskets. Use an oil stone, for example.

5 Position new gaskets (1) on the heat exchanger.

6 Position new gasket (2) on the sealing face of the

oil cooler housing.

7 Position cover (1).

8 Drive in clamping pins (2) to center the cover.

NOTE: Do not displace the gaskets when positioning

the cover.

2-20


008422

008421

9 Screw in M8x70 (1) and M8x50 (2) cap screws and

washers until hand-tight.

10 Fit spring washers to the cap screws.

11 Screw in M8x25 (3), M8x50 (2) and M8x70 (1) cap

screws;


12 Screw in M8x20 cap screw (4);


13 Turn the oil cooler over.

14 Fit M8x25 (1) cap screws with spring washers and

screw them in;


2-21


001564

001564

4.3 Assembly of connection components for


1 Coat O-rings (1) with Vaseline and insert them into

the groove in the connection piece.

2 Insert oil pipes (2, 3) into connection piece (4).

2-22


1

2

3

4

1

001568

001568

008423

008424

5 Removal, installation, disassembly and

assembly of converter.

5.1 Removal of torque converter.

1 Unscrew ten hex or Allen head bolts (1).

2 Remove four flex plates from the torque converter.

3 Rotate the transmission in its assembly stand so that

the torque converter is pointing upwards.

4 Remove assembly cover (1) using a suitable tool.

NOTE: An M30x1.5 screw plug is mounted instead of

the assembly cover on transmissions from no. 96173

(modification no. 65556).

CAUTION

Do not remove cap screws (1) from around the circum-

ference.

NOTE: Measure and note down installation dimension

“F” (see 5.2.2) before removing the torque converter.

5 Attach bracket brace 1X56 137 658 (2) to the

converter and the transmission housing.

2-23

Ecomat HP 500 / HP 590 Converter

2

1

008425

008426

008427

6 Unscrew and remove screw plugs (1).

7 Screw holding fixture 1X56 137 158 (1) into the

converter circuit cover until hand-tight.

NOTE: Ensure a rubber washer is fitted on the holding

fixture thread.

NOTE: In addition to the pneumatic holding fixture, it

is also possible to use a ZF mechanical holding fixture

1X56 136 864 together with the hex insert

1X56 136 863.

8 Connect compressed air unit 1X56 137 130 to

holding fixture 1X56 137 158.

9 Open regulator (1) by turning it anti-clockwise.

10 Open cut-off cock (2). Move the lever to horizontal

position.

11 Use the regulator to set a pressure of 22 psi

(1.5 bar).

2-24

Converter Ecomat HP 500 / HP 590

008428

008430

008429

12 Insert 1/2” socket wrench extension (1) and loosen

the cap screws.

NOTE: Use suitably long grip. M16 socket head bolt is

tightened to 140 ft-lbs (190 Nm) in the turbine shaft.

13 Close the cut-off cock.

14 Unscrew and remove holding fixture 1X56 137 158

from the converter circuit cover.

15 Unscrew cap screw (1) and remove it from the

converter.

16 Screw lifting device 1X56 136 862 into the

converter and tighten it until hand-tight.

17 Remove bracket brace 1X56 137 658.

18 Carefully remove the converter from the housing.

NOTE: Before lifting out the converter completely,

raise it to just above the turbine shaft. Tip the converter

slightly until the oil has drained from the converter.

2-25


008432

008431

19 Unscrew the lifting device.

20 Turn the converter over and remove shim(s) (1)

either from the converter or from the turbine shaft.

21 Remove spacer ring (1) from the stator quill shaft.

2-26


DANGER

The converter weighs approx. 130 lb. (60 kg).

Secure the converter before removing the lifting

device to prevent it rolling away.

!

008433

008435

008434

5.2 Installation of converter.

5.2.1 Measurement of converter end play.

1 Screw lifting device 1X56 136 862 far enough into

the converter until the converter turbine wheel is

clamped tight.

2 Turn the converter over.

3 Measure dimension “C” from the edge of the spur

gear to the turbine wheel contact surface.

4 Note down dimension “C”.

5 Measure dimension “B” from the edge of the spur

gear to the contact surface of the internal sprag

race.

6 Note down dimension “B”.

2-27


DANGER

The converter weighs approx. 130 lb. (60 kg).

Secure the converter before removing the lifting

device to prevent it rolling away.

!

D B

C

001580

001580

008436

008437

7 Calculate theoretical dimension “D” from the

contact face of the internal sprag race to the flat

surface of the turbine wheel as follows.

C - B = D

Note down dimension “D”.

8 Check rectangular ring (1) for damage. Renew it if

necessary.

9 Align the rectangular ring centrally.

NOTE: The rectangular ring has hooked ends.

10 Slide spacer ring (2) onto the stator quill shaft and

position it so there is no end play.

11 Screw lifting fixture 1X56 137 213 into the turbine

shaft.

12 Raise the lifting fixture by hand until there is no

end play on the turbine shaft.

13 Place a depth gauge in the recess of the lifting

fixture against the end of the shaft.

14 Measure distance “A” from the end of the turbine

shaft to spacer ring (1) that was slid onto the stator

quill shaft.

15 Note down dimension “A”.

16 Unscrew the lifting fixture from the turbine shaft.

2-28


008438

17 Calculate thickness “S” of shim (1).

D - A = E

Dimension “E” plus the specified converter end play

Dimension “G”* 0.012 to 0.016 inch (0.3 to 0.4 mm),

gives thickness “S” of shim (1) to be installed.

E + 0.012 to 0.016 inch (0.3 to 0.4 mm) = S

Calculation example:

C = 6.99” (174.7 mm) D = 4.78” (119.5 mm)

-B = 2.21” ( 55.2 mm) - A = 4.73” (118.3 mm)

D = 4.78” (119.5 mm) E = 0.05” ( 1.2 mm)

* + G = 0.014” ( 0.35 mm)

S = 0.064” ( 1.55 mm)

CAUTION

Dimension “G” must be added and not subtracted.

Otherwise bearings will be damaged!

Shims are available in the following thicknesses:

0730 362 123 = 1.0 mm (0.041”)

0730 362 218 = 1.1 mm (0.043”)

0730 362 122 = 1.2 mm (0.047”)

0730 362 121 = 1.5 mm (0.059”)

0730 362 219 = 1.7 mm (0.067”)

0730 362 071 = 1.8 mm (0.071”)

0730 362 220 = 1.9 mm (0.074”)

0730 362 070 = 2.0 mm (0.078”)

0730 362 120 = 2.5 mm (0.098”)

0730 362 067 = 2.6 mm (0.102”)

NOTE: Thicker shims mean larger play.

18 Thinly coat shim (1) with grease and attach.

19 Center the shim.

20 Center the rectangular ring.

21 Thinly coat the running surface of sealing ring (2)

with oil.

2-29


008439

008440

22 Screw lifting device 1X56 136 862 into the

converter.

23 Carefully lower the converter onto the transmission

with its turbine shaft centered. Position the

converter so there is no end play.

24 Loosen lifting device 1X56 136 862 by unscrewing

it a few turns.

CAUTION

Do not damage the sealing ring. Ensure the shim is

correctly positioned on the turbine shaft.

NOTE: The turbine shaft splines must mesh with the

stator quill shaft splines. If necessary, turn the converter

slightly to engage it. The gear on the converter must

also mesh with the input gear of the primary pump.

2-30


008441

F

Außen Ø

001581

008442

5.2.2 Measurement of installation dimension of

converter.

1 Ensure the torque converter has been inserted

correctly and there is no end play.

2 Measure installation dimension “F” from the

converter mounting face to the transmission

mounting face.

3 Measure dimension “F” at several points around the

circumference to obtain the average value.

NOTE: Installation dimension “F” must be X ± 0.02”

(0.5 mm). Ecomat transmissions are equipped with

different converter versions. The table below gives the

installation dimensions for dimension “F” (converter)

according to the converter type.

External ø External ø

~ 17” (430 mm) ~ 19” (475 mm)

X = 2 25/32” (71.25 mm)

X = 3” (77.00 mm) X = 3” (77.00 mm)

X = 3 11/64” (81.25 mm) X = 3 11/64” (81.25 mm)

X = 3 23/64” (86.25 mm)

If installation dimension “F” lies between X + 0.02”

(0.5 mm) and X - 0.02” (0.5 mm), the setting is correct.

4 If the installation dimension is smaller than

X - 0.02” (0.5 mm), fit a second shim on the stator

quill shaft.

5 If the installation dimension is greater that

X + 0.02” (0.5 mm), remove the shim.

NOTE: The spacer ring is 0.04” (1 mm) thick.

CAUTION

If dimension “F” is reset by changing the shim on the

stator quill shaft, the shim on the turbine shaft must also

be changed accordingly. Otherwise bearing failure will

result.

6 Unscrew and remove the lifting device

1X56 136 862 from the converter.

7 Screw M16 cap screw (1) into the converter.

8 Check the installation dimension again.

2-31


008443

9 Insert brace bracket 1X56 137 658 into the

transmission housing and screw it onto the

converter.

10 Screw holding fixture 1X56 137 158 into the

converter circuit cover until hand-tight.

NOTE: Ensure rubber washeris fitted on the holding

fixture thread.

11 Connect compressed air unit 1X56 137 130 to

holding fixture 1X56 137 158.

12 Turn regulator (1) anti-clockwise to open it.

13 Open the cut-off cock. Move lever (2) to the

horizontal position.

14 Use the regulator to set a pressure of 22 psi

(1.5 bar).

15 Insert 1/2" socket wrench extension (3) and tighten

the cap screws;

Tightening torque: 133 - 140 ft-lbs (180 - 190 Nm).

16 Close the cut-off cock.

17 Unscrew and remove holding fixture 1X56 137 158

from the converter circuit cover.

2-32


008444

008445

001568

001568

18 Fit new copper sealing washer (1) to screw plug (2).

19 Tighten the M33x2 screw plug;

Tightening torque: 140 - 150 ft-lbs (190 - 210 Nm).

20 Insert cover (1) into the assembly aperture.

NOTE: A screw plug is installed instead of the circuit

cover in transmissions from no. 96173 (modification no.

65556).

Tighten M30x1.5 screw plug to 44 ft-lbs (60 Nm).

NOTE: Follow the manufacturer’s instructions if flex

plates are fitted to the engine.

21 Tighten ten M12x1.5 hex or Allen head bolts (1);


2-33


1

008446

008448

008447

5.3 Disassembly of converter.

1 Turn the torque converter over and place it on

planks.

2 Unscrew and remove all M8 and M10 cap screws

(1).

3 Press off the circuit cover from the impeller by

screwing in lifting device 1X56 136 862.

CAUTION

Do not use a hammer on the circuit cover or the

impeller.

4 Remove the roller bearing and shaft disc from the

stator.

5 Unscrew and remove twelve M8 cap screws (1).

6 Slightly raise impeller (2) and, using a plastic

mallet, drive out spur gear (3).

NOTE: On transmissions with PTOs, the spur gear and

impeller are fitted with four clamping pins. If necessary,

drive out the clamping pins.

2-34


008449

008450

008451

2-35


7 Remove housing disc (1) from spur gear (2).

8 Remove O-ring (3) and gasket (4) from the spur

gear.

CAUTION

Do not swap shaft and housing discs between any other

bearing packs. Mark them accordingly.

9 Remove the complete stator from the turbine wheel.

10 Remove shaft disc (1) from the stator.

11 Remove needle bearing (2) from the turbine wheel.

12 Remove housing disc (1) and shim (2) from the

turbine shaft.

CAUTION

Do not switch over bearing packs during installation.

008452

008453

008454

5.3.1 Disassembly of stator.

1 Place stator (1) on a support.

2 Place appropriate pressure piece (2) on freewheel

ring (3).

3 Press out freewheel ring from stator.

4 Remove rollers (1) from the freewheel ring.

5 Remove axial disc (2) from the freewheel ring.

6 Press out freewheel ring (1) ball bearing (2).

2-36

Stator Ecomat HP 500 / HP 590

DANGER

Do not clean bearing with compressed air. The

bearing races could come loose and damage the

bearing due to lack of lubrication.

!

008455

008457

008456

7 Place stator (1) on press using appropriate support

(2).

8 Use suitable pressure piece(s) to press out ball

bearing from stator.

CAUTION

The diameter of the pressure piece must match the

external diameter of the bearing.

9 Remove ball bearing (1) and axial shim (2) from the

stator.

5.3.2 Assembly of stator.

1 Insert the axial shim into the stator.

2 Place the stator and ball bearing in the press using

an appropriate support.

3 Use special tool 1X56 137 152 to press in the

bearing fully.

2-37

Ecomat HP 500 / HP 590 Stator

008459

008460

008458

4 Insert support 1X56 137 152 into press with recess

facing upwards.

5 Turn the stator over and place it on support

1X56 137 152.

6 Insert freewheel ring (1) into the stator with its

longer collar facing downwards. Press in the

freewheel ring.

NOTE: The installation dimension of the freewheel ring

is given by the support 1X56 137 152.

7 Insert the rollers into the stator.

NOTE: After insertion, oil the rollers well and rotate

the stator a few times.

8 Insert axial disc (1) into the stator.

9 Insert support 1X56 137 152 in press and place the

stator complete with the ball bearing onto the

support.

10 Place second support 1X56 137 152 onto the ball

bearing.

11 Press the ball bearing fully into the stator.

NOTE: Ensure the recesses on both supports

1X56 137 152 face the stator. The installation

dimension is given by the supports.

2-38

Stator Ecomat HP 500 / HP 590

008462

008463

008461

5.3.3 Disassembly of turbine wheel and circuit cover.

1 Remove turbine wheel (1) from circuit cover (2)

using suitable assembly irons.

2 Remove rectangular ring (1) from the annular

groove.

NOTE: The rectangular ring has sharp edges.

Press the end of the rectangular ring down into the

groove base using your thumb. Slide your index finger

to the other end of the rectangular ring until the ring

disengages.

3 Press off ball bearing (1) from turbine wheel (2)

using two assembly levers.

NOTE: Do not remove disc (3) if it is undamaged.

2-39

Ecomat HP 500 / HP 590 Turbine wheel / Circuit cover

008464

008466

008465

4 Drive out disc (3) (see Step 3) from the turbine

wheel, from the rear using a suitable punch.

5 Unscrew twelve hex bolts (1) from end disc (2) and

remove the end disc.

NOTE: Steps 6 to 8 only apply for HP 500 converter

version (external diameter 17” / 430 mm).

6 Remove the inner and outer discs from the circuit

cover.

7 Remove cup spring (1).

8 Remove the rollers.

2-40

Turbine wheel / Circuit cover Ecomat HP 500 / HP 590


version (outer diameter 19” / 475 mm).

9 Remove inner and outer discs (1/2) from circuit

cover.

NOTE: The pressure springs are located on the last

outer disc (2). Remove pressure springs with last outer

disc.

10 Remove cup springs (4).

11 Remove rollers (5).

2-41


!

003971

008467

001569

1

001569

2

1

43

52

12 Grip plate piston (1) using a pair of pliers.

13 Lightly tap sealing surface (2) of the circuit cover

with a plastic hammer. This loosens the plate piston

and allows it to be removed.

14 Hook an appropriate tool (1/64” - 1/32” / 0.5 -

0.75 mm thick) under inner rectangular ring (2) and

carefully remove it from the plate piston.

DANGER

Grooved edge of plate piston may have sharp edges.

Wear protective gloves at all times

15 Push outer rectangular ring (1) on both sides as

shown by arrows. Grasp protruding section of

rectangular ring and remove from groove.

The basic procedure for removing all external

rectangular rings is the same.

008468

008470

008469

5.3.4 Assembly of circuit cover and turbine wheel.

NOTE: Clean all components thoroughly and dry them

using compressed air. Only use lint-free cloths to wipe

down the rectangular rings.

1 Check the rectangular rings for damage and renew

them if necessary.

2 Coat inner rectangular ring (2) and outer

rectangular ring (1) with Vaseline and insert them

into the plate piston.

NOTE: Stretch the inner rectangular ring slightly before

installing it so it locates firmly against the groove base.

CAUTION

Insert plate piston (1) into circuit cover. Ensure the plate

piston is not misaligned. Ensure the rectangular rings

are firmly located against the ring groove base around

their entire circumference.

3 Tap the circumference of the plate piston lightly

with a plastic mallet. Ensure the plate piston lies

flat.

4 Insert twelve rollers (2) into the bores around the

circumference.

5 Place the cup spring on the plate piston with its

camber facing downwards.

6 Using a straight-edge, check that the outer and inner

discs are level and not distorted. Perform a visual

check. Check the discs against the end disc or a flat

surface.

CAUTION

Dished or corrugated discs must be replaced. Maximum

permissible wear 0.012” (0.3 mm).

Coated discs with damaged or blackened coating must be

replaced. Inner discs with damaged tooth flanks must be

replaced.

Permissible wear per tooth flank: 0.008” (0.2 mm).

2-42




7 Insert outer disc (1).

8 Insert inner disc (2).

9 Depending on the version, insert one or two outer

discs (3).

10 Insert inner disc (4) into the circuit cover.

NOTE: Insert outer discs (3) so that the bores slide over

the rollers.



11 Position outer disc (1) so that bores slide over

rollers.

12 Position four springs (2) over the rollers on the

outer disc at 90° intervals. Check position of

springs in relation to recess on circuit cover.


14 Insert two outer discs (4) over remaining rollers

ensuring tooth spaces are aligned with springs and

bores.


16 Insert end disc (1) into the circuit cover.

17 Line up the bores in the end disc with the bores in

the circuit cover.

