Epair Anual: HP 500 / HP 590 / HP 600 "Long" Version Stage 3

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REPAIR MANUAL

004273

HP 500 / HP 590 / HP 600


“Long” version
Stage 3
4139 751 621a
Subject to alterations in design

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: 09.95

4139 751 621a


HP 500 / 590 / 600 “long” version Table of contents

Chapter Contents Page


Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Important work safety notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Transmission cross section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Transmission overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Adjustment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Spring table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

1. Installing and removing transmission in/from assembly jig . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1


1.1 Installing transmission in assembly jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
1.2 Removing transmission from assembly jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2. Removing, installing, dismantling and assembling retarder accumulator . . . . . . . . . . . . . . . . 2-5


2.1 Removing and installing retarder accumulator solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2 Removing and installing retarder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.3 Removing and installing retarder accumulator from/in side-mounted oil cooler . . . . . . . . . . . . . . 2-10
2.4 Dismantling and assembling retarder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.5 Dismantling and assembling retarder accumulator from/in side-mounted oil cooler . . . . . . . . . . . 2-14

3. Removing and installing, dismantling and assembling oil cooler . . . . . . . . . . . . . . . . . . . . . . . 2-15


3.1 Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
3.2 Removing and installing side-mounted oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
3.3 Dismantling and assembling oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
3.4 Dismantling and assembling connection parts for side-mounted oil cooler . . . . . . . . . . . . . . . . . . 2-25

4. Removing and installing, dismantling and assembling torque converter . . . . . . . . . . . . . . . . . 2-26


4.1 Removing and installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
4.1.1 Removing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
4.1.2 Installing torque converter, measuring end float and installation depth of torque converter . . . . . 2-32
4.2 Dismantling and assembling torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
4.2.1 Dismantling torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
4.2.2 Assembling toque converter, measuring end float of thrust bearing . . . . . . . . . . . . . . . . . . . . . . . . 2-48
4.3 Checking torque converter for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

5. Removing and installing cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65


5.1 Removing cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
5.2 Installing cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

6. Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75


6.1 Removing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
6.2 Installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

1-1
Table of contents HP 500 / 590 / 600 “long” version

Chapter Contents Page

7. Removing and installing inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80


7.1 Removing inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
7.2 Installing inductive sensor, establishing set distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82

8. Removing and installing hydraulic transmission control unit, dismantling and assembling 2-85
8.1 Removing and installing hydraulic transmission control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
8.1.1 Removing hydraulic transmission control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
8.1.2 Installing hydraulic transmission control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
8.2 Dismantling and assembling hydraulic transmission control unit in sub-assemblies . . . . . . . . . . 2-88
8.2.1 Dismantling hydraulic transmission control unit in sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . 2-91
8.2.2 Assembling hydraulic transmission control unit in sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . 2-95
8.3 Dismantling and assembling throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
8.3.1 Dismantling throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
8.3.2 Assembling throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
8.4 Dismantling and assembling valve block B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
8.4.1 Dismantling valve block B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
8.4.2 Assembling valve block B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
8.5 Dismantling and assembling valve block A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117
8.5.1 Dismantling valve block A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119
8.5.2 Assembling valve block A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123

9. Removing and installing retarder valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129


9.1 Removing retarder valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130
9.2 Installing retarder valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132

10. Removing and installing, dismantling and assembling output cover . . . . . . . . . . . . . . . . . . . . 2-136
10.1 Removing and installing “output speed” inductive sensor; establishing set distance . . . . . . . . . . 2-138
10.2 Removing and installing speedo connection piece and screw plugs . . . . . . . . . . . . . . . . . . . . . . . 2-142
10.3 Removing and installing output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-143
10.4 Removing and installing output end cover; measuring end float of sun gear shaft . . . . . . . . . . . . 2-145
10.4.1 Removing output end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-145
10.4.2 Measuring end float of sun gear shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-146
10.4.3 Setting disc play of brake “G” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-149
10.4.4 Installing output end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-151
10.5 Dismantling and assembling output end cover; setting tapered roller bearing . . . . . . . . . . . . . . . . 2-153
10.5.1 Dismantling output end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-155
10.5.2 Assembling output end cover; setting tapered roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-160

