ZF-ECOMAT HP 500 HP 590 NBS Stage 3 Repair Manual 4139751627d – PDF DOWNLOAD
FILE DETAILS:
ZF-ECOMAT HP 500 HP 590 NBS Stage 3 Repair Manual 4139751627d – PDF DOWNLOAD
Language : English
Pages : 273
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
ZF-ECOMAT HP 500 HP 590 NBS Stage 3 Repair Manual 4139751627d – PDF DOWNLOAD
Preface:
- 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.
TABLE OF CONTENTS:
ZF-ECOMAT HP 500 HP 590 NBS Stage 3 Repair Manual 4139751627d – PDF DOWNLOAD
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
Chapter Contents Page
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
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
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V