18 Tighten M8 hex bolts;


NOTE: Before tightening the hex bolts, tap the plate

piston once again with a plastic mallet to ensure it is

lying flat.

2-43


008471

003971

008472

5

3

1

4

2

A

001 5

70

19 Using feeler gauge (1), measure the disc play

between the last inner disc and end disc (2), and

note down as dimension “A”.

20 Permissible play: 0.02” to 0.044” (0.5 to 1.1 mm).

NOTE: If disc play is less than 0.02” (0.5 mm) or more

than 0.044” (1.1 mm), install suitable new outer discs.

Then, remeasure dimension “A”.

Outer discs can be supplied in the following thicknesses:

HP590 converter outer dia. 19” (475 mm)

4139 338 002 = 0.118” (3.0 mm)

4139 338 206 = 0.138” (3.5 mm)

HP500 converter outer dia. 17” (430 mm)

4139 334 005 = 0.138” (3.5 mm)

4139 334 006 = 0.157” (4.0 mm)

21 Turn over the turbine wheel. If spacer disc (1) was

removed, drive in spacer disc (1) fully.

22 Using a center punch, secure the spacer disc four

times around its circumference.

NOTE: Install the spacer disc with bores (2) facing

upwards.

2-44


008473

004234/001570

008474

A

004 2

34

A

A

outer dia. 19” (475 mm)

outer dia. 17” (430 mm)

converter

converter

23 Using a suitable tube, drive the ball bearing onto

the turbine wheel.

24 Insert rectangular ring (1) into annular groove (2)

and hook in the open ends of the rectangular ring.

25 Line up the inner discs. The discs should cover each

other.

26 Insert turbine wheel (1) into the circuit cover.

CAUTION

Ensure the gearing on the turbine wheel meshes with the

teeth on the inner discs. Rotate the turbine wheel

backwards and forwards until it engages. Ensure the

turbine wheel is fully engaged and positioned evenly. If

necessary, lightly tap the edge of the inner gearing using

a plastic mallet.

Take care not to damage the inner discs.

2-45


DANGER

The rectangular ring has sharp edges. Use

protective gloves.

!

008475

008476

008477

008478

008479

5.4 Assembly of torque converter.

CAUTION

Rework necessary during repairs:

New O-ring seal on HP 590 torque converter (outer dia.

19” / 475 mm) with 36 bolts around circumference.

Machine O-ring groove in pump wheel.

See Section 5.4.1.1 - extra page 52/1.

1 Clean the spur gear and use an oil stone to clean the

sealing surface.

2 Place the bearing packet near to hand. Note its

markings!

3 Insert housing disc (2) in the spur gear.

CAUTION

Ensure its chamfered side is facing the spur gear.

NOTE: Plate (1) is marked “WS” and housing disc (2)

is marked “GS”.

4 Position new O-ring (1) in spur gear (2).

5 Position new gasket (3) on sealing face of spur gear

(2) and align with bores.

2-46

Torque converter Ecomat HP 500 / HP 590

008480

008481

008482

6 Align spur gear with bores in pump wheel.

7 Place spur gear in pump wheel.

NOTE: The spur gear and pump wheel are fixed with 4

slotted pins in transmissions with PTOs. If required,

drive in slotted pins.

8 Turn over pump wheel complete with spur gear.

9 Insert 12 new Torx-Powerlok screws and tighten to

26 ft-lbs (35 Nm).

CAUTION

Always use new Powerlok screws. The countersunk

screwhead bores in the pump wheel must be flat. If

required, sink once by max. 0.02” (0.5 mm).

10 Place roller bearing (1) onto the housing disc in the

impeller.

11 Place plate (2) onto the roller bearing with its

chamfer facing upwards.

12 Place 0.02” (0.5 mm) thick shim (3) onto the plate.

13 Insert complete stator (1) into the impeller.

CAUTION

Ensure longer collar (2) of the freewheel ring faces the

impeller. When inserting the stator, ensure that the

freewheel ring and bearings do not fall out of the stator.

NOTE: Place support 1X56 137 152 onto the stator

bearing. Using a plastic mallet, drive in the stator and

complete bearing pack with light taps until fully

inserted.

2-47

Ecomat HP 500 / HP 590 Torque converter

008483

008485

008484

14 Place the marked bearing pack near to hand.

15 Place shaft disc (1) onto the stator.

16 Place needle cage (2) onto the shaft disc.

17 Place housing disc (3) onto the needle cage.

5.4.1 Measurement and setting of end play of axial

bearings.

1 Place new gasket (3) on sealing face.

NOTE: If there is an O-ring seal on the HP 590 torque

converter (outer diameter 19” / 475 mm with 36 bolts

around circumference), measure without the gasket.

2 Place measurement blocks (1) onto the sealing

surface of the impeller.

3 Place measurement bar (2) onto the measurement

blocks.

4 Place a depth gauge onto the measurement bar and

measure dimension “A” from the measurement bar

to the impeller sealing surface with its gasket in

place. Note down dimension “A”.

NOTE: Make sure the measurement bar does not touch

the stator.

5 Slide the depth gauge along the bar to the

center.

6 Measure dimension “B” from the measurement bar

to the face of housing disc (1).

7 Note down dimension “B” and subtract it from

dimension “A”.

Dimension “A” - Dimension “B” = Dimension “C”

2-48


008486

008487

8 Place the measurement apparatus on the circuit

cover.

NOTE: Do not place a gasket on the circuit cover for

this measurement.

9 Using a depth gauge, measure dimension “D” from

the measurement bar to the circuit cover sealing

surface.

10 Note down dimension “D”.

11 Measure dimension “E” from the measurement bar

to the contact surface for spacer (1).

12 Note down dimension “E” and subtract from it

dimension “D”.

Dimension “D” - Dimension “E” = Dimension “F”

Subtract dimension “F” from dimension “C”

Dimension “C” - Dimension “F” = Dimension “G”

13 Calculate the thickness “S” of the spacer disc to be

inserted as follows:

G - (0.004 to 0.01” / 0.1 - 0.3 mm) = S

0.004 to 0.01” (0.1 - 0.3 mm) = end play of axial

bearing

Sample calculation:

G = 0.055” (1.4 mm)

-*H = 0.008” (0.2 mm)

S = 0.047” (1.2 mm)

*H = average of 0.004 and 0.012”

(0.1 mm and 0.3 mm) end play

CAUTION

The figures in this calculation are purely theoretical.

2-49


Spacer discs can be obtained in multiples of

0.008” (0.2 mm) thickness:

0630 000 219 = 1.0 mm (0.041”)

0630 004 152 = 1.2 mm (0.047”)

0630 004 154 = 1.4 mm (0.055”)

0630 004 156 = 1.6 mm (0.063”)

0630 004 158 = 1.8 mm (0.071”)

0630 004 127 = 2.0 mm (0.078”)

0730 000 982 = 2.2 mm (0.086”)

008488

008489

008490

14 Insert spacer disc (1) into the turbine wheel.

15 Remove the upper housing disc from the stator.

16 Insert housing disc (1) into the turbine wheel with

its chamfered edge facing towards spacer disc (2).

17 Remove the needle sleeve from the stator and insert

it into the turbine wheel.

18 Remove complete stator (1) from the impeller.

Insert stator (1) into the turbine wheel with the

short collar of the freewheel ring facing the turbine

wheel.

NOTE: Coat all bearings with oil before installation.

19 Remove plate (2) from the impeller. Place plate (2)

onto the stator with its chamfered edge facing the

stator.

2-50


008491

008492

008493

20 Remove roller bearing (1) from the impeller. Place

roller bearing (1) onto the stator.


version (external diameter 17” / 430 mm).

21 Lay gasket (1) onto the circuit cover.

22 Screw two M8 guide bolts 1X56 136 821 (2) into

opposite sides of the circuit cover flange.

23 Place impeller (1) onto the circuit cover.

24 Unscrew M8 guide bolts 1X156 136 821 (2) and

remove them.

2-51


008494

008495

25 Fit 36 M8 cap screws (1) with one washer each.

26 Tighten cap screws:

Tightening torque = 25 ft-lbs (34 Nm).

27 Check the end play of the freewheel ring (1).

28 Hold the inside of the freewheel ring with both your

hands and try to move it axially. You must be able

to feel the end play.

2-52


005272

005552

5.4.1.1 New O-ring seal on HP 590 converter

(ZFW 380-30) fitted during repairs

NOTE:

This repair solution applies for all ZFW 380-30 torque

converters with an external diameter of 19” (475 mm)

and 36 bolts for affixing pump wheel with circuit cover.

1 Pump wheel depending on spec. list

2 O-ring 420x2.5

3 Cylindrical screw M10x55

Parts required:

Qty. Item no. Description Made from

1 * 4166 338 221 Pump wheel 4166 338 136

* 4166 338 222 4166 338 137

* 4166 338 223 4166 338 194

* 4166 338 224 4166 338 205

1 0634 314 402 O-ring

36 0636 101 900 Cylindrical screw

* Depending on spec. list

NOTE: The gasket used previously has been omitted.

Procuring remachined pump wheels:

a) Purchase from ZF Friedrichshafen AG:

- Item no. of pump wheel depending on spec. list

b) Remachining:

- by After-Sales Service Centre

- or a mechanical workshop appointed by

ZF Friedrichshafen AG

- or enduser

providing suitable equipment is available.

CAUTION

Remachining must be carried out in accordance with

drawing 4166 338 220 and is only permitted on pump

wheels in perfect condition.

2-52-1


DETAIL X 31

2

005560

005552

Checking used pump wheels:

Calculate the distance between the spur gear/pump

wheel sealing face and pump wheel/circuit cover sealing

face.

Permissible distance = max. 3.9488” (100.3 mm).

CAUTION

If this distance is greater, the pump wheel has widened

and must not be re-used.

2-52-2


CAUTION

On used pump wheels, which previously had M10x50

screws, the M10 thread must be remachined along the

whole thread.

Permissible distance

on used pump wheels

max. 3.9488”

(100.3 mm)

1

00

1 2

005559

205

25

ø160

ø150

ø104,9

85-0

,035

LK

R. 128±

0,2

(4x90°)

M8

20 min.

005551

CAUTION

Remachining must be carried out in accordance with

drawing 4166 338 220 and is only permissible on pump

wheels in perfect condition.

If possible, a clamping flange (1) should be used to hold

the pump wheel in the 3-jaw chuck (above spur gear

centring bore).

To avoid vibrations (rattling) when machining, the

spindle face must be pushed against the pump wheel

blades using a suitable plate (2).

The face (previous sealing face) of the pump wheel must

be flat and free of raised material.

If necessary, the face may be re-machined by a maximum

of 0.008” (0.2 mm) to ensure it is perfectly flat.

NOTE: The depth 0.0748 +0.004” (1.9+0.1 mm) for the

O-ring groove refers to the finished machined face.

Ref. no. Made from Dia. A

4166 338 221 4166 338 136 16.929” (430 mm)

4166 338 222 4166 338 137 16.929” (430 mm)

4166 338 223 4166 338 194 17.047” (433 mm)

4166 338 224 4166 338 205 17.047” (433 mm)

2-52-3


Machining O-ring groove in pump wheel:

1 2

Clamping flange

Dia

. A

0.1

18+

0.0

08”

(3+

0,2

mm

)

0.0748 +0.004”

(1.9+0.1 mm)

Face withoutraised material

005560

Dia

. 4.1

3327 -

0.0

0138”

(ø104,9

85 -

0,0

35

mm

)

min. 0.8” (20 mm)

5.0

393 ±

0.0

08”

4x90 d

eg.

(LK

R. 128 ±

0,2

mm

)

Dia

. 5.9

” (ø

150 m

m)

Dia

. 6.3

” (ø

160 m

m)

0.2 ”

(5 mm)0.8”

1” (25 mm)

(20 mm)

005272

004289

Reassembling HP 590 converter

(outer diameter 19” / 475) - continued -

CAUTION

Following omission of the gasket, the end play setting

on the axial roller bearing has changed.

Remeasure and reset end play of axial roller bearing as

described under Section 5.4.1.

1 Pump wheel

2 End shim/disc

3 O-ring 420x2.5

4 Circuit cover

5 Cylindrical screw M10x55

29 Place circuit cover (4) on wooden blocks.

30 Place O-ring (3) over end shim (2) on circuit cover

sealing face (4).

31 Insert two opposite facing M10 threaded pins in

pump wheel (1) flange.

32 Place pump wheel (1) on circuit cover (4).

33 Unscrew threaded pins.

34 Insert four M10x25 cylindrical screws (5) and

tighten by hand.

CAUTION

The cylindrical screws (5) are coated.

Always use new cylindrical screws.

35 Turn converter and place on two wooden blocks.

Insert remaining M10x55 cylindrical screws (5) and

tighten to 44 ft-lbs (60 Nm).

Check end play of freewheel inner ring as described on

page 52, Step 28.

2-52-4


5

3

1

2

003393

45

008496

008497

003 127

003127

5.4.2 Check for converter leaks.

1 Insert forcing device 1X56 137 129 into the spur

gear side of the converter.

2 Screw a locking nut onto the forcing device.

3 Use lifting device to submerge the converter in a

water tank until the sealing face (1) between the

impeller and the spur gear is just beneath the water

surface.

4 Connect compressed air unit 1X56 137 130 to the

forcing device.

CAUTION

Mix water in tank with anti-freeze (1:120 solution).

Water temperature = 68 °F (20°C).

2-53


DANGER

Torque converter weighs approx. 130 lbs.

(60 kg).

!

1

1 2

003126

008499

008498

5 Turn regulator (1) counter-clockwise.

6 Open the shut-off cock.

7 Set the pressure to 36.5 psi (2.5 bar) using

regulator (1).

CAUTION

There must not be any converter leaks whatsoever.

8 Shut off compressed air unit 1X56 137 130 and

disconnect from forcing device 1X56 137 129.

9 Use a lifting device to lift the converter out of the

tank. Lower the converter onto a worktop.

10 Remove the lifting device and turn the converter

over.

11 Unscrew locking nut (1) and remove it.

12 Fit the converter onto the circuit cover and remove

forcing device 1X56 137 129 from the converter.

NOTE: Dry the converter using compressed air. Apply

a thin coat of oil to the spur gear.

2-54


008500

008501

008502

6 Removal and installation of cover plate.

6.1 Removal of cover plate.

-Remove the converter (see Section 5.1)

NOTE: Tilt the transmission to drain oil before

removing the cover plate.

1 Remove union screws (2).

2 Remove the union screws, sealing washers and oil

pipe (1) from the cover plate.

3 Unscrew nineteen M8 hex bolts (1) and remove

them from cover the plate together with their

sealing washers.

4 Unscrew and remove fifteen M8 cap screws (2).

5 Screw the threaded spindles (1) of three extractors

1X56 136 815 into the threaded bores provided.

2-55

Ecomat HP 500 / HP 590 Cover plate

008503

6 Place bars (1) of extractors 1X56 136 815 onto

threaded spindles and screw on clamping nuts (2).

7 Tighten the clamping nuts evenly, alternating from

bar to bar. Pull out the cover plate.

8 Unscrew extractors 1X56 136 815 from the cover

plate and remove them.

2-56

Cover plate Ecomat HP 500 / HP 590

008504

008505

6.2 Installation of cover plate.

1 Check shaft seal (1) for damage.

2 If necessary, press out the shaft seal from cover

plate from the rear.

3 Fit new O-ring (2) onto the cover plate.

4 Apply a thin coat of Vaseline to the O-ring and the

sealing face of the cover plate.

5 Screw a stud bolt into the control insert for fixing

purposes. Insert the cover plate, ensuring it is lined

up correctly.

6 Drive in the cover plate by tapping it evenly around

its edge with a plastic mallet. Ensure the cover plate

is fully inserted.

CAUTION

A new copper seal, washer, new copper seal (in this

order) must be placed under the socket head screws on

each of the three screw bores with a thread (arrow). This

is a special seal combination.

7 Fit M8x130 cap screws (1) with new copper

washers and screw them in;

Tightening torque: 17ft-lbs (23 Nm).

8 Fit M8x40 cap screw (2) with new copper



9 Fit eight M8x85 hex bolts (3) with new copper



10 Fit eleven M8x20 hex bolts (4) with new copper



2-57

Ecomat HP 500 / HP 590 Cover plate

008506

008507

11 Insert oil pipe (1).

12 Tighten union screws (2);


CAUTION

Fit two copper sealing washers on each union screw

connection: one under the screw head and one under the

oil pipe connection.

13 Insert the shaft seal as follows.

14 Lightly coat the outside of the shaft seal with a

lubricant.

NOTE: Use water soluble washing-up liquid as

lubricant.

15 Coat the sealing lip(s) with Vaseline.

16 Position the shaft seal against the hole with its

sealing lip(s) facing the cover plate.

17 Drive in the shaft seal using punch

1X56 136 605. Make sure the seal is fully inserted.

2-58

Cover plate Ecomat HP 500 / HP 590

008508

008509

008510

7 Removal and installation of oil pan

7.1 Removal of oil pan

1 Unscrew four M8 hex bolts (1) and remove together

with washers.

2 Remove cover (2) from the filter housing.

3 Pull off the screen filter (1) from intake tube.

4 Unscrew and remove thirty-three M8 hex bolts (1)

together with washers from around the edge of the

oil pan.

5 Remove oil pan (2) and its gasket from the

transmission.