11. Removing and installing intermediate housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-169


11.1 Removing intermediate housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-171
11.2 Adjusting end float of sun gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-175
11.3 Adjusting disc play of brake “F” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-176
11.4 Installing intermediate housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-177

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HP 500 / 590 / 600 “long” version Table of contents

Chapter Contents Page

12. Removing and installing mechanical transmission part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-181


12.1 Removing, dismantling and assembling planet carriers II and I, brakes “F” and “E” . . . . . . . . . . 2-183
12.1.1 Removing planet carriers II and I; brakes “F” and “E” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-185
12.1.2 Removing planet carriers II and I; version HP 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-189
12.1.3 Dismantling planet carrier II; version HP 500 / HP 590 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-191
12.1.4 Dismantling planet carrier II; version HP 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-194
12.1.5 Dismantling planet carrier I; version HP 500 / HP 590 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-195
12.1.6 Dismantling planet carrier I; version HP 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-197
12.1.7 Assembling planet carrier I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-198
12.1.8 Assembling planet carrier II; version HP 500 / 590 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-201
12.1.9 Assembling planet carriers II and I; version HP 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-205
12.2 Removing piston E and disc carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-207
12.3 Removing and installing quill shaft and drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-211
12.3.1 Removing quill shaft and drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-212
12.3.2 Installing quill shaft and drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-214
12.4 Installing piston E and disc carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-216
12.5 Installing planet carriers I and II, brakes “E” and “F” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-220
12.6 Installing planet carriers I and II, version HP 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-228
12.7 Measuring and adjusting inductive sensor ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-230

13. Removing and installing, dismantling and assembling control unit . . . . . . . . . . . . . . . . . . . . 2-231
13.1 Removing control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-233
13.1.1 Dismantling control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-235
13.1.2 Assembling control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-236
13.1.3 Installing control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-239
13.2. Removing and installing valves of control element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-242
13.2.1 Removing valves of control element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-244
13.2.2 Installing valves of control element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-247
13.3 Dismantling and assembling control element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-251
13.3.1 Dismantling control element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-253
13.3.2 Assembling control element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-261
13.4 Dismantling and assembling clutch carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-268
13.4.1 Dismantling clutch carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-270
13.4.2 Assembling clutch carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-280
13.4.3 Checking clutch carrier for leaks and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-295

14. Mechanical transmission part, removing and installing brake “D” . . . . . . . . . . . . . . . . . . . . 2-296
14.1 Removing brake “D” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-297
14.2 Installing brake “D” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-299

1-3
Preface HP 500 / 590 / 600 “Long” version

This repair manual is intended for skilled personnel


trained by ZF Friedrichshafen AG to carry out mainte-
nance 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 not contained in this manual.

We 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 centers.

Service points equipped by ZF Friedrichshafen AG all


over the world offer you:

1. Continually trained personnel

2. Specified equipment, e.g. special tools

3. Genuine ZF spares, to our latest specifications

All work performed at these service points is carried


out conscientiously and with utmost care.

Repair work carried out at ZF service points is


subject to the contractual conditions prevailing in
the individual case.

ZF FRIEDRICHSHAFEN AG Damage resulting from work performed by non-ZF


C.V./Special Transmissions personnel in an improper and unprofessional manner
Service Plant 2 and any consequential costs are excluded from the
Tel.: (0 75 41) 77-0 contractual liability agreement. Exclusion of liability
Fax: (0 75 41) 77-5726 also applies if genuine ZF spares are not used.

1-4
HP 500 / 590 / 600 “Long” version General comments

In case of doubt always turn to the relevant GASKETS, LOCKING PLATES


department within ZF After-Sales Services for
advice. Parts which cannot be removed without being damaged
All work on transmissions is to be performed expertly must always be replaced with new parts (e.g. gaskets
and under clean conditions. and locking plates).
Use specified tools to dismantle and assemble
transmissions.