2-59

Ecomat HP 500 / HP 590 Oil pan

008511

008512

008513

7.2 Installation of oil sump.

1 Place new gasket (1) onto the sealing face.

2 Lay the oil pan on the transmission.

NOTE: Ensure the gasket is not displaced when

positioning the oil pan.

3 Fit hex bolts (1) with washers. Screw in the hex

bolts and tighten them;


NOTE: Fit hex bolts (2) with new copper sealing

washers.

4 Apply a light coating of Vaseline to O-ring (1) in

the screen filter.

2-60

Oil pan Ecomat HP 500 / HP 590

008516

008514

008515

5 Push screen filter (1) onto the intake tube until it is

fully inserted.

6 Insert new O-ring (1) into cover (2).

7 Apply a light coat of Vaseline to the O-ring.

8 Place cover (1) onto the oil pan.

9 Fit M8x80 hex bolts (2) with washers. Screw in and

tighten the hex bolts;


2-61

Ecomat HP 500 / HP 590 Oil pan

008517

008518

008519

8 Removal and installation of inductive sensor.

8.1 Removal of inductive sensor.

1 Unscrew and remove screw plug (1).

2 Remove cable plug (1) from inductive sensor using

a pair of flat-nose pliers.

3 Use a socket wrench and extension piece to

unscrew the inductive sensor (2).

4 Remove inductive sensor (1) and shim(s) (2).

NOTE: A shim may remain stuck on the fixing plate in

the transmission.

2-62

Inductive sensor Ecomat HP 500 / HP 590

008520

008521

001571

001571

8.2 Installation of inductive sensor.

1 Swing the transmission into the installation

position.

2 Place small a screwdriver against the inductive

sensor ring.

3 Use an assembly lever to rotate the output flange.

Using the small screwdriver, establish where the

projection on the impulse sensor ring is located.

4 Stop turning the output flange when one of the

projections is located under the inductive sensor

insertion bore.

5 Screw sliding ring (1) approx. 1/4” (6 mm) onto

measurement rod 1P01 137 833.

6 Insert measurement rod 1P01 137 833 into the

inductive sensor bore until the end of the

measurement rod touches the projection on the

impulse sensor ring.

NOTE: Measure the highest point on the impulse sensor

ring. Ensure the measurement rod is positioned verti-

cally in the threaded bore.

CAUTION

Ensure a projection on the impulse sensor ring is located

directly underneath the threaded bore for the inductive

sensor. If this measurement is made at a lower point on

the impulse sensor ring, the inductive sensor will collide

with the projections when the engine is started, and will

be damaged.

1 = Impulse sensor ring

2 = Fixing plate

3 = Measurement rod 1P01 137 833

2-63

Ecomat HP 500 / HP 590 Inductive sensor

1 2 3

008523

008523

7 Withdraw measurement rod 1P01 137 833.

8 Measure dimension “B” from the end of the

measurement rod to sliding ring (1).


CAUTION

Ensure sliding ring (1) does not move after the measure-

ment rod is withdrawn from the bore.

10 Measure dimension “C” on the inductive sensor

from its contact surface to the shim contact surface.

11 Subtract dimension “B” from dimension “C”.

C - B = D

12 Note down dimension “D”.

2-64


001572

001572

008524

NOTE: Ensure dimension “A” is between 0.023” and

0.031” (0.6 to 0.8 mm). Set dimension “A” using a shim

(4) of the correct thickness.

1 = Impulse sensor ring

2 = Fixing plate

3 = Inductive sensor (speed sensor)

4 = Shim

13 Calculate the thickness of the shim as follows:

14 D + A = thickness “S” of the shim.

NOTE: The figures in the example below are purely

theoretical.

Example:

B = 0.936” (24 mm)

C = 1.014” (26 mm)

A = 0.023” to 0.031” (0.6 to 0.8 mm)

D = C - B

D = 1.014” - 0.936” (26 mm - 24 mm)

D = 0.078” (2 mm)

S = D + A

S = 0.078” + 0.023 to 0.031”

(2 mm + 0.6 to 0.8 mm)

S = 0.102 to 0.110” (2.6 to 2.8 mm)

15 Shims (1) are available in the following thicknesses.

0730 003 049 = 0.6 mm (0.023”)

0730 003 050 = 0.8 mm (0.031”)

0730 002 069 = 1.0 mm (0.041”)

0730 002 068 = 1.2 mm (0.047”)

0730 002 067 = 1.4 mm (0.055”)

0730 002 066 = 1.6 mm (0.062”)

0730 002 065 = 1.8 mm (0.071”)

0730 002 064 = 2.0 mm (0.078”)

0730 002 063 = 2.2 mm (0.086”)

0730 002 062 = 2.4 mm (0.094”)

0730 002 061 = 2.6 mm (0.102”)

0730 003 299 = 2.8 mm (0.110”)

0730 003 300 = 3.0 mm (0.118”)

2-65

Ecomat HP 500 / HP 590 Inductive sensor

1

2

3

4A

008525

008526

16 Fit the shim(s) onto inductive sensor (1). Screw in

the inductive sensor and tighten it;

Tightening torque: 37 ft-lbs (50 Nm); do not

exceed.

17 Connect cable plug (2) onto the inductive sensor.

There is no need to observe correct polarity when

fitting this cable plug.

18 Use an inner hex head driver to tighten M42x2

screw plugs (1);

Tightening torque: 60 to 74 ft-lbs (80 to 100 Nm).

2-66


008527

008528

008529


of hydraulic transmission control unit.

9.1 Removal of hydraulic transmission control unit.

1 Unscrew M8 hex bolts (1) and remove together with

washers.

2 Push the cannon socket into the transmission

housing.

3 Rotate the transmission in its assembly stand so the

hydraulic control unit is at the top.

4 Disconnect the plug from the socket.

NOTE: The plug connection (1) is held together by a

tooth and notch profile. Use a small screwdriver to

disconnect the plug and socket.

2-67

Ecomat HP 500 / HP 590 Hydraulic transmission control unit

008530

6 Unscrew and remove thirty-nine M8 hex bolts (1)

together with washers.

CAUTION

Do not loosen M6 hex bolts.

7 Remove complete hydraulic control unit (2) from

the transmission. Take care not to damage the

connections when doing this.

2-68

Hydraulic transmission control unit Ecomat HP 500 / HP 590

DANGER

The hydraulic control unit weighs 40 lbs.

(18 kg). Watch out for sharp edges.

!

005549

005547

9.1.1 Retrofitting impurity collecting magnets on

hydraulic control unit

Components:

- 4 x magnetic discs - ref. no. 4139 306 673

Purchased from:

- ZF Friedrichshafen AG

NOTE: The magnetic discs have been installed during

production since transmission no. 078844.

CAUTION

If magnetic discs have not already been fitted, these

must be retrofitted during repairs.

Configuration:

Attach two magnetic discs each to valve blocks A and B

as shown.

4 x magnetic discs

008532

008533

008531

9.2 Installation of hydraulic transmission control

unit.

1 Insert the hydraulic control unit into the

transmission.

NOTE: Make sure the cannon socket slides into its seat

in the transmission housing. Make sure the fixing lug of

the socket points towards the transmission input. Do not

trap the inductive sensor cables.

2 Fit nine M8x35 hex bolts (1) with washers. Screw

them in, but do not tighten them.

3 Fit thirty M8x45 hex bolts (1) with washers. Screw

them in and tighten them;


Now tighten the bolts inserted in Step 2.


NOTE: Work from the center to the edges when

tightening these bolts.

2-69


008534

008535

4 Connect plug and socket (1) for the inductive

sensor. The plug connection is coded for polarity.

5 Line up cannon socket (1) with the bolt holes.

6 Fit M8x28 hex bolts (2) with washers. Screw the in

and tighten them;


- See Section 8.2 for installation of the inductive

sensor.

- See Section 7.2 for installation of the oil pan.

2-70


008536

008538

008537

9.3 Disassembly of hydraulic control unit.

Valve block A:

1 = Solenoid valve for brake “F”

2 = Solenoid valve for lock-up clutch “WK”

3 = Solenoid valve for clutch “C”

4 = Solenoid valve for clutch “A”

Valve block B:

5 = Solenoid valve for clutch “B”

6 = Solenoid valve for brake “E”

7 = Solenoid valve for brake “D”

8 = Solenoid valve for brake “G” / NBS option

1 Pull the flat-pin plugs off the solenoid valves.

2 Unscrew and remove M5 cap screws (2) from the

solenoid valves (1).

3 Pull the solenoid valves out of the valve blocks.

4 Pull flat-pin plug (1) off throttle valve (2).

2-71


008539

5 Turn the hydraulic control unit over.

6 Unscrew and remove M6 hex bolts (1) and remove

the throttle valve from the duct plate.

2-72


008540

008541

008542

9.3.1 Disassembly of throttle valve.

1 Unscrew and remove M5 cap screws (1).

2 Remove switching solenoid (2) from the throttle

valve.

3 Unscrew and remove M6 hex bolts.

4 Take cover (2) off the throttle valve.

5 Remove all pistons and balls (1) from the valve

housing.

6 Unscrew and remove M6 hex bolts (1).

2-73

Ecomat HP 500 / HP 590 Throttle valve

008543

008544

7 Remove cover (1) and gasket (2).

8 Check filter (1).

2-74

Throttle valve Ecomat HP 500 / HP 590

008545

008546

008547

9.3.2 Assembly of throttle valve.

1 Check screen (1) and replace if necessary.

2 Insert piston (1) into the valve housing.

3 Insert ball (1) and piston (2) into the housing.

2-75

Ecomat HP 500 / HP 590 Throttle valve

008548

008549

008550

4 Screw cover (1) on tightly;

Tightening torque: 7 ft-lbs (9.5 Nm).

5 Insert piston (1) as illustrated.

6 Insert solenoid (1) and screw it on tightly;


7 Screw on cover (2) and gasket (3) tightly;


2-76

Throttle valve Ecomat HP 500 / HP 590

008551

008552

008553

Disassembly of hydraulic control unit, continued:

8 Unscrew M6 hex bolts (1).

9 Remove complete fixing plate (1) for the inductive

sensor and cable harness.

10 Remove spacer rings (2).

11 Unscrew the NBS (Neutral at Bus Stop) pressure

limiting valve from Block “B”.

2-77


008554

008556

008555

12 Remove the screw plug together with sealing ring

(1) and piston with pressure spring (2) from

pressure limiting valve (3).

13 Unscrew twelve M6 hex bolts (1).

14 Remove valve block “A” (2).

15 Unscrew M6 hex bolts from valve block “B”.

16 Remove valve block “B”.

2-78


008557

17 Remove the intermediate plate.

18 Use a plastic mallet to drive converter safety valve

(1) into the duct plate until the snap ring is

accessible.

19 Unclip snap ring (2).

20 Remove the converter safety valve.

2-79


008558

008559

008560

9.3.3 Disassembly of valve block for brake “F”,

lock-up clutch and clutches “C” and “A”.

1 Loosen cover plate (1) by tapping with a plastic

mallet. Remove the cover plate from the valve

block.

2 Remove the gasket.

CAUTION

Do not use a narrow-bladed tool to lever off the cover

plate. This can cause damage to its sealing surface.

3 Remove valve ball (1) from the lock-up clutch duct.

4 Unscrew eight M6 hex bolts (1).

5 Press cover plate (2) against the valve block and

unscrew hex bolt (3).

6 Remove the cover plate and its gasket.

2-80


DANGER

Cover plate is under spring pressure. Release

this pressure carefully when removing the cover

plate.

!

008561

008562

7 Mark the installation positions of pressure

springs (1).

8 Remove pistons (2) and pressure springs from the

valve block.

CAUTION

Do not switch over the pressure springs.

A spacer may be fitted in any of the various pistons.

Make sure the spacer from any one piston stays with its

respective piston.

Do not swap over any pistons which do have spacers.

9 Unscrew and remove fifteen M6 hex bolts (1).

CAUTION

Do not remove hex bolt (2) from the valve strip.

10 Press cover plate (3) against valve strip (4).

11 Unscrew and remove hex bolt (2) and remove cover

plate.

12 Remove the gasket from the valve strip.

2-81


DANGER



plate.

!

008563

008565

008564

13 Remove the valve strip from the valve block.

14 Remove pressure springs (1) from the control

pistons.

15 Pull pressure springs (1) and vent pistons (2) out of

the valve strip.

16 Remove bushes (1) complete with O-rings (2) from

the valve strip.

17 Remove control pistons (3) from the valve strip.

18 Remove O-ring (4) from the valve strip.

2-82


008566

19 Remove pistons (1) from valve block (2).

20 Remove stop washers (3) from the valve block.

2-83


008567

008568

008569

9.3.4 Disassembly of valve block for clutch “B”

and brakes “E”, “D” and “G”.

1 Loosen cover plate (1) by tapping it with a plastic

mallet.

2 Remove the cover plate from the valve block and

remove its gasket.

CAUTION

Do not use a narrow-bladed tool to lever off the cover

plate. This can cause damage to its sealing surface.

3 Unscrew seven M6 hex bolts (1).

4 Press cover plate (2) against the valve block and

unscrew hex bolt (3).

5 Remove the cover plate.

6 Remove the gasket.

7 Pull pistons (1) out of the valve block.

CAUTION

A spacer may be fitted in any of the various pistons.

Make sure the spacer from any one piston stays with its

respective piston.

Do not swap over any pistons which do have spacers.

2-84


DANGER



plate.

!

008570

008571

008572

8 Mark the installation positions of pressure

springs (1).

9 Remove the pressure springs from the valve block.

CAUTION

Do not switch over the pressure springs.

10 Unscrew and remove fifteen M6 hex bolts (2).

CAUTION

Do not remove hex bolt (1) from the valve strip.

11 Press cover plate (3) against the valve strip.

12 Unscrew and remove hex bolt (1) and remove them

together with the shackle.

2-85


DANGER



plate.

!

008573

008574

008575

13 Remove cover plate (1) and gasket (2).

14 Remove valve strip (2) from the valve block.

15 Remove pressure springs (1) from the control

pistons.

16 Pull pressure springs (3) and the vent pistons out of

the valve strip.

17 Remove bushes (1) complete with O-rings (2) from

the valve strip.

2-86


008576

008577

18 Remove control pistons (1) from the valve strip.

19 Remove O-ring (2) from the valve strip.

20 Remove pistons (1) and stop rings (2) from the

valve block.

2-87


008578

008579

9.4 Assembly of hydraulic control unit.

NOTE: Check the duct plate for damage and replace it

if necessary.

1 Insert the converter safety valve into the duct plate.

2 Clip snap ring (1) onto the converter safety valve.

3 Push the converter safety valve down until the snap

ring is firmly located in the duct plate.

4 Place the cover plate on the duct plate.

2-88


008580

008581

008582

9.4.1 Assembly of valve block for brake “F”,

lock-up clutch and clutches “C” and “A”

NOTE: Check the valve block for damage.

1 Check orifices (1, 2, 3, 4) to make sure the seats are

in perfect condition.

2 Check the orifice bore diameter using plug gage

1P01 137 173. Replace the orifices if necessary.

3 If necessary, knock out the orifices using punch

1X56 137 156.

CAUTION

Sharpen the punch point before knocking out the

orifices.

4 Insert new orifices and peen them using punch

1X56 137 151.

NOTE: Always peen new orifices twice, at 90° internal.

2-89


008583

008584

008585

5 Insert four stop washers (1) into the valve block

with their collars pointing downwards.

6 Insert four pistons (4) into the valve block as

illustrated.

NOTE: Prevent the pistons from falling out when

turning over the valve block.

7 Insert all pressure springs (1) for the “A”, “C”

clutches, lock-up clutch and “F” brake pistons.

8 Push in pistons (2) with or without spacers.

CAUTION

Do not switch over any pistons with spacers or any

springs. In case of spring breakage, select a new spring

as listed in the spare parts catalogue.

A clutch

C clutch

WK clutch

F brake

9 If using a new spring, recheck the spring wire

diameter and spring length (unloaded).

10 Compare these measurements with the entries in the

Table of Springs. Refer to pages 1-18 / 1-19.

2-90


008586

008587

008588

11 Position new gasket (3).

12 Place cover plate (3) onto gasket, press against the

valve block and tighten by hand using M6x16 hex

bolt (1).

13 Tighten eight M6x16 hex bolts (1);


14 Screw M6 threaded pins 1X56 150 111 into the

duct plate as illustrated.

2-91


DANGER

Hold the cover plate firmly until hex bolt (1) is

screwed in.

!

008589

008590

008591

15 Push valve block (1) onto the threaded pins.

16 Insert valve ball (2) for the vent valve into the lock-

up clutch duct.

CAUTION

Check the valve ball diameter is 0.197” (5 mm).

Replace if necessary.

17 Position new gasket (1) with printed side upwards.

CAUTION

Ensure vent holes (2) are positioned over the vent

valves (3).

18 Place cover plate (1) onto the valve block.

19 Fix the valve block in position using two M6 hex

bolts.

20 Unscrew the threaded pins.

21 Screw in and tighten the remaining hex bolts;


NOTE: Do not insert bolts in bores (2).

22 Screw threaded pins 1X56 150 111 into the valve

block.

2-92


008592

008594

008593

23 Insert pressure control piston (2) into the valve

strip.

24 Coat new O-ring (1) with Vaseline and insert into

the valve strip.

25 Insert bushes (3) with their collars facing into the

valve strip.

26 Coat new O-rings (1) with Vaseline and insert into

bushes (2).

27 Use threaded pins (2) to position valve strip (1)

against the valve block.

28 Fit four vent pistons (3) with one pressure spring

(4) each and insert vent pistons (3).

29 Insert pressure springs (5) for the control pistons.

2-93


008595

008596

008597

30 Place new gasket (1) onto valve strip.

31 Push cover plate (1) onto threaded pins (2) and

position against valve strip.

32 Screw in M6x60 hex bolt (3) and tighten the cover

plate against the valve strip.

33 Unscrew threaded pins.

34 Screw in M6x18 hex bolts (1) and four M6x60 hex

bolts (2);


2-94


008598

008599

008600

9.4.2 Assembly of valve block for clutch “B” and

brakes “E”, “D” and “G”.

NOTE: Valve block “B” is assembled in the same way

as valve block “A” as described in Section 9.3. Any

modifications are described below.

1 Insert four stop washers.

2 Insert four pistons.

3 Insert the pressure springs and pistons (with or

without spacers).

CAUTION

Do not switch over any pistons with spacers or any

springs. In case of spring breakage, select a new spring

as listed in the spare parts catalogue.

Further assembly proceeds identically as for valve block

“A”.

2-95


008601

008602

008603

4 Position new gasket (1) for NBS (Neutral at Bus

Stop).

NOTE: Use a special gasket for the NBS.

5 Screw on the cover plate;

Tightening torque 7 ft-lbs (9.5 Nm).

6 Insert piston (1) and pressure spring (2) into the

NBS valve (3).

7 Insert new sealing ring (4) and tighten it using

screw plug (5).

8 Position complete NBS valve (1) on the cover plate

of valve block “B” (2) and screw on tightly;


2-96


008604

008605

008607

9 Position valve strip (1) on the valve block.

10 Screw cover plate (2) with holes for the cable

harness shackle (3) onto the valve block “B”.

11 Screw in all M6 hex bolts;


12 Place one spacer ring (1) onto valve block “A” and

“B”.

13 Position fixing plate (1) for the inductive sensor as

illustrated.

2-97


008608

008609

008610

14 Screw on shackle (1) for the inductive sensor cable.

15 Screw shackles (1) for the cable harness onto the

valve blocks.

16 Insert solenoid valves into the valve strips.

17 Connect the flat-pin plugs to the valves.

18 Insert plug connection for inductive sensor into

shackle (1) and tighten bolts;


2-98


008611

19 Screw throttle valve (1) onto the duct plate.

20 Connect electrical cables (2) to the throttle valve.

2-99


008612

008613

008614

10 Removal and installation of retarder valve.

10.1 Removal of retarder valve.

Remove the oil pan, see Section 7.1

CAUTION

New housing (from serial no. 88196) must be equipped

with new retarder valve. The new retarder valve can also

be installed in older housings. Do not confuse the new

and old retarder valve when installing. Only replace as

complete set.

1 Unscrew M8 hex bolts (1) and remove solenoid

valve (2).

2 Unscrew M8 hex bolts (1) and remove cover (2).

3 Pull piston (1) out of the valve housing.

2-100

Retarder valve Ecomat HP 500 / HP 590

008616

008615

008617

4 Remove pressure springs (1, 2) from the piston.

5 Screw M18x1.5 threaded pin or bolt (3) into stop

(1).

6 Pull out stop (1) and bush (2) using a threaded pin

or bolt.

7 Press both pistons (1, 2) out of the valve housing

using a screwdriver.

2-101

Ecomat HP 500 / HP 590 Retarder valve

008618

8 Pull both pistons (1) apart and remove pressure

spring (2).

2-102


008619

008620

008621

10.2 Installation of retarder valve.

CAUTION

New housing (from serial no. 88196) must be equipped

with new retarder valve - see spec. list! The new retarder

valve can also be installed in older housings. Do not

confuse the new and old retarder valve when installing.

Only replace as complete set.

1 Insert pressure spring (1) into piston (2).

2 Insert piston (3) into piston (2).

3 Insert the piston assembly fully into the valve seat

with the pressure spring and piston (1) pointing

outwards.

4 Screw stop (1) onto an M18x1.5 bolt or M18x1.5

threaded pin and push in until the stop is fully

inserted.

5 Remove the threaded pin or bolt.

2-103


008622

008623

B

001579

001579

6 Push new O-ring (1) onto bush (2).

7 Press the bush into the valve housing until the bush

is fully inserted.

NOTE: Ensure the holes (3) in the bush are pointing

vertically upwards.

8 Check the play between the bush and cover is

between 0 and 0.004” (0 and 0.1 mm). Adjust as

follows:

9 Place a depth gauge against the housing face, press

bush (1) fully against stop and measure dimension

“A” to the face of the bush.


11 Place a depth gauge against the shoulder of the

cover and measure dimension “B” to the cover

surface (e.g. height of shoulder).

12 Subtract dimension “B” from dimension “A”.

A - B = C = actual play between bush and cover.

2-104


008624

008625

008626

13 Ensure dimension “C” is between 0 and 0.004” (0

and 0.1 mm).

Shims (1) are available in the following thicknesses:

0730 004 295 = 0.3 mm (0.012”)

0730 004 296 = 0.4 mm (0.016”)

0730 004 297 = 0.5 mm (0.020”)

0730 002 566 = 0.6 mm (0.024”)

0730 002 565 = 0.8 mm (0.030”)

0730 004 298 = 1.0 mm (0.040”)

14 Check seal (1) for damage.

15 If required, break apart the old seal and push a new

seal onto piston (2).

NOTE: Push on seal with open side pointing to the base

of the piston.

16 Insert shims (3) with the same thickness as the

shims which were removed into the piston.

17 Insert pressure springs (1, 2) into the piston.

18 Push the complete piston into the valve housing.

2-105


008627

008628

008629

19 Insert shim(s) (1) of correct thickness.

20 Insert new O-ring (2) into the cover.

NOTE: Coat O-ring with Vaseline.

21 Push the cover into the valve housing bore.

22 Tighten M8x25 hex bolts (1);


23 Insert new O-ring (1) into the solenoid valve.

NOTE: Coat O-ring with Vaseline.

2-106


008630

24 Tighten solenoid valve (1) using two M8x55 hex

bolts (2); Tightening torque: 17 ft-lbs (23 Nm).

Install hydraulic control unit, see Section 9.2.

Fit the oil pan, see Section 7.2.

2-107


008631

008633

008632


of output cover.

11.1 Removal of output cover/inductive sensor.

CAUTION

If the converter has been removed, screw lifting device

(1) 1X56 137 213 into the turbine shaft.

4 Pull off both cable connections using a pair of

pliers.

5 Unscrew inductive sensor (1) using a socket

wrench.

6 Remove the inductive sensor and shim(s).

CAUTION

One or more shims may remain in the output cover.

Ensure all of the shims are removed.

2-108

Output cover Ecomat HP 500 / HP 590

1 Move the transmission to the installation position.

2 Unscrew two M6 hex nuts (1) and remove together

with their washers.

3 Remove cover (2).

001566

008634

008635

11.1.1 Installation of inductive sensor.

1 Rotate the output flange until a tooth (1) of the

planetary carrier gearing is visible through the

threaded bore.

2 Calculate the specified distance ”a” 0.02 to 0.027”

(0.5 to 0.7 mm) between the inductive sensor

contact face and the gearing face as follows.

1 = Planetary carrier gearing

2 = Output cover

3 = Inductive sensor

4 = Shim

3 Push sliding ring (1) to approx. 0.20” (5 mm) from

the end of measurement rod 1P01 137 833.

2-109

Ecomat HP 500 / HP 590 Output cover

005273

1

2

a

3

4

008636

008637

4 Push measurement rod 1P01 137 833 into the

inductive sensor bore until the end of the

measurement rod touches the surface of the

gearing.

NOTE: Ensure that the measurement rod is introduced

at a right angle to the planetary carrier profile teeth.

5 Carefully remove the measurement rod.

6 Measure dimension “b” from the end of

measurement rod to the sliding ring.

7 Note down dimension “b”.

2-110


008638

008640

008639

11 Screw in inductive sensor (1) and spacer discs;

Tightening torque: max. 37 ft-lbs (50 Nm).

8 Measure dimension “c” from the contact surface of

the inductive sensor to the contact surface for the

spacer ring(s).

9 Subtract dimension “b” from dimension “c”.

c - b = d

10 Note down dimension “d”.

d+a = thickness “S” of the shim.

CAUTION

The figures given in the example below are theoretical.

Sample calculation:

b = 0.936” (24 mm)

c = 1.014” (26 mm)

a = 0.02” to 0.027” (0.5 to 0.7 mm)

d = c - b

d = 1.014” - 0.936” (26 mm - 24 mm)

d = 0.078” (2 mm)

S = d + a

S = 0.078” + 0.02 to 0.027”

(2 mm + 0.5 to 0.7 mm)

S = 0.098 to 0.106” (2.5 to 2.7 mm)

Shims are available in 0.008” (0.2 mm) steps from

0.023” (0.6 mm) to 0.118” (3.0 mm).

See Section 8.2, Page 2-65, working step 15.

2-111


008642

008641

12 Connect both cable connections (1) to the inductive

sensor using a pair of flat-nosed pliers.

NOTE: You do not have to observe polarity when re-

attaching the cable connections.

13 Fit cover (2) with an O-ring and insert it into the

bore.

NOTE: Lightly oil the O-ring.

14 Screw on two M6 hex nuts (1) and washers;


2-112


!

008643

008644

008645

Removal of output cover, continued

15 Unscrew speedometer connection (1).

17 Unscrew two M12 hex bolts.

NOTE: Secure the output flange using a flange holder

in order to unscrew both hex bolts.

18 Remove thrust disc (1).

NOTE: If necessary, loosen the thrust disc by tapping it

lightly with a plastic mallet.

2-113


16 Use a narrow-bladed instrument (e.g. chisel) to pry

off tab washer (1).

DANGER

Wear protective eye glasses or goggles!

Metal chips may fly off.

008646

008647

008648

19 Attach 2 or 3-arm pullers.

20 Insert pressure piece (1) and pull output flange (2)

off the output shaft.

CAUTION

Never use 2 or 3-arm pullers without a pressure piece.

Otherwise, the output shaft thread may become

damaged.

NOTE: Secure the flange with a flange holder when

pulling off.

21 Swing the transmission so the output shaft points

upwards.

22 Screw lifting device 1X56 136 260 firmly onto the

output shaft. Unscrew all M10 hex bolts from

around the edge of output cover.

NOTE: Make sure the cable connections for the

inductive sensor have been removed.

See steps 2-4 on page 2-108.

23 Attach lifting equipment to the output cover and

carefully lift the output cover off the transmission.

24 Remove gasket (1).

25 Remove lifting device 1X56 136 260.

CAUTION

Thread cable (2) for the inductive sensor carefully

through the housing bore.

2-114


008650

11.2 Installation of output cover.

1 Remove spacer disc (1) from sun gear (2).

NOTE: Spacer disc (1) may also be in the planetary

carrier.

NOTE: A new output cover with new breather valve (1)

(ref. no. 4139 203 085) was introduced into production

from transmission no. 094884.

CAUTION

A new gasket (2) (ref. no. 4139 301 618) must be used

in conjunction with the new breather valve (1).

NOTE: The new gasket (ref. no. 4139 301 618) can also

be used for the old output cover version.

2 Put on new gasket (1).

3 Set up measurement equipment (measurement

blocks (2) and measurement bar (3)) onto the

housing sealing face.

2-115


005550

2

1

008651

008652

008653

11.2.1 Measurement of end play of sun gear.

1 Measure and note down dimension “A” from the

measurement bar to the spacer disc contact surface

on the sun gear.

2 Measure and note down dimension “M” from the

measurement bar to the gasket.

3 Subtract dimension “M” from dimension “A” to

calculate theoretical dimension “C” from the gasket

to the spacer disc contact face.

A - M = C

4 Measurement of output cover dimension: use a

depth gage to measure dimension “B” from the

measurement bar to the spacer disc contact face.

Note down dimension “B”.

5 Calculate the thickness “X” of the spacer disc to

install as follows:

CAUTION

Ensure the height of the measurement equipment for

measuring dimension “B” is the same as for measuring

dimension “A” and “M”.

2-116

Output cover / Sun gear Ecomat HP 500 / HP 590

M - B = D

C - D = E

X = E - (0.023 to 0.031” / 0.6 to 0.8 mm)

0.023 to 0.031” (0.6 to 0.8 mm) = end play of spacer

disc.

CAUTION

The measurements given in the example are purely

theoretical.

Sample calculation:

A = 1.81” (46 mm)

B = 1.57” (40 mm)

M = 1.63” (41.5 mm)

This gives:

A - M = C

1.81” - 1.63” = 0.18” (46 mm - 41.5 mm = 4.5 mm)

M - B = D

1.63” - 1.57” = 0.06” (41.5 mm - 40 mm = 1.5 mm)

C - D = E

0.18” - 0.06” = 0.12” (4.5 mm - 1.5 mm = 3.0 mm)

X = E - 0.023 to 0.031” (E - 0.6 to 0.8 mm)

X = 0.12” - 0.023 to 0.031” (3,0 mm - 0.6 to 0.8 mm)

X = 0.086 - 0.094” (2.2 to 2.4 mm)

The spacer disc thickness may vary between 0.086 to

0.094” (2.2 and 2.4 mm).

Spacer discs are available in 0.008” (0.2 mm) steps.

0730 103 362 = 1.8 mm (0.071”)

0730 103 279 = 2.0 mm (0.078”)

0730 103 278 = 2.2 mm (0.086”)

0730 103 277 = 2.4 mm (0.094”)

0730 103 276 = 2.6 mm (0.102”)

0730 103 275 = 2.8 mm (0.110”)

0730 103 274 = 3.0 mm (0.118”)

0730 103 273 = 3.2 mm (0.125”)

0730 103 272 = 3.4 mm (0.133”)

CAUTION

Do not grind down spacer discs to achieve the correct

thickness. The spacer discs must be centered.

2-117

Ecomat HP 500 / HP 590 Output cover / Sun gear

008654

008656

008655

6 Attach spacer disc (1) of the calculated thickness to

the planetary carrier (2) using Vaseline.

7 Screw lifting device 1X56 136 260 (1) firmly onto

the output shaft.

8 Attach lifting equipment to the output cover and

suspend above the transmission. Line up the output

cover with threaded pins (2).

9 Slowly lower the output cover.

10 Whilst lowering the output cover, thread cable (1)

for the inductive sensor through hole (2) in the

output cover.

11 Lower the output cover fully and remove lifting

equipment.

CAUTION

When lowering the output cover, ensure the planet gears

engage in the gearing of the disc carrier, ring and sun

gear. You may have to rotate the output shaft slightly to

achieve this. Take care not to damage the inductive

sensor cable.

2-118


008657

008659

008658

12 Screw in fourteen M10x55 hex bolts (1).

13 Screw in two M10x75 hex bolts (2).

14 Tighten opposite pairs of hex bolts, working round

output cover until it is fully tightened onto the

transmission.

15 Fully tighten the hex bolts;


NOTE: Leave both bores (3) for the retarder

accumulator mountings free.

16 Unscrew lifting device 1X56 136 260.

17 Coat the sealing face of thrust disc (1) with sealing

compound and place onto output flange.

18 Screw in two M12x30 hex bolts (2). Secure the

output flange with a flange holder to prevent it from

turning.

Tightening torque of hex bolts: 44 ft-lbs (60 Nm).

NOTE: Attach the thrust disc with its chamfered edge

pointing outwards.

19 Use punch 1X56 136 471 to fit a new tap washer

onto the hex bolts.

20 Drive the tab washer onto the hex bolts.

2-119


001578

001578

008660

NOTE: If the speedometer connection leaks, fit a new

sealing ring as follows:

21 Push tapered adapter (1) onto the speedometer

shaft.

22 Coat the external diameter of shaft sealing ring (2)

with sealing compound.

23 Fill the area behind the sealing lip with grease.

24 Use adapter 1X56 100 632 (3) to push the sealing

ring over the tapered adapter (ensure the sealing

ring sealing lip is pointing towards the pinion. Drive

the sealing ring into the speedometer connection.

25 Coat the thread of speedometer drive (1) with oil.

26 Push new copper sealing washer (2) onto the

speedometer drive.

27 Screw in the speedometer drive;


28 Check that you can feel the tooth backlash of the

speedometer pinion by hand (0.004 to 0.008” /

0.1 to 0.2 mm).

29 Fit inductive sensor, see Section 11.1.1.

Install retarder accumulator, see Section 2.3.

Fit oil cooler, see Section 3.3.

2-120


12 3

008661

008662

11.3 Dismantling output cover

NOTE: A new output cover with new breather valve (1)

(item no. 4139 203 085) was introduced into production

from transmission no. 094884. The old output cover

with old breather valve (2*) (ref. no. 0768 360 015) was

installed in transmissions up to no. 094883.

1 New version: Loosen valve (1) by lightly tapping

with plastic hammer on output cover. Remove valve

from valve bore.

1.1 Old version: Unscrew breather valve (2*) and set

aside together with O-ring and copper seal.

2 Place the output cover on the output flange.

3 Grip F piston (1) using a pair of pliers and drive the

F piston out of the output cover by striking the

output cover with a plastic mallet.

NOTE: When striking the F piston, spread the mallet

blows evenly around the circumference of the piston.

4 Place the output cover on supports under a press so

the planetary carrier can be pressed out.

5 Press the planetary carrier out of the output cover.

CAUTION

Place cushioning material underneath the planetary

carrier.

2-121


DANGER

Do not hold the underside of the planetary

carrier.

!

005554

12*

008663

008665

008664

6 Press the shaft seal out of the output cover.

NOTE: The shaft seal is easier to remove if you drive it

in on one side and lever it out using assembly irons.