After removing the transmission from the vehicle, SHAFT SEALS


clean thoroughly with a suitable cleaning agent before
opening. Always change shaft seals with rough, ripped or
Pay particular attention to the projections and recesses hardened packing washers. Seal contact surfaces must
of housings and covers when cleaning. be totally clean and in perfect condition.
Parts joined with Loctite are easier to separate if
warmed with a fan heater.

RE WO RK I NG

CLEANING PARTS Rework may be carried out on seal contact surfaces


using plunge-cut grinding only, never use an emery
Remove remains of old gaskets on all seal-faces. cloth. Ensure that there are no traces of grinding or
Carefully remove burrs or similar patches of roughness riffling.
using an oil-stone.
If rework is needed on distance washers, shims etc.
Lube bores and grooves must be free of anti-corrosion because of clearance settings, ensure that the reworked
agents and foreign matter; check for perfect passage. areas contain no face runout and have the same surface
quality.
Carefully cover opened transmissions to prevent foreign
matter from entering.

TRANSMISSION ASSEMBLY

REUSING PARTS Find a clean site to assemble the transmission. Gaskets


are installed without the use of sealing compound or
Parts such as ball or roller bearings, multi-discs, thrust grease. When measuring silicon-coated gaskets, take
washers etc., must be inspected by a competent person, care not to include the silicon layer in the
who should decide whether or not they can be re-used. measurement.
Replace parts which are damaged or have suffered from During assembly, comply with all adjustment data,
excessive wear. checking data and tightening torques in the Repair
Manual.

1-5
General comments HP 500 / 590 / 600 “Long” version

B E AR I NG S d) Dual shaft seals have two sealing


lips. The dust-proof sealing lip (X)
If bearings are mounted in heated condition, they are to must face outwards.
be heated evenly (e.g. heating cabinet). X
Temperature should be at ca. 85 °C and must not e) Fill the gap between the sealing
exceed 120 °C. Each mounted bearing must be oiled lips so it is 60% filled with grease (e.g. produced
with operating oil. by Aral such as Aralub HL2 or by DEA such as
Spectron FO 20).

f) If possible, heat shaft seal bores to between 40 and


50 °C (makes fitting easier). Press the seal shaft
S EALI NG with mounting or faceplate onto the relevant
installation depth plan.
If a specific sealing agent* is to be used for sealing,
comply with the manufacturer’s directions for use.
Apply a thin layer of sealing agent to the surfaces and
spread evenly. Do not allow sealing to enter oil ducts
and bores. On oil-carrying ducts and bores, wipe off the RETAINING AGENTS
sealing agent on the surfaces to be sealed near apertures
to ensure that no sealing agent enters the oil feeds when Retaining agents* may only be used in places as
the surfaces are sealed. specified in the parts list.
Always comply with manufacturer’s directions for use
when using retaining agents (e.g. Loctite).
During assembly, comply with all adjustment data,
checking data and tightening torques.
SHAFT SEALS

a) Apply a light coat of sealing agent* on outer edge of


shaft seals with “steel surround”.
TRANSMISSION OIL
b) Never apply sealing agent to shaft seals with
“rubber surround”, but apply a thin coat of Vaseline After completing repairs, fill transmissions with
8420 to the outer edge or wet with a lubricant, e.g. a transmission oil. For the procedure and approved oils,
water-soluble, concentrated washing-up liquid (e.g. refer to the transmission operating manual and List of
Pril, Coin, Palmolive). Lubricants TE-ML (refer to identification plate) which
are available from any ZF After-Sales Service Point.
c) Shaft seals with steel and rubber surrounds should After filling the transmission with oil, tighten the screw
be treated on the outer edge of the rubber surround plugs at the oil filling point and the oil overflow to the
as described above in section b). specified torques.