7 Remove tapered roller bearing (1) from the output

cover.

8 Heat output cover to approx. 185 °F (85 °C) using

hot air blower 1X56 136 513.

9 Use a plastic rod to drive out both bearing outer

rings (1).

NOTE: Always insert the plastic rod in grooves (2).

Drive the input bearing outer ring out from the output

end, drive the output bearing outer ring out from the

input end.

10 Remove spacer disk (1) from speedometer worm

(2).

2-122


DANGER

Put on protective gloves before touching the

heated output cover.

!

008666

008668

008667

11 Place extractor 1X56 126 464 onto the speedometer

worm.

CAUTION

Take care not to damage the speedometer worm gearing

when attaching the extractor.

12 Attach a 2-arm puller to the slots in the extractor.

CAUTION

Position pressure piece (1) on the end of the output

shaft.

13 Pull the speedometer worm off the output shaft.

14 Pull spacer bush (1) off the output shaft.

15 Push grip 1X56 136 706 onto the tapered roller

bearing inner race.

16 Tighten the extractor edge with the threaded ring

until it grips the base of the tapered roller bearing.

17 Screw base tool 1X56 122 306 onto grip

1X56 136 706.

18 Pull off tapered roller bearing inner race.

2-123


008669

008670

008671

19 Insert inner extractor 1X56 122 205 into the

bearing bore and attach extractor edge under the

base of the needle bearing.

20 Screw counter bracket 1X56 122 227 onto the inner

extractor.

21 Pull needle bearing (1) out of planetary carrier III.

22 Release planetary gear pins (1).

23 Stand planetary carrier III on supports.

24 Drive out planetary gear pins (1).

2-124


DANGER

Wear protective glasses when releasing the

planetary gear pins.

!

008672

008673

25 Remove planetary gears (1) out of the planetary

carrier III.

26 Remove two roller bearings (1) out of each

planetary gear.

27 Remove two thrust washers from each planetary

gear.

NOTE: 2 or 3-hole thrust plates may also be fitted.

2-125


004836

NOTE: There are several different versions of planet

carrier III.

Version shown in figure:

Planet carrier III with thrust plates (3) and planet gear

axles (2) secured with slotted pin.

Loosening planet gear axles:

- Drive in slotted pins (1) to middle of planet gear

axles using suitable drift.

Never drive in slotted pins to limit of travel.

- Remove planet gear axles (2) from planet carrier

and drive out slotted pins from bore.

Dismantling planet carrier III:

- As described under Steps 25 to 27.

3

1

2

008675

008674

008676

11.4 Assembly of output cover.

1 Stand planetary carrier III with its output shaft

pointing downwards and secure it to stop it tipping

over.

2 Insert bottom thrust washers (1) or thrust plates.

CAUTION

If using 2 and 3-hole thrust plates, note that these are bi-

metallic plates. Each has one steel and one aluminium

surface. The steel surface is marked (1) and must be the

side which touches the planetary carrier.

3 Insert two roller bearings (2) into each planetary

gear (1).

CAUTION

Never replace individual planetary gears, only complete

sets.

NOTE: Grease the bearing surface of the planetary

gears and roller bearings with Vaseline before

installation.

2-126


008677

4 Insert complete planetary gear (1) and bearings into

the planetary carrier III.

5 Insert top thrust washers (2) or thrust plates.

CAUTION



surface. The steel surface is marked and must be the


6 Line up the bearings, thrust washers (or thrust

plates) and planetary gear with the bores in the

planetary carrier.

7 Drive in planetary gear pin (1) until level with the

planetary carrier surface.

NOTE: Install the other planetary gears using the same

method.

8 Place support 1X56 137 464 under a press.

9 Place the planetary carrier onto the support.

CAUTION

Ensure pin (1) engages with the holes for the planetary

gear pins.

2-127


008679

008678

10 Place punch 1X56 137 466 under the press.

11 Press open the collar edges to secure the planetary

gear pins.

CAUTION

Always ensure that the planetary gear pin being secured

is braced against the support pin.

NOTE: There are several different versions of planet

carrier III

Version shown in figure:

Planet carrier III with thrust plates (3) and planet

gear axles (2) secured with slotted pin (1).

Reassembly of planet carrier III secured with

slotted pin:

- As described under Steps 1 to 6.

Securing planet gear axles with slotted pin:

- Align bores for slotted pins and push planet gear

axles securely onto planet carrier.

- Drive new slotted pins (1) fully into planet gear

axles (2) on planet carrier and secure by peening

(2 x 180°).

12 Measure the end play of planetary gears between

the thrust washer and planetary carrier.

NOTE: Permitted end play is 0.02 to 0.05”

(0.5 to 1.2 mm).

Measure on all the planetary gears.

2-128


008680

004836

008681

3

1

2

008682

008684

008683

13 Drive a new needle bearing into planetary carrier III

using rod 1X56 137 101.

NOTE: Using rod 1X56 137 101 gives the correct

installation dimension for the needle bearing. Place rod

against the bearing edge which has the stronger collar.

Oil the needle bearing before installation.

11.4.1 Adjustment of tapered roller bearing.

1 Clamp adjustment device 1P01 136 816 in a vice.

NOTE: Wash both tapered roller bearings and apply a

thin coat of oil to them.

2 Push tapered roller bearing output inner race (1)

onto the adjustment device.

3 Drive hollow tension pins (2) approx. 5 mm out of

the adjustment ring in advance.

4 Push the spacer bush and adjustment ring (3) onto

adjustment device 1P01 136 816.

CAUTION

Ensure hollow tension pins (2) are protruding upwards.

2-129


008685

008687

008686

5 Heat output cover to approx.185 °F (85 °C) using

hot air blower 1X56 136 513.

6 Insert bearing input outer race (1) into the output

cover with broader collar pointing upwards. Use

inserter 1X56 136 824 to drive the bearing outer

ring (1) in fully.

7 Turn over output cover.

8 Install bearing output outer race (1) as described in

working step 6.

CAUTION

Make sure the bearing outer rings do not cool below

185 °F (85 °C) before they are installed.

9 Place output cover on adjustment device

1P01 136 816.

Ensure the output cover is seated evenly.

10 Insert tapered roller bearing output inner race (1).

Make sure the bearing race is evenly seated.

2-130


DANGER

Put on protective gloves before touching the heated

output cover.

!

008688

008689

008690

11 Position disc (1) of the adjustment device with its

recess pointing towards the adjustment device.

12 Screw M12 hex bolt (2) fully in.

NOTE: The temperature of the adjustment device

components must be approx.68°F (20°C) for the

following adjustment procedure.

Specified bearing adjustment

= 0.002 to 0.006" (0.05 to 0.15 mm) preload

This equates to a bearing rolling torque of

1.3 ft-lbs to 4.7 ft-lbs (1.8 to 6.4 Nm) at ambient

temperature.

13 Wrap a cord several times around the neck of the

output cover. Connect the end of the cord to a

spring balance.

14 Exert an even tension on the spring balance until

the output cover starts to turn. Check that the force

required to do this is between 3.3 and 4.4 lbs

(15 and 20 N).

15 Tighten the hex bolt if the force required is less

than 3.3 lbs (15 N).

CAUTION

If the hex bolt is tightened too much, e.g. the force

required is above 4.4 lbs (20 N), dismantle the complete

adjustment device and start the measurement process

again.

16 Loosen hex bolt (1) and remove the disc.

17 Remove the output cover from the adjustment

device.

CAUTION

Take care not to move the tension pins when loosening

the hex bolt.

2-131


008691

008693

008692

18 Remove the adjustment ring.

19 Lay the adjustment ring on a flat surface with the

tension pins pointing downwards.

20 Use a depth micrometer to measure dimension “A”

from the top edge of the adjustment ring to the

bottom edge of the tension pins.

21 Use a depth micrometer to measure dimension “B”

for the speedometer worm (1) in the same way.

Note down dimension “B”.

22 Subtract dimension “B” from dimension “A”. The

result is dimension “C”.

Calculate the thickness “S” of the shim to fit as

follows:

S = C + 0.002” (0.05 mm)

0.002” (0.05 mm) = constant addition factor

23 Check calculated thickness of the shim to be fitted

using a micrometer.

Shims are available in the following thicknesses:

0730 103 586 = 1.20 mm 0.047”

0730 103 587 = 1.10 mm 0.043”

0730 106 668 = 1.05 mm 0.041”

0730 103 588 = 1.00 mm 0.041”

0730 106 667 = 0.95 mm 0.037”

0730 106 666 = 0.90 mm 0.035”

0730 103 589 = 0.80 mm 0.031”

0730 103 590 = 0.60 mm 0.023”

0730 103 591 = 0.40 mm 0.015”

2-132


008694

008695

008696

24 Heat output tapered roller bearing inner race (1) to

185°F (85°C) using hot-air blower 1X56 136 513.

Push the bearing inner race fully onto the output

shaft.

CAUTION

Never heat the rollers. Install bearing with its narrow

taper pointing towards the output.

25 Push spacer bush (2) onto the output shaft.

26 Heat speedometer worm (1) to 185°F (85°C) using

hot-air blower 1X56 136 513. Push the speedometer

worm onto the output shaft.

CAUTION

Install speedometer worm with collar pointing towards

the output.

27 Once the parts have cooled, press on the toothed

disc, bearing inner race and speedometer worm

using inserter 1X56 136 824. Make sure all parts

are pressed on fully.

2-133


008697

008698

008699

28 Slide on shim (1) of the calculated thickness.

29 Place the output cover on the planetary carrier.

30 Heat output bearing inner race (1) to 185°F (85°C)

using hot-air blower 1X56 136 513.

31 Insert the bearing inner race into the output cover

until it is evenly seated.

32 Coat the outer edge of shaft sealing ring (1) with

lubricant.

33 Push the shaft sealing ring onto inserter

1X56 136 824 with the shaft sealing ring sealing lip

pointing towards the output cover.

2-134


1

008700

008701

34 Use a press and inserter 1X56 136 824 to press the

shaft sealing ring fully into the output cover.

35 Using inserter 1X56 136 824 automatically sets the

correct clearance of 0.6 -0.04 inch (15 -1 mm)

between the top of the bearing inner race and the

top of the sealing ring.

CAUTION

Fill the sealing lip and disc lip of the shaft sealing ring

with non-acidic grease.

NOTE: Insert the connection bolts for the propshaft

flange (if appropriate) before fitting the output flange.

36 Heat output flange (1) to approx. 230°F (110°C)

using hot-air blower 1X56 136 513.

37 Press the output flange fully onto the output shaft.

NOTE: If you cannot push the output flange on fully

although it is heated to the specified temperature, place

the planetary carrier on support 1X56 137 154.

Push on the output flange fully using a mandrel press.

2-135


008659

38 Coat the sealing face of thrust disc (1) with sealing

compound and place onto output flange.

NOTE: Attach the thrust disc with its chamfered edge

pointing outwards.

39 Smear bolt heads of the M12x30 hex bolts on their

underside with sealing compound (WEVO-L100

produced by WEVOCHEMIE), screw in and

tighten. Secure the output flange with a flange

holder to prevent it from turning.


NOTE

Always use new hex bolts here.

008658

015824

008702

40 Use punch 1X56 136 471 to fit a new tap washer

onto the hex bolts.

41 Drive the tab washer onto the hex bolts.

NOTE

Let output cool down to ambient temperature.

42 Re-check bearing rolling torque. Wrap a cord

several times around the neck of the output cover.

Connect the end of the cord to a spring balance.

43 Exert an even tension on the spring balance until

the output cover starts to turn. Check that the force

required to do this is between 3.3 and 4.4 lbs

(15 and 20 N). This equates to a bearing rolling

torque of 1.3 ft-lbs to 4.7 ft-lbs (1.8 to 6.4 Nm) at

ambient temperature.

CAUTION

If bearing rolling torque is not within the specified

tolerance range, adjustment needs to be corrected.

11.4.2 Setting of disc play in brake “F” and “NBS”.

1 Place gasket (1) onto the housing sealing face.

NOTE: In the version without NBS, the final disc is an

outer disc. Measure dimension "A" using a depth gauge

positioned on this outer disc (not illustrated).

2 Use a depth gauge to measure from the

measurement bar to the outer edge or highest point

of plate spring (2). Note down dimension “A”.

2-136

“NBS”F brake Ecomat HP 500 / HP 590

DANGER

When the lock plate (1) has been driven in, you

may be left with a sharp edge. Carefully remove

this edge using a file or other suitable tool.

!

008703

008704

008705

3 Use a depth gauge to measure from the

measurement bar to the gasket. Note down

dimension “B”.

4 B - A = C Note down dimension “C”.

5 Insert the F piston into the output cover. Ensure the

F piston is evenly seated.

6 Use a depth gauge to measure from the output cover

sealing face (without gasket) to the F piston contact

surface. Note down dimension “D”.

7 Disk play = D - C

The disc play must be between 0.13 to 0.15” (3.2

and 3.7 mm). Set using the outer discs. Discs are

available in the following thicknesses.

0.08” 0.10” 0.12” (2.0 mm 2.5 mm 3.0 mm)

CAUTION

Do not use the F piston end disc for setting the disc play.

8 Set NBS (Neutral at Bus Stop) by gripping F piston

(1) with a pair of pliers. Hit around the edge of the

output cover using a plastic mallet.

9 Remove the F piston.

2-137

Ecomat HP 500 / HP 590 “NBS”F brake

008707

008706

008709

10 Insert outer lip sealing ring (1) into the F piston.

Make sure the sealing lip is facing the pressure

side.

11 Insert lip sealing ring (2).

12 Insert the inner lip sealing ring.

13 Adjustment device for NBS.

14 Place adjustment device 1P01 137 906 onto the F

piston with the “Piston Side” downwards (see

markings). Loosen fixing bolts (1) on the

adjustment device.

15 Press rings (2) of the adjustment device against the

piston and carefully tighten the fixing bolts.

2-138

“NBS”F brake Ecomat HP 500 / HP 590

008708

008710

008711

16 Place spring elements into transmission housing

without springs.

17 Place the adjustment device “Disc Side” down onto

the disc pack plate spring. Check the adjustment

device is centered and the holes are lined up with

the spring elements.

18 Insert measurement tubes into the adjustment

device. Set each spring element using a Torx

screwdriver so the top of each measurement tube is

level with the outer ring of the adjustment device.

2-139

Ecomat HP 500 / HP 590 “NBS” F brake

008712

008713

008714

19 Check the adjustment made in working step 18

using a straight-edge.

20 Lift off the adjustment device. Position the F piston

and place the adjustment device onto the F piston

for improved measurement accuracy.

21 Check the NBS end play using a feeler gauge

between the F piston and plate spring.

Permissible play is 0.002 to 0.01”

(0.05 to 0.25 mm).

2-140

"NBS" F brake Ecomat HP 500 / HP 590

008715

008717

008716

12 Removal and installation of mechanical

transmission section.

12.1 Removal of mechanical transmission section.

1 Remove cable (1) for the inductive sensor from the

transmission.

2 Pull off sun gear (1) from the input shaft.

3 Remove thrust washer (1) from input shaft.

NOTE: The thrust washer may also be stuck to the base

of the sun gear.

2-141

Ecomat HP 500 / HP 590 Mechanical transmission section

008718

008720

008719

4 Remove the springs and spring elements for NBS.

5 Use assembly hooks 1X56 097 775 to remove

planetary carrier II (1) from the transmission.

6 Remove disc pack (1) for the F brake from the

transmission.

CAUTION

Mark the disc pack accordingly. Do not switch discs

between different disc packs.

2-142

Mechanical transmission section Ecomat HP 500 / HP 590

DANGER

The assembly hooks do not hold the planetary

carrier stably

!

008721

008722

7 Remove thrust washer (1) from the transmission.


of planetary carrier II.

8 Remove pressure springs (1), pins (2) and guide

tubes (3) from the transmission.

2-143


008723

008724

008725

12.1.1 Disassembly of planetary carrier II

1 Use a screwdriver to unclip retaining ring (1) at all

four access points (2).

CAUTION

Make sure the retaining ring does not snap back into its

ring groove.

2 Pull off the output ring gear (1) from planetary

carrier II (2). Remove the retaining ring.

NOTE: If required, use a plastic mallet to separate the

ring gear from planetary carrier II.

3 Use a suitable punch to release planetary gear pins

(1).

2-144

Planetary carrier II Ecomat HP 500 / HP 590

DANGER



!

008726

008727

008728

4 Use a punch to drive planetary gear pins (1) down

out of planetary carrier II.

5 Remove planetary gears (2) from planetary

carrier II.

6 Remove roller bearings (1) from each planetary

gear.

7 Remove thrust plates (1) from planetary carrier II.

NOTE: Remove 3-hole thrust plates first.

2-145

Ecomat HP 500 / HP 590 Planetary carrier II

008729

8 Use a suitable pin to press retaining ring (1) out

through hole (2).

9 Use a screwdriver to lever out the retaining ring.

10 Place a plastic rod against the shoulder (arrowed) of

ring gear (3).

11 Drive the ring gear off planetary carrier II.

See Section 12.1.3, working step 3.

2-146


008730

008731

008732

12.1.2 Assembly of planetary carrier II.

1 Insert lower thrust plates (1).

CAUTION



surface. The steel surface is marked (1) and must be the


2 Insert two roller bearings (2) in each planetary gear

(1).

NOTE: Apply Vaseline to the bearing bore of the

planetary gears and to the roller bearings before

installation.

2-147


008733

008734

008735

3 Insert complete planetary gear (1) and bearings into

the planetary carrier II.

4 Insert top thrust washer (2) with its steel side facing

the planetary carrier.

5 Line up the bearings, thrust washers and planetary

gear with the holes in the planetary carrier.

6 Drive in planetary gear pin until level with the


CAUTION

Always use new planetary gears.


method. Always replace planetary gears in complete

sets.

7 Place support 1X56 137 464 under a press.

8 Place the planetary carrier (1) onto the support.

9 Place punch 1X56 137 466 under the press. Press

open the collar edges to secure the planetary gear

pins.

2-148


008736

008738

008737

CAUTION

Ensure pin (1) engages with the holes for the planetary

gear pins. Always ensure that the planetary gear pin

being secured is braced against the support pin.

10 Measure end play of planetary gears between the

thrust washer and planetary carrier using a feeler

gauge.

NOTE: Permitted end play is 0.02 to 0.05” (0.5 to

1.2 mm). Measure on all the planetary gears.

11 Place output ring gear (1) under a press with its ring

groove pointing upwards.

12 Place planetary carrier II (2) onto the ring gear.

13 Line up the planetary carrier and ring gear gearing.

14 Place a suitably sized pressure piece onto the

planetary carrier.

15 Press the ring gear onto the planetary carrier.

2-149


008739

008741

008740

16 Clip in retaining ring (1).

CAUTION

Insert the retaining ring so that its separation is adjacent

to the hole (2). Ensure the retaining ring is fully inserted

into the ring groove.

17 Place planetary carrier II under a press.

18 Position retaining ring.

19 Place input ring gear (1) on the planetary carrier

with its ring groove pointing towards the planetary

carrier.

20 Place an appropriately sized pressure piece onto the

planetary carrier.

21 Press the ring gear onto the planetary carrier. Stop

pressing on before the retaining ring binds.

22 Use a screwdriver to clip the retaining ring into the

ring groove in the ring gear.

23 Press ring gear on fully. Use a screwdriver to press

retaining ring (1) into the ring groove at all access

points (2).

CAUTION

Insert the retaining ring so the ring join is located at one

of the access points (2). Ensure the retaining ring is fully

clipped into the ring groove.

2-150


008743

008742

008744

Removal of mechanical transmission section,

continued:

24 Use assembly hooks 1X56 097 775 to remove

planetary carrier I from the transmission.

25 Remove thrust washer (1) from the transmission.


of planetary carrier I.

12.1.3 Disassembly of planetary carrier I.

1 Use a suitable pin to press retaining ring (1) out

through hole (2).

2 Use a screwdriver to lever out the retaining ring.

2-151


DANGER

The assembly hooks do not hold the planetary

carrier stably.

!

008745

008746

008747

3 Place a plastic rod against the shoulder of ring gear

and drive the ring gear off the planetary carrier.

4 Use a suitable punch to release planetary gear

pins (1).

5 Use a punch to drive planetary gear pins (1) down

out of planetary carrier I.

6 Remove planetary gears (1) and thrust washers (2)

by pushing them towards the center of planetary

carrier I.

7 Remove the needle bearing from the planetary

gears.

2-152


DANGER



!

008748

008750

008749

12.1.4 Assembly of planetary carrier I.

1 Insert lower thrust plates (1) into planetary carrier I

with curved profile pointing outwards.

CAUTION

The thrust plates are bi-metallic plates. Each has one

steel and one aluminium surface. The steel surface is

marked (1) and must face the planetary carrier.

2 Insert needle bearing (2) into each planetary

gear (1).

NOTE: Coat the bearing bore of the planetary gears and

the needle bearings with Vaseline.

3 Insert complete planetary gear and bearings into the

planetary carrier I.

4 Insert top thrust washer (1) with its steel side facing

the planetary carrier.

2-153

Ecomat HP 500 / HP 590 Planetary carrier I

008751

008752

008753

5 Line up the bearings, thrust washers and planetary

gear with the holes in the planetary carrier.

6 Drive in planetary gear pin (1) until level with the


CAUTION

Always use new planetary gears.

Always replace planetary gears in complete sets.


method.

7 Place support 1X56 137 464 under a press. Place

planetary carrier (1) onto the support.

8 Place punch 1X56 137 466 under the press. Press

open the collar edges to secure the planetary gear

pins.

CAUTION

Ensure pins (2) engage with the holes in the planetary

gear pins. Always ensure that the planetary gear pin

being secured is braced against the support pin.

9 Measure end play of planetary gears between the

thrust washer and planetary carrier using a feeler

gauge.

CAUTION

Do not measure at the recess.

NOTE: Permitted end play is 0.02 to 0.05” (0.5 to 1.2

mm). Measure on all the planetary gears.

2-154

Planetary carrier I Ecomat HP 500 / HP 590

008755

008754

10 Place ring gear (1) under a press with its ring

groove pointing upwards.

11 Place planetary carrier I (2) onto the ring gear.

12 Line up the planetary carrier and ring gear gearing.

13 Place a pressure piece onto the planetary carrier.

Press the ring gear onto the planetary carrier.

14 Clip in retaining ring (1).

CAUTION

Insert the retaining ring so that its ends are adjacent to

the hole (2). Ensure the retaining ring is fully inserted

into the ring groove.

2-155

Ecomat HP 500 / HP 590 Planetary carrier I

008756

008758

008757


continued:

1 Turn pressure ring (1) until the pressure ring teeth

(2) are lined up with the tooth profile (3) of the


2 Remove pressure ring (1) from the transmission.

3 Take disc pack (2) out of the transmission.

CAUTION

Mark the disc pack accordingly. Do not switch discs

between different disc packs.

4 Leave centring pins (3) standing on the last disc.

Lift out the centring pins carefully, for example by

lifting them out with the last disc.

5 Remove E piston (1) from the transmission

housing.

2-156


DANGER

Make sure the centring pins do not fall into the

transmission.

!

008759

008760

008761

NOTE: If the E piston binds: blow compressed air in

through one of the oil ducts (1). This will loosen the E

piston.

6 Remove lip sealing rings (1) from the E piston.

7 Lift disc carrier (1) out of the transmission.

2-157


DANGER

Cover the transmission housing with a large rag

before using compressed air to loosen the

E piston. Protect eyes against oil spray.

!

1

1

008762

008763

8 Remove needle bearing (1) and thrust washer (2)

from the input shaft.

NOTE: Needle bearing (1) and thrust washer (2) may

also be attached to the base of the disc carrier.

9 Remove top needle bearing (1) from the disc

carrier.

2-158


008764

008765

008766

12.1.5 Removal of sun gear from disc carrier.

1 Use a screwdriver to unclip the outer and inner

retaining rings.

2 Rotate the inner and outer retaining rings so one of

the ring ends is visible in groove (1).

3 Use a suitable rod to drive sun gear (2) out of the

disc carrier.

12.1.6 Installation of sun gear in disc carrier.

1 Insert sun gear (1) into the disc carrier with its

longer collar uppermost.

2 Drive in the sun gear fully until it is evenly seated.

3 Insert the inner and outer retaining rings into the

ring groove.

NOTE: Turn each retaining ring so that the ring ends

are lined up with access point (1).

2-159


008768

008769

008767


5 HP 500:

4 Lift the quill shaft out of the transmission housing.

NOTE: Remove the quill shaft by turning it until its

gearing lines up with the inner discs of the B and C

clutches.

5 Remove both needle cages.

6 Remove the thrust washer from the input shaft or

quill shaft.

Installation of mechanical transmission section,

5 HP 500:

7 Attach the thrust washer to the quill shaft using

Vaseline and place both needle cages onto the quill

shaft.

8 Line up the inner discs of B and C clutches using a

screwdriver.

9 Insert the quill shaft into the transmission housing.

2-160


008770

008772

008771


continued:

1 Remove input shaft (1) from the transmission.

2 Remove thrust washer (1) from the turbine shaft.

NOTE: The thrust washer may be attached to the input

shaft.

3 Insert inner extractor 1X56 122 205 into the

bearing bore. Grip underneath the needle bearing.

2-161


008773

4 Screw counter bracket 1X56 122 227 onto the inner

extractor.

5 Tighten counter nut (1) by hand and pull the needle

bearing out of the input shaft.

2-162


008774

008775

008776

12.2 Installation of mechanical transmission section.

1 Use punch 1X56 137 101 to drive a new needle

bearing into the input shaft. Make sure the needle

bearing is evenly seated.

NOTE: Using punch 1X56 137 101 ensures that the

needle bearing installation dimension is correct.

Drive the punch against the side of the bearing with a

reinforced edge.

2 Attach thrust washer (1) to the input shaft using

Vaseline.

3 Line up and center outer discs (1) of the A clutch

using a screwdriver.

2-163


008777

008779

008778

4 Insert input shaft (1).

CAUTION

Ensure the input shaft is evenly seated.

5 Place thrust washer (2) onto the input shaft.

NOTE: Coat the thrust washer with Vaseline.

NOTE: For 5 HP 500 transmission, install the quill

shaft.

6 Coat output needle bearing (1) with Vaseline and

insert into sun gear (2).

7 Coat lower needle bearing (1) with Vaseline and

insert into sun gear (2).

2-164


008783

008782

008781

8 Place complete disc carrier (1) onto the input shaft.

CAUTION

Take care the lower needle bearing is not displaced.

Make sure the disc carrier is evenly seated. If necessary,

carefully rotate the disc carrier to achieve this.

9 Insert inner (1) and outer (2) lip sealing rings into

the E piston.

CAUTION

Check the lip sealing rings and replace if necessary. Fit

the lip sealing rings with their grooves pointing towards

the pressure side. Stretch the inner lip sealing ring

before installing it to make sure it fits into the groove

properly (e.g. flush with base of groove).

10 Coat the E piston sealing faces and lip sealing rings

lightly with Vaseline.

11 Insert E piston (1) into the transmission as

illustrated. Carefully drive in the E piston using a

plastic mallet until it is evenly seated.

CAUTION

Take care not to damage the lip sealing rings when

installing the E piston. The E piston should be a tight

fit.

2-165


008784

008785

008786

12 Measure the 1st outer disc of the E brake.

CAUTION

The 1st outer disc of the E brake is 0.12” (3 mm) thick.

13 Check outer and inner discs for wear.

14 Use a straight-edge to check that all discs are flat.

15 Discard uneven or bowed discs. Also discard

damaged discs.

CAUTION

There is a 1st and 2nd version of the E brake. In the 1st

version, the first 0.12” (3 mm) thick outer disc which is

inserted has holes in it. The lower pins for this version

are shorter than those in the F brake.

In the 2nd version and NBS version, the first 0.12”

(3 mm) thick outer disc has no holes. In this version, the

lower pins are the same length as those in the F brake.

NOTE: Follow steps 16 to 18 A), B) or C) as

appropriate when inserting the E brake discs. A) is for

the first version, B) is for the second version and C) is

for the NBS version.

A) First version

Mark the positions of the housing bores which are cast

more deeply into the housing (see arrow).

16A Insert the first outer disc so the holes (2) in the

outer disc line up with the deeper housing bores.

17A Insert an inner disc.

18A Insert the second outer disc with the “gaps” in its

tooth profile positioned over the holes in the first

outer disc.

2-166


008789

008787

008788

B) Second version

Mark the positions of the housing holes which are cast

more deeply into the housing (see arrow).

16B Insert the first outer disc so the middle tooth (2) of

each group of three teeth lines up with deeper

housing holes which were marked in advance (see

arrow).

17B Insert an inner disc.

18B Insert the second outer disc with the “gaps” in its

tooth profile positioned over each middle tooth (2)

of the groups of three teeth in the first outer disc.

C) NBS version

16C Insert the first outer disc so the middle tooth (2) of

each group of three teeth lines up below the spaces

for the spring elements (3).

17C Insert an inner disc

18C Insert the second outer disc with the “gaps” in its

tooth profile positioned over each middle tooth (2)

of the groups of three teeth in the first outer disc.

19 Insert the remaining discs in the correct sequence.

NOTE: Refer to the spare parts list for details of the

outer and inner discs.

20 Insert the pressure ring. Ensure the notches around

the outside of the pressure ring are positioned

correctly for installing the spring elements.

21 Lift the pressure ring slightly and turn it until its

teeth slide under the projections of the housing

profile.

22 Measure the E brake disc play using a feeler gage.

NOTE: The disc play must be 0.12 to 0.14” (3.0 to 3.5

mm) (HP 590) or 0.10 to 0.12” (2.5 to 3.0 mm) (HP

500). Correct the disc play by fitting a final outer disc

with a different thickness.

NOTE: Remove pressure ring and complete disc pack

from the transmission again.

2-167


008790

008792

008791

23 Use Vaseline to attach thrust washer (1) to the disc

carrier.

24 Use assembly hooks 1X56 097 775 to lower

planetary carrier (1) into the transmission.

25 Install the E brake disc pack as already described.

CAUTION

Make sure the first outer disc is the 0.12” (3 mm) disc.

CAUTION

Insert the pressure ring with round notches (1) lined up

with the housing holes.

26 Insert two spring elements (2) to fix the pressure

ring.

2-168


DANGER

Also support planetary carrier I using other

assistance to make sure it does not slip off the

assembly hooks.

!

008793

008794

008795

27 Use Vaseline to attach thrust disc (1) to the input

end of planetary carrier II.

28 Turn over planetary carrier II. Use assembly hooks

1X56 097 775 to lower planetary carrier (1) into the

transmission.

CAUTION

Make sure the thrust washer on the input side does not

fall off the planetary carrier.

29 Use Vaseline to attach the thrust washer to the input

contact surface of the sun gear.

NOTE: The input contact surface of the sun gear has

two machined recesses.

30 Push sun gear (1) onto the input shaft.

31 If required, drive the sun gear fully on by tapping

lightly with a plastic mallet.

2-169


DANGER

Also support planetary carrier I using other

assistance to make sure it does not slip off the

assembly hooks.

!

008796

008798

008797

32 Check outer and inner discs for wear. Check

evenness of all discs using a straight-edge.

Discard all uneven or bowed discs. Also discard all

damaged discs. (See also the description in

Section 5.3.4).

33 Measure and fit the F clutch discs.

NOTE: Refer to the Spare Parts List for the number of

inner and outer discs.

34 Insert inner and outer discs in alternate sequence.

CAUTION

Insert the outer discs with the gaps (1) between the

driver lugs lined up with the pressure springs (2).

NOTE: The final outer disc does not have any holes in

it and has larger engagement lugs.

2-170


008799

008801

008800

35 NBS (Neutral at Bus Stop)

Place angle ring and plate spring in position.

36 Insert the gasket for the output cover onto the


37 Insert cable (1) for the inductive sensor into the


CAUTION

Make sure you thread the inductive sensor cable through

the correct housing duct.

Fit the output cover, see Section 11.2.

2-171


12.2.1 Measurement and adjustment of inductive

sensor ring.

1 Set the transmission so its base is pointing upwards.

2 Maximum concentricity error of inductive sensor

ring is + 0.008” (0.2 mm). The concentricity error

refers to the protrusions on the inductive sensor

ring. Correct errors by tapping carefully with a soft

hammer.

(4-speed version)

- Install hydraulic control unit, see Section 9.2.

- Install oil pan, see Section 7.2.

- Install oil cooler, see Section 3.3.

- Install retarder accumulator, see Section 2.3.

2-172



of control unit.

13.1 Removal of control unit.

NOTE: Step 1 only applies for transmissions with new

housing (from transmission no. 97173).

1 Loosen M8 hex bolts (1). Remove hex bolts and

securing plate (2) for suction pipe (3).

2-173

Ecomat HP 500 / HP 590 Control unit

2 Use inner extractor 1X56 122 208 and counter

bracket 1X56 122 227 to pull suction tube (1) out

of the transmission housing.

3 Remove O-ring (1) from suction tube (2).

005548

008802

008803

12

3

6 Connect lifting equipment to lifting device

1X56 137 213.

7 Use hot air blower 1X56 136 513 to heat the

transmission housing around the control unit to

approx. 185 °F (85 °C).

8 Lift the control unit out of the transmission housing

and place it on wood blocks.

2-174

Control unit Ecomat HP 500 / HP 590

DANGER



!

DANGER

Do not remove lifting device 1X56 137 213,

otherwise the turbine shaft will fall downwards

through the control unit.

!

4 Fix the transmission with its input end pointing

upwards.

5 Unscrew M8 cap screws (1) from around the

circumference. Remove cap screws and washers.

CAUTION

Use inner hex head driver 1X56 137 273 to remove cap

screws around the circumference. Take care not to

damage the cover plate sealing surface.

008804

008806

008805

008808

008807

008809

13.2 Installation of control unit

1 Line up the hole pattern of the intermediate ring (1)

with the hole pattern of the control unit.

NOTE: Make sure the lug (arrowed) of the intermediate

ring engages with the notch in the sealing ring.

(See Section 13.4).

2 Insert two cap screws to assist centring.

3 Screw M8 guide bolts 1X56 136 821 into the

transmission housing to assist centring.

4 Screw lifting device 1X56 137 213 onto the turbine

shaft.

5 Use hot air blower 1X56 136 513 to heat the

interference fit for the control unit in the

transmission housing to approx. 185 °F (85 °C).

6 Use lifting equipment to suspend the control unit

above the transmission. Line up the control unit

with the guide bolts and lower it into the

transmission.

NOTE: Ensure the control unit is evenly seated straight-

away.

2-175


DANGER



!

008811

008810

7 Unscrew guide bolts.

8 Screw five M8x65 cap screws (1) into the control

unit.