* refer to expendable material

1-6
HP 500 / 590 / 600 “Long” version Important information

SAFETY NOTICE GENERAL INFORMATION

Companies repairing ZF units are responsible for their Read this manual carefully before starting any tests or
own work safety. repair work.

To avoid injury to personnel and damage to pro-


ducts, all safety regulations and legal requirements CAUTION
which apply to repair and maintenance work must Pictures, drawings and components do not always
be adhered to. represent the original object, but are used to
Before starting work, mechanics must familiarize illustrate working procedures.
themselves with these regulations. Pictures, drawings and components are not to scale.
Conclusions about size and weight should not be
Personnel required to carry out repairs on ZF products drawn (even within a complete illustration).
must receive appropriate training in advance. It is the Always follow the working steps as described in the
responsibility of each company to ensure that their text.
repair staff is properly trained.

After completion of repair work and testing, skilled


staff must satisfy themselves that the product is
The following safety instructions appear in this functioning correctly.
manual:

! THREATS TO THE ENVIRONMENT !


NOTE Lubricants and cleaning agents must not be allowed
Refers to special processes, techniques, data, use to enter the soil, ground water or sewage system.
of auxiliary equipment, etc. • Ask your local environment agency for
safety information on the relevant products
and adhere to their requirements.
CAUTION • Collect used oil in a suitably large container.
This is used when incorrect, unprofessional • Dispose of used oil, dirty filters, lubricants
working practices could damage the product. and cleaning agents in accordance with
environmental protection guidelines.
• When working with lubricants and cleaning
! DANGER agents always refer to the manufacturer’s
This is used when lack of care could lead to instructions.
personal injury or death.

CAUTION
The transmission must NOT be hung by the input
shaft NOR by the output flange.

1-7
Transmission cross section HP 500 / 590 / 600 “long” version

ZF-Ecomat transmission, 5-speed, “long” version

1 2 3 4 26 5 6 7 9 10 11 12 27 13

004 252

25 24 23 22 21 20 19 18 17 16 29 15 28 14

1 Drive flange 16 Brake ”E”


2 Cover plate 17 Brake ”D”
3 Drive gears for PTO 18 Shift control unit
4 Control element 19 “Turbine” inductive sensor
5 Oil supply flange 20 Oil pan
6 Clutch “A” 21 Retarder
7 Clutch “B” 22 Primary pump
9 Housing 23 Converter
10 Planetary gear set I 24 Converter lock-up clutch “WK”
11 Planetary gear set II 25 Turbine shaft
12 Planetary gear set III 26 Connection for PTO
13 Output flange 27 Planet gear set IV
14 “Output speed” inductive sensor 28 Brake “G”
15 Brake “F” 29 Pressure measuring point

1-8
HP 500 / 590 / 600 “long” version Transmission cross section

ZF-Ecomat transmission, 6-speed, “long” version

1 2 3 4 5 26 6 7 8 9 10 11 12 27 13

004 249

25 24 23 22 21 20 19 18 17 16 29 15 28 14

1 Drive flange 15 Brake “F”


2 Cover plate 16 Brake “E”
3 Drive gears for PTO 17 Brake “D”
4 Control element 18 Shift control unit
5 Oil supply flange 19 “Turbine” inductive sensor
6 Clutch “A” 20 Oil pan
7 Clutch “B” 21 Retarder
8 Clutch “C” 22 Primary pump
9 Housing 23 Converter
10 Planetary gear set I 24 Converter lock-up clutch “WK”
11 Planetary gear set II 25 Turbine shaft
12 Planetary gear set III 26 PTO
13 Output flange 27 Planetary gear set IV
14 “Output speed” inductive sensor 28 Brake “G”
29 Pressure measuring point

1-9
Transmission overview HP 500 / 590 / 600 “long” version

Transmission type with parts list


No. of speeds HP 500 HP 590 HP 600 Transmission Version
5 speed 4139 008 … 4139 058 … 4139 068 … 5.6 - 1.0 long
6 speed 4139 005 … 4139 055 … 4139 065 … 5.6 - 0.83 long