9 Screw in M8x55 cap screw.

10 Screw in M8x70 cap screw.

11 Attach control unit to housing bore using two M8

bolts and wide intermediate plate or wide washers

(see arrow), ensuring there is zero play.

CAUTION

Non-conformance with these help measures may lead to

leakages on the transmission.

NOTE:

– This help measure prevents a drop in lubrication

pressure.

– Use wide intermediate plate.

– Do not damage sealing face.

2-176


003140

2-177


12 Tighten all socket head screws (1/2/3) using driver

1X56 137 273.


CAUTION

Do not damage sealing faces when screwing in and

tightening socket head screws.

13 Unscrew the M8 bolts required for the help measure

(step 11) and remove together with intermediate

plate.

14 Grease O-ring (1) with technical vaseline and place

in transmission housing.

15 Grease suction pipe (1) with technical vaseline and

place in transmission housing.

NOTE: If the suction pipe is difficult to position,

carefully drive in using plastic hammer.

16 Position securing plate (2) with two M8x18 hex

bolts (3) for securing suction pipe.


17 Secure each hex bolt (3) with securing plate shackle

(4).

NOTE: Steps 16 and 17 only apply to transmissions

with new housing (from transmission no. 97173).

003598/003597

003599

005548

1113

003 598

003 599

1

1

32

3

2

4

1

008812

008813

008814

13.3 Disassembly of control unit.

1 Unscrew lifting device 1X56 137 213 from the

turbine shaft.

CAUTION

When unscrewing the lifting device, hold the turbine

shaft to prevent it from falling down.

2 Lower the turbine shaft through the control unit

until retaining ring (1) is accessible.

3 Use circlip pliers to remove the retaining ring.

4 Lift turbine shaft (1) out of stator quill shaft (2).

5 Screw hooks 1X56 136 612 into the control unit.

6 Attach lifting equipment.

7 Lift the control unit slightly off its base.

8 Use rod 1X56 137 109 to separate the clutch carrier

from the control insert.

9 Remove the clutch carrier and lower the control

insert.

2-178


DANGER

Never hold the clutch carrier from underneath

when separating it from the control insert.

!

008815

008816

008817

13.3.1 Disassembly of control insert.

1 Hold spacer ring (1) and pull out cylindrical pin (2).

2 Remove spacer ring.

3 Remove the pressure spring.

4 Take piston (1) for the cooler change-over valve out

of the valve housing.

5 Push clamping device 1X56 137 108 onto the

control insert.

6 Screw the clamping device spindle into the

converter back-up pressure valve.

2-179


DANGER

The spacer ring is spring-loaded.

!

008818

008819

008820

7 Unload the retaining rings using the spindle.

8 Use circlip pliers to remove retaining ring (1).

9 Unscrew the spindle and remove sealing washer (2)

and retaining ring (1).

NOTE: Remove main pressure valve (3) in the same

sequence.

NOTE: A „P 3.1“ repair set (ref. no. 4139 298 987) can

be obtained from ZF Friedrichshafen AG for the main

pressure valve P2 (3), which is fitted as standard during

production. If, during the transmission lifetime, the

main pressure drops when the converter clutch is

disengaged, this can be rectified using this service

solution without the need to remove the transmission.

- See Service Memo no. 11/94 .-

10 Remove pressure spring (1) and piston (2) of the

converter back-up pressure valve from the housing

bore.

11 Screw fixture 1X56 137 107 into the spacer ring.

12 Hold the fixture and spacer ring and remove

cylindrical pin (1).

13 Pull out the spacer ring using fixture

1X56 137 107.

2-180


DANGER

Sealing washer is spring-loaded. Ensure the

sealing washer does not jump out when

unscrewing the spindle.

!

DANGER

Spacer ring is spring-loaded.!

008822

008821

008823

14 Push piston (1) of the lubricating pressure valve

forwards using a screwdriver. Pull out the piston

and pressure spring.

15 View of all valves and pressure springs.

CAUTION

There are various versions of the main pressure valve.

See spare parts list or spec. list and Service Memo no.

11/94 for further procedure.

16 Press out plug (1) for pressure line using two

screwdrivers.

CAUTION

Do not damage the control insert sealing face.

17 Remove O-ring (2) for the suction tube.

2-181


DANGER

The housing has sharp edges. Never insert

unprotected fingers into the housing.

!

008824

008825

008826

18 Turn over the control unit.

19 Place pressure piece 1X56 137 104 onto the oil feed

flange.

20 Insert extractor device 1X56 122 322 into grooved

ball bearing (1) and clamp on using the ring.

21 Pull the grooved ball bearing off the oil feed flange.

NOTE: Use 46 mm AF open-jawed wrench to brace the

extractor check-nut (2).

22 Remove four rectangular rings (1) which have

intersecting ends.

2-182


001582

001582

008827

008828

NOTE: Remove rectangular rings with intersecting ends

as follows:

Press one end of the rectangular ring into the base of the

groove using your thumb.

Slide your index finger around the ring until the

connection releases.

23 Unscrew and remove all M8 hex bolts (1) from the

oil feed flange.

2-183


DANGER

The rectangular rings have sharp edges. Always

use a rag or protective gloves to prevent the risk

of injury when removing rectangular rings.

!

008829

008831

008830

24 Remove spring guide (1) together with pressure

springs (2), cup springs (3) and guide pins (4) from

the stator ring.

CAUTION

The spring guide pins are fitted with 48 cup springs

each. Ensure that the spring guide pins do not jump out.

25 Remove pressure spring (1), spring guide (2) and

cup springs (3) from guide pin (4). Spring seat (5)

may be attached to the pressure spring.

26 If necessary, remove spring seat (1) from the stator

ring.

2-184


DANGER

Prevent the springs from jumping out.

!

008832

008833

008834

27 Turn over the control insert.

28 Unscrew M8 cap screws (1).

29 Use inner hex head driver 1X56 137 273 to unscrew

cap screw (1) from primary pump (2).

30 Lift the control insert off the oil feed flange.

2-185


008835

008837

008836

31 Screw two M8 hex bolts (1) into the stator quill

shaft at 180° to each other.

32 Lightly tap hex bolts (1) using a plastic mallet to

loosen the stator quill shaft.

33 Unscrew the hex bolts from the stator quill shaft.

34 Remove stator quill shaft (1) from the control

insert.

NOTE: The two clamping pins can remain installed.

35 Remove rectangular ring (1).

2-186


001582

001582

1

003161

003161

008838

NOTE: Remove rectangular rings with intersecting ends

as follows:

Press one end of the rectangular ring into the base of the

groove using your thumb.

Slide your index finger around the ring until the

connection releases.

36 Unclip rectangular ring (1) using a screwdriver.

37 Insert extractor 1X56 137 432 into the ring groove

in the piston ring carrier.

38 Place pressure piece (1) onto the stator quill shaft.

39 Attach 2-arm pullers and grip behind extractor

1X56 137 432.

40 Pull the piston ring carrier off the stator quill shaft.

41 Remove extractor and pressure piece.

42 Remove needle cage (2).

2-187


DANGER

The rectangular rings have sharp edges. Always

use a rag or protective gloves to prevent the risk

of injury when removing rectangular rings.

!

008839

008841

008840

43 Check bearing inner race (1) for damage. If

necessary, replace it together with the needle cage.

44 Attach extractor plate 1X56 124 659 to the bearing

inner race with its stamped numbers pointing

upwards.

45 Screw in both M8 hex bolts evenly.

CAUTION

Ensure the stamped figures on each half of the extractor

plate are lined up.

46 Place pressure piece (1) onto the stator quill shaft.

47 Place the stator quill shaft and extractor plate under

a press and press the bearing inner race off the

stator quill shaft.

48 Check the bush and rectangular rings in the stator

quill shaft for damage.

49 If necessary, drive out the bush using punch

1X56 136 820.

CAUTION

Only remove the bush if it is damaged.

2-188


1

001583

001583

008842

008843

NOTE: The bush and rectangular rings represent a

complete component.

CAUTION

Do not hit the primary pump.

50 Place the complete control insert on supports

approx. 4” (100 mm) in an industrial oven. Heat to

approx. 300 °F (150 °C).

51 Heat the control unit until the primary pump falls

out under its own weight.

NOTE: Place the control insert in the oven with the

primary pump input gear pointing upwards.

52 Unscrew three M8 cap screws (1) from the rear of

oil feed flange (2).

53 Remove the cap screws and washers.

2-189


008844

54 Turn over the oil feed flange.

55 Remove thrust ring (1).

56 Lift stator ring (2) out of the oil feed flange.

2-190


008845

008846

008847

13.3.2 Assembly of control insert.

1 Place stator ring (1) into the oil feed flange so the

vanes overlap.

2 Place thrust ring (2) into the stator ring and line up

with the threaded holes.

NOTE: Make sure the recess in the thrust ring is

pointing towards the stator ring.

You should be able to turn the stator ring easily.

3 Turn over the oil feed flange.

4 Fit M8 cap screws with washers. Screw in M8 cap

screws; Tightening torque: 12 ft-lbs (16 Nm).

5 Place the oil feed flange onto

support 1X56 136 818.

6 Place control insert (1) onto oil feed flange (2) and

line up with the holes.

2-191


008848

008849

008850

7 Fit three M8x70 cap screws (1) with one washer

each. Screw in the cap screws until hand-tight.

8 Fit four M8x55 cap screws (1) with one washer

each. Screw in the cap screws until hand-tight.

9 Fit M8x40 (1) and M8x45 (2) cap screws with one

washer each. Screw in the cap screws until hand-

tight.

10 Tighten all cap screws to 17 ft-lbs (23 Nm).

2-192


003 638003638

008851

11 Screw guide bolt 1X56 136 821 into the hole for the

primary pump bolt.

12 Place the control insert in an industrial oven and

heat to 300 °F (150 °C).

13 Push primary pump (1) over the guide bolt and

install in the pump seat.

CAUTION

The primary pump will fall into the pump seat by itself

if the control insert is heated to the correct temperature.

Never hit the primary pump. Ensure the primary pump

is evenly seated.

14 Remove the guide bolt.

15 Fit M8x40 cap screw with a washer. Screw in the

cap screw until hand-tight.

NOTE: Wait until the control insert has cooled to room

temperature and then screw the cap screws in tightly;


2-193


DANGER


heated control insert.

!

1

001583

001583

008853

008854

NOTE: The bush and rectangular rings (1) is a

complete component.

16 Use hot-air blower 1X56 136 513 to heat the stator

quill shaft to approx. 300 °F (150 °C).

NOTE: Line up the hole in the bush with the hole in the

stator quill shaft.

17 Insert the bush into the stator quill shaft. Make sure

the bush is evenly seated.

18 Use hot-air blower 1X56 136 513 to heat the

bearing inner race to approx. 185 °F (85 °C).

19 Push the bearing inner race fully onto the stator

quill shaft.

2-194


DANGER


heated bearing inner race.

!

008855

008857

008856

20 Oil needle cage (1) and push it onto the stator quill

shaft.

21 Use hot-air blower 1X56 136 513 to heat piston ring

carrier (2) to 185 °F (85 °C). Push on piston ring

carrier (2) until evenly seated.

CAUTION

Do not hit the piston ring carrier.

22 Clip the retaining ring into the stator quill shaft ring

groove.

23 Insert rectangular ring (1) into the piston ring

carrier. Clip the ends of rectangular ring (1)

together.

CAUTION

Ensure the piston ring is inserted correctly and its ends

are clipped together.

24 Center the stator quill shaft on clamping pins (1).

25 Drive on the stator quill shaft fully until it is evenly

seated by hitting lightly with a plastic mallet.

2-195


DANGER


piston ring carrier.

!

DANGER

Allow the control insert to cool before installing

the stator quill shaft.

!

008858

26 Turn over the control insert.

27 Fit M8x45 hex bolts (1) with washers. Screw the

hex bolts into the stator quill shaft;


28 Insert the four rectangular rings (1) in sequence.

NOTE: Always insert the lowest rectangular ring first.

Ensure the ring ends are correctly clipped together.

CAUTION

Do not break the rectangular rings. Ensure that all

rectangular rings are fully clipped into the ring groove.

29 Use hot-air blower 1X56 136 513 to heat the

bearing bore of the oil feed flange to approx. 185 °F

(85 °C).

30 Insert grooved ball bearing (1) into the bearing

bore. Drive the grooved ball bearing fully on until

evenly seated by tapping it lightly around the

circumference with a plastic mallet.

CAUTION

Ensure the grooved ball bearing remains level when

driving it on.

2-196


DANGER

Do not touch heated surfaces.

!

008859

008860

008861

31 Push the stator ring to open position and insert

spring seat (1).

32 Fit spring guide pins (1) with 48 cup springs (2).

CAUTION

Always fit the cup springs in groups of six springs all

pointing in the same direction. Insert the next group of

six cup springs facing in the opposite direction, etc.

33 Put the spring guide (1) and pressure spring (2) over

guide pin (3) with cup springs.

34 Measure the clearance between the spring guide and

guide pin.

35 The clearance must be 0.063 + 0.02” (1.6 + 0.5 mm).

If necessary, correct by adding more cup springs.

NOTE: Repeat this procedure for the other two spring

guides.

2-197


003831

1,6 ± 0,5

4 3 2 1

008862

008874

008863

36 Insert three complete pressure units (1) into the

stator ring.

CAUTION

Make sure the spring guide pins are exactly located on

the oil feed flange.

CAUTION

Assemble and insert pistons for individual components

of the control insert extremely carefully and under

conditions of complete cleanliness.

NOTE: A „P 3.1“ repair set (item no. 4139 298 987)

can be obtained from ZF Friedrichshafen AG for the

main pressure valve „P2“ (3), which is fitted as standard

during production. If, during the transmission lifetime,

the main pressure drops when the converter clutch is

disengaged, this can be rectified using this service

solution without the need to remove the transmission.

- See Service Memo no. 11/94. -

37 Assemble the piston and springs for the main

pressure valve as illustrated.

38 Insert complete piston (1) for the main pressure

valve into the control insert.

2-198


008865

008867

008866

39 Fit clamping device 1X56 137 108 to the control

insert.

40 Push ring (1) onto the spindle.

41 Insert new O-ring (2) into the spacer.

42 Apply a thin coat of Vaseline to the O-ring.

43 Place spacer against the main pressure valve piston.

Use the spindle screw to carefully press the spacer

and piston into the housing bore.

44 Use the spindle screw to press the main pressure

valve piston approx. 0.16” (4 mm) behind the ring

groove for the retaining ring.

45 Insert ring (1) into the valve bore.

46 Insert retaining ring (2) and clip it into the ring

groove.

47 Remove clamping device 1X56 137 108.

48 Insert piston (1) for the lubrication pressure valve.

2-199


DANGER

Before screwing the spindle, ensure that the

retaining ring is correctly clipped into the ring

groove.

!

008868

008869

008870

49 Insert pressure spring (1) into the lubrication

pressure valve piston.

50 Screw the spacer ring onto fixture 1X56 137 107.

51 Use fixture 1X56 137 107 to push the spacer ring

into the lubrication pressure valve bore until it

reaches bore (1).

52 Line up the hole in the spacer ring with the housing

bore (1).

2-200

Control unit HP 500 / HP 590

008871

008872

008873

53 Insert the cylindrical pin into the bores.

54 Unscrew fixture 1X56 137 107 and remove it.

55 Insert piston (1) and pressure spring (2) of the

converter back-up pressure valve into the valve

bore.

56 Fix clamping device 1X56 137 108 onto the control

insert.

57 Place thrust washer (2) against the valve with its

crowned side pointing inwards. Clamp the thrust

washer lightly using the spindle.

58 Hang retaining ring (1) on the spindle.

2-201


008874

008876

008875

59 Press the thrust washer into the valve bore using the

spindle. Ensure the thrust washer goes in without

tilting.

60 Clip retaining ring (1) into the ring groove.

61 Unscrew the spindle and remove the clamping

device.

62 Insert piston (1) and pressure spring into the bore

for the cooler change-over valve.

63 Insert spacer ring (2) into the valve bore.

NOTE: Line up the spacer ring and housing bores.

64 Insert cylindrical pin (1).

2-202


DANGER

Ensure the retaining ring is fully clipped into

the ring groove before unscrewing the spindle.

!

008877

65 Apply a thin coat of Vaseline to the new O-ring (2).

66 Insert O-ring (2) into plug (1) for the pressure line.

67 Insert the plug into the pressure line.

2-203


008878

008879

008880

13.3.3 Disassembly of clutch carrier.

1 Remove intermediate ring (1) from the clutch

carrier.

2 Unscrew and remove M8 hex bolts (1). Remove

rotor (2) from the clutch carrier.

3 Remove sealing ring (1) from the clutch carrier.

4 Remove rectangular ring (2) from the sealing ring.

2-204

Clutch carrier Ecomat HP 500 / HP 590

DANGER

The clutch carrier weighs approx. 55 lbs.

(25 kg). Two persons are required to move it.

!

008881

008882

008883

5 Turn over the clutch carrier.

6 Place the insert of clamping device 1X56 137 127

into the clutch carrier. Lay the pressure plate on top

and screw on the handwheel.

7 Clamp the clutch carrier together by tightening the

handwheel.

8 Release and unclip retaining ring (1).

NOTE: Tap the C piston lightly to assist in unclipping

the retaining ring.

9 Remove the retaining ring and C piston from the

clutch carrier.