Long version A B1 B2 D E F1 F2 G B1 = Inner piston area of clutch B


5-speed i = 5.6 to 1 B2 = Outer piston area of clutch B
F1 = Outer piston area of brake F
Reverse
Neutral
• •• F2 = Inner piston area of brake F
1st gear
• •
2nd gear
• •
3rd gear
• •
4th gear
• •
5th gear
••

Long version A B C D E F1 F2 G
6-speed i = 5.6 to 0.83

Reverse
Neutral
• ••
1st gear
• •
2nd gear
• •
3rd gear
• •
4th gear
• •
5th gear
••
6th gear
• •

1-10
HP 500 / 590 / 600 “long” version Tightening torques

Tightening torques for nuts and bolts, extract from


ZFN 148

This standard applies to bolts acc. to DIN 912, DIN Surface condition of bolts: thermally blackened and
931, DIN 933, DIN 960, DIN 961 and to nuts acc. to oiled or galvanized and oiled or galvanized, chrome-
DIN 934. plated and oiled.
This Standard contains data on tightening torques (MA)
for bolts and nuts in strength categories 8.8, 10.9 and Tighten screws with a calibrated torque spanner.
12.9 and nuts in strength categories 8, 10 and 12.
NOTE
Irregular tightening torques are listed separately in the
Repair Manual.

Regular screw thread Fine screw 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 8x1 24 36 43


M 5 5.5 8.1 9.5 M 9x1 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

Edition: August 1991 / checked 1997

1-11
Adjustment data HP 500 / 590 / 600
“long” version

Description Dimension Measuring device Remarks

Torque converter

01. Installation depth of torque 71.25 ± 0.5 mm Depth gauge Installation depth measured
converter 77.00 ± 0.5 mm from flange surface on torque
(depending on version) 81.25 ± 0.5 mm converter to flange surface on
86.25 ± 0.5 mm transmission housing.
Installation depth can be set
using one or more spacer
rings on the stator shaft

02. Converter end float 0.3 bis 0.4 mm Depth gauge End float can be set using
between face end of converter shim on face end of turbine
one-way clutch inner ring and shaft
spacer ring on stator shaft

03. Disc play of lock-up clutch 0.5 bis 1.1 mm Feeler gauge Disc play is measured
in converter between end washer and inner
disc

04. End float of thrust bearing 0.1 bis 0.3 mm Measuring strips and Setting is made using shim
in converter depth gauge rings between housing and
turbine gear flange

05. Maximum pressure for 2.5 +0.5 bar Forcing device The converter is tested using
testing the converter for leaks 1X56 137 129, air under water
compressed air unit
1X56 137 130 and
water container

06. Tightening torque of Allen Torque wrench For changing screws and new
screws on O-ring seal on
HP 500 converter (M8) and = 35 Nm HP 590/600 converter,
HP 590/600 converter (M10) = 60 Nm see Service Info No.: 06/95.

07. Tightening torque of M16 180 to 190 Nm Torque wrench and Lock converter with brace
Allen screw in the turbine shaft locking device 1X56 137 658
1X56 137 158

08. Tightening torque of 190 to 210 Nm Torque wrench Attach new Cu seal ring.
M33x2 screw plug in converter Lock converter with brace
1X56 137 658

09. Tightening torque of 68 Nm Torque wrench


hexagon bolts on the M10x35
end washer
(HP 590 / HP 600)

1-12
HP 500 / 590 / 600 Adjustment data
“long” version

Description Dimension Measuring device Remarks

Output

10. Specified distance between 0.5 to 0.7 mm Depth gauge, Distance can be set using
sensing face of inductive measuring rod shim washers
sensor and face end of toothed 1P01 137 833
disc (impulse sensor)

11. End float of speedometer 0.1 to 0.3 mm Depth gauge Can also be checked by hand
shaft (can be felt)

12. Gear backlash of 0.1 to 0.2 mm Experience Play is specified, to check test
speedometer shaft by hand (can be felt)

13. Installation