11 Remove clamping device 1X56 137 127.

12 Remove reverse gear pot.

13 Pull the O-ring out of the reverse gear pot.

2-205

Ecomat HP 500 / HP 590 Clutch carrier

008884

008885

008886

14 Lift the last outer disc off the clutch carrier.

15 Remove pins (1) and springs (2) from the holes.

16 Lift the complete disk pack out of the clutch carrier.

17 Use a bar magnet to draw out two torsional fixing

pins (1) from the clutch carrier.

2-206


008887

008888

008889

18 Turn end disc (1) so its teeth line up with the

recesses in the clutch carrier.

19 Lift out the end disc from the clutch carrier.

20 Lift out complete disc pack (1) of the B clutch from

the clutch carrier together with pins (2).

21 Remove the pins from the discs.

22 Use a pair of pliers to pull retaining pins (2) out

towards the inside.

23 Remove split rings (1).

24 Remove end disc (3).

2-207


008890

008892

008891

25 Lift out complete disc pack (1) of the A clutch from

the clutch carrier.

26 Remove the fixing plate and the cup spring.

27 Turn over the clutch carrier and remove the C

piston.

28 Remove the inner lip sealing ring of the C piston.

29 Remove the lip sealing ring from the clutch carrier.

2-208


008893

008894

008895

30 Place the clutch carrier on the lower section of

clamping device 1X56 137 127.

31 Place pressure piece 1X56 137 105 onto the

remaining plate spring (1).

32 Screw on the handwheel. Press the plate spring

down until you can unclip the snap ring.

33 Unclip the snap ring and slide it over the ring

groove together with the fixing plate.

NOTE: Position pressure piece 1X56 137 105 with its

opening facing the ring ends.

34 Remove the pressure piece.

35 Remove snap ring (1) and fixing ring (2).

36 Remove cup spring (3) from the clutch carrier.

37 Grip A piston (1) with a pair of pliers and loosen

the A piston by hitting the hub lightly with a plastic

mallet.

2-209


008896

008897

008898

38 Remove A piston (1) from the clutch carrier.

39 Remove outer lip sealing ring (2) from the A piston.

40 Remove inner lip sealing ring (3) from the A piston.

41 Loosen B piston (1) by hitting the end of the clutch

carrier as illustrated. Remove the B piston.

42 Remove outer lip sealing ring (2) from B piston.

43 Remove inner lip sealing ring (3) from the B piston.

2-210


008899

008900

44 Attach inner extractor 1X56 122 209 underneath

the base of the needle bearing.

45 Screw counter bracket 1X56 122 227 onto inner

extractor 1X56 122 208.

46 Tighten check-nut (1) by hand.

47 Pull the needle bearing out of the bearing bore.

48 Place the clutch carrier in an industrial oven and

heat to approx. 300 °F (150 °C).

49 Hit hub (1) with a plastic mallet to drive it out of

the clutch carrier.

2-211


DANGER


heated clutch carrier.

!

008901

008902

13.3.4 Assembly of clutch carrier.

1 Screw two guide bolts 1X56 136 821 into the clutch

carrier at opposite points.

2 Place the clutch carrier in an industrial oven and

heat to approx. 300 °F (150 °C).

Slide hub (1) over the guide bolts. Make sure the

hub is evenly seated and in the correct radial

position.

3 Unscrew guide bolts.

4 Insert the needle bearing into the hub. Drive in the

needle bearing fully using rod 1X56 137 103.

NOTE: Coat the needle bearing with Vaseline before

fitting it. Insert the needle bearing with the rod driving

against its stronger bearing side. The impact side of the

needle bearing is its written side.

2-212


DANGER


heated clutch carrier.

!

008903

008905

008904

5 Insert A piston (1) into the clutch carrier without

fitting its lip sealing rings.

6 Place the cup spring without slots onto the A piston

so the edge of its bore is touching the piston.

7 Push the fixing ring over the plate spring with the

closed side of the fixing ring pointing upwards.

8 Check outer (1) and inner (2) discs for wear.

9 Use a straight-edge to check all discs are flat.

10 Replace all uneven or bowed discs. Replace all

damaged discs also.

11 Insert complete disk pack (1) of the A clutch into

the clutch carrier, starting with an inner disk.

NOTE: The last disk is an outer disk. Refer to the Spare

Parts Catalogue for the number of disks.

2-213


008906

008907

008908

12 Position end disc (1).

13 Insert split rings (2).

14 Measure dimension “A” from the top of the hub to

the end disc.


16 Lift and hold the end disc against the split ring.

17 Measure dimension “B” from the top of the hub to

the top of the lifted end disc.


19 Subtract dimension “B” from dimension “A” to

calculate the disc play.

2-214


008909

008910

NOTE: A clutch disc play should be 0.12 to 0.14”

(3.2 to 3.7 mm).

20 Set the disc play using steel discs of different

thicknesses (0.08 to 0.10”) (2.0 to 2.5 mm).

21 Remove the complete disc pack, fixing ring and cup

spring from the clutch carrier again.

22 Remove the A piston from the clutch carrier.

23 Check the sealing rings on the B piston for damage

and replace if necessary.

24 Insert the sealing rings into the B piston ring

grooves.

NOTE: Ensure both sealing rings are firmly seated in

the base of the groove.

25 Coat the sealing rings and B piston contact surfaces

with Vaseline.

26 Insert B piston (1) centrally into the clutch carrier

without tilting it.

27 Lightly hit the B piston with a plastic mallet to

ensure it is evenly seated.

CAUTION

Do not damage the sealing rings. The piston should be

a tight fit.

2-215


008911

008912

008913

28 Insert the outer and inner lip sealing rings into the

ring grooves in the A piston. Insert the sealing rings

with their grooves facing the pressure side.

NOTE: Stretch the inner lip sealing ring before

fitting it.

Ensure that both lip sealing rings are firmly located

against the base of the groove.

29 Insert A piston (1) into the clutch carrier. Hit the A

piston lightly with a plastic mallet to ensure it is

evenly seated.

CAUTION

Coat the lip sealing rings and contact faces of the A

piston with Vaseline before installing the A piston. Take

care not to damage the lip sealing rings when installing

the A piston.

30 Place cup spring (2) onto the A piston so the

projections in the spring mesh with the projections

on the piston.

31 Slide fixing ring (1) over the hub with its recess

pointing upwards.

32 Slide snap ring (2) over the hub.

2-216


008914

008916

008915

33 Place pressure piece 1X56 137 105 onto the cup

spring.

NOTE: Turn the pressure piece so the ends of the snap

ring are visible in the opening of the pressure piece.

34 Press the cup spring downwards using clamping

device 1X56 137 127.

35 First push fixing ring (1) over the ring groove and

then clip in snap ring (2).

CAUTION

Make sure the snap ring is clipped in all the way round.

36 Check the inner and outer discs of the B and C

clutch for wear.

37 Use a straight-edge to check all discs for evenness.

38 Discard uneven or bowed discs. Discard damaged

discs.

See also the Test Instructions in Section 5.3.4.

39 Lay first disc (1) of the B clutch in the clutch

carrier.

CAUTION

The first disc is an outer disc 0.12” (3 mm) thick. The

first disc does not have any gaps.

2-217


008917

008919

008918

40 Insert an inner disc (1) followed by an outer disc (2)

into the clutch carrier.

CAUTION

Insert the second and all other outer discs of the B

clutch so their recesses (3) line up with the holes (4).

Check that the 3 and 4-tooth groups for the discs are

lined up correctly.

41 Insert the complete disc pack. Ensure that outer and

inner discs alternate through the clutch carrier.

NOTE: Refer to the appropriate parts list for details of

which discs to fit.

42 Insert the end disc and rotate it into position.

CAUTION

Insert the end disc so its hardened bores (1) are lined up

with the bores (2) with rectangular milled recesses in

the clutch carrier. Hardened bores are recognizable by

their sheen.

43 Insert two retaining pins (1) into the bores with

rectangular groove (2).

2-218


008920

008921

008922

44 Use a feeler gage to measure the B clutch disc play

between the end disc and the last outer disc.

45 Measure the disc play several times around the

circumference.

NOTE: The disc play of the B clutch should be 0.08 to

0.10” (2.0 to 2.5 mm) (for HP 590) or 0.06 to 0,08” (1.6

to 2.1 mm) (for HP 500). Set the disc play using steel

discs of various thicknesses (0.08 and 0.10”) (2.0 and

2.5 mm).

46 Place the cup spring without slots onto the A piston

with the edge of its bore in contact with the piston.

47 Slide the fixing disc over the cup spring with its

closed side pointing upwards.

48 Insert the complete A clutch disc pack into the

clutch carrier.

CAUTION

The first disc is an inner disc and the last disc must be

an outer disc.

2-219


008923

008925

008924

49 Insert end disc (1) into the clutch carrier.

50 Insert split rings (2).

51 Lift the end disc and insert three pins (1).

4 speed version:

52 Insert pins into the pressure springs.

53 Insert pins and pressure springs into the clutch

carrier.

2-220


008927

008828

008926

54 Place the lower section of clamping device

1X56 137 127 into the clutch carrier.

55 Place the inductive sensor ring onto the clutch

carrier.

56 Line up the holes in the inductive sensor ring with

the holes in the clutch carrier. Insert two threaded

pins into the holes.

57 Lay the plate of clamping device 1X56 137 127

over the lower section. Screw on the handwheel of

the clamping device and press the inductive sensor

ring down onto the clutch carrier.

58 Unscrew and remove the threaded pins. Fit the hex

bolts with washers and screw them into the holes in

the inductive sensor ring;


5 speed version:

59 Check the C clutch discs according to the Test

Instructions in Section 5.3.4.

60 Insert the complete disc pack into the clutch carrier.

2-221


008929

008930

008931

61 Insert pins into the pressure springs.

62 Insert pins and pressure springs into the clutch

carrier.

63 Insert lip sealing ring (1) around the outside of the

clutch carrier. Insert with its groove pointing

towards the pressure side.

64 Place the last discs onto the pressure spring pins.

Ensure the last disc is an outer disc with a full set of

broad outer teeth.

2-222


008932

008934

008933

65 Place the clutch carrier onto the clamping fixture.

66 Oil a new O-ring and insert it in the reverse gear

pot.

67 Locate the reverse gear pot on the clutch carrier so

its guide grooves snap over the guide lugs.

NOTE: Ensure the last outer disc does not slide off the

pressure springs.

68 Use the clamping fixture to press together the

reverse gear pot and clutch carrier.


2-223


008935

008936

008937

70 Insert the inner lip sealing ring into the ring groove

in the C piston. Insert the lip sealing ring with its

groove pointing towards the pressure side.

NOTE: Stretch the inner lip sealing ring before

installing it.

Ensure the lip sealing ring is firmly seated against the

base of the groove.

71 Place the C piston into the reverse gear pot.

NOTE: Take care not to damage the lip sealing rings.

Insert the piston with a sliding fit.

72 Clip snap ring (1) into the ring groove.

NOTE: Ensure the snap ring is firmly located against

the base of the ring groove around its entire circum-

ference.

73 Measure the specified C clutch disc play using a

feeler gage between the outer disc and the reverse

gear pot. Measure disc play at several points around

the circumference and not the average value.

Disk play must be 0.06 to 0.08” (1.6 to 2.1 mm)

(HP 590) or 0.05 to 0.07” (1.2 to 1.7 mm) (HP

500). Set the disc play using discs of varying

thicknesses 0.08 and 0.10” (2.0 and 2.5 mm).

2-224


008939

008938

008940

4 and 5-speed version:


75 Place sealing ring (1) onto the clutch carrier.

76 Clip in rectangular ring (2) with the marking

“TOP” or “R” pointing upwards.

77 Screw two guide bolts 1X56 136 821 into the clutch

carrier.

78 Line up rotor (1) with the bores and lower into

place.

NOTE: The irregular hole pattern of the rotor means it

can only be installed in one position.

79 Unscrew the threaded pins.

80 Screw in eighteen M8x40 hex bolts (1);


2-225


008941

008942

008943

13.3.5 Clutch carrier leakage test and functional

check

1 Push insertion bush 1X56 137 128 into the clutch

carrier.

NOTE: Oil sealing rings (1) lightly before pushing in

the insertion bush.

2 Screw knurled nut (1) onto the insertion bush and

tighten until the insertion bush is evenly seated.

3 Connect compressed air unit 1X56 137 130 to the

A, B or C piston connection.

4 Turn regulator (1) a few turns clockwise.

5 Open the air flow by moving lever (2) to the

horizontal position. Set the maximum pressure to

43.5 psi (3 bar) using regulator (1).

6 Move lever (2) to the vertical position to cut off the

air supply. Measure the rate of pressure loss.

Maximum pressure loss is from 36 +7psi (2.5 + 0.5

bar) down to 20 psi (1.4 bar) within 10 seconds.

7 Remove the compressed air unit.

CAUTION

If the pressure drop at one piston is excessive, remove

the appropriate piston and correct the leak.

2-226


008944

008945

008946

13.4 Assembly of control unit.

1 Place intermediate ring (1) into position.

CAUTION

Ensure lug (2) on the intermediate ring meshes with

recess (3) in the sealing ring.

2 Screw hooks 1X56 136 612 into the control insert

at opposite points.

3 Attach lifting equipment to the hooks and suspend

the control insert over the clutch carrier.

4 Use hot air blower 1X56 136 513 to heat grooved

ball bearing (1) to approx. 185 °F (85 °C).

2-227


DANGER

Do not touch the heated grooved ball bearing.

!

008947

008948

008949

5 Lower control insert (1) onto clutch carrier (2).

6 Hit the control insert lightly with a plastic mallet to

drive it fully onto the clutch carrier.

7 Insert O-ring (3) for the suction tube in the control

unit. Check the O-ring.

8 Remove the lifting equipment and insert turbine

shaft (1) into the control unit.

CAUTION

Check that none of the three pins (1) are protruding

through into hub (2) before sliding in the turbine shaft.

2-228


008950

008951

9 Push in the turbine shaft until the ring groove is

accessible.

10 Clip retaining ring (1) into the turbine shaft ring

groove.

11 Screw lifting device 1X56 137 213 into the turbine

shaft.

CAUTION

Take care not to damage the oil tube when lifting the

control unit.

12 Place supports under the control unit so it does not

rest on the turbine shaft.

- Fit the control unit, see Section 13.2, page 2-175.

2-229


008952

008953

008954

14 Removal and installation of D brake.

14.1 Removal of D brake.

1 Use two screw clamps to press end disc (2) parallel

against the stop.

2 Unclip retaining ring (1) using a screwdriver.

3 Unscrew the clamps evenly and remove them.

4 Remove end disc (1) from the transmission.

5 Remove pressure springs (1) and pressure pins.

6 Lift complete disc pack (2) out of the transmission

housing.

2-230

D brake Ecomat HP 500 / HP 590

DANGER

Loosen the screw clamps evenly because the

end disc is spring-loaded.

!

008957

008955

008956

7 Cover the transmission housing with a cloth.

8 Loosen D piston (1) by blowing in compressed air

through one of the oil ducts (2).

9 Lift D brake piston (1) out of the transmission

housing.

10 Remove outer and inner lip sealing rings (1, 2) from

the D piston.

2-231

Ecomat HP 500 / HP 590 D brake

008958

008960

008959

14.2 Installation of D brake.

1 Insert the inner lip sealing ring into the D piston

with its groove pointing towards the pressure side.

2 Insert the outer lip sealing ring into the D piston

with its groove pointing towards the pressure side.

NOTE: Coat the outer and inner lip sealing rings lightly

with Vaseline.

3 Insert D piston (1) into the transmission housing.

4 Hit the D piston lightly with a plastic mallet to

make sure it is evenly seated.

CAUTION

Do not damage the lip sealing rings.

5 Check the outer and inner discs for wear.

6 Use a straight-edge to check all discs for evenness.

7 Discard uneven or bowed discs. Discard all

damaged discs.

See also the Test Instructions in Section 5.3.4.

2-232


DANGER

Check the lip sealing rings for damage before

installing them. Fit new lip sealing rings if

necessary.

!

008961

008962

008963

8 Insert first outer disc (1).

CAUTION

Insert the outer disc so one of the disc bores (2) is lined

up with the arrowed recess in the housing.

9 Insert pressure pins (1) in the outer disc bores.

10 Place pressure springs onto the pressure pins.

11 Insert an inner disc (2).

12 Place the next outer disc (1) so the gap between the

teeth (2) lines up with the pressure springs.

13 Insert inner and outer discs in alternative sequence

until the complete disc pack is installed.

NOTE:The last disc is an outer disc. Refer to the Spare

Parts Catalogue for the number of discs.

2-233

Ecomat HP 500 / HP 590 D brake

008964

008965

008966

14 Lay on end disc (1).

CAUTION

Insert the end disc with its twin-stepped surface

pointing upwards.

15 Insert two screw clamps and press the end disc

parallel against the block.

16 Clip retaining ring (1) into the ring groove.

17 Remove the screw clamps.

18 Measure disc play of „D“ brake between end shim

and last outer disc using depth gauge.

NOTE: Measure several times around circumference

and note average value. Permitted disc play of „D“

brake is 0.06 to 0.08” (1.6 to 2.1 mm).

If the above limits are exceeded, use suitable first outer

disc to compensate difference.

Outer discs can be supplied in the following thicknesses:

0.08”; 0.10”; 0.12” (2.00 mm; 2.50 mm; 3.00 mm).

2-234


DANGER

Check that the retaining ring is fully clipped in

around the entire length of the ring groove

before taking off the screw clamps.

!

Ecomat HP 500 / HP 590 Notes

2-235

Documents

5HP500-590 4139_751_627d[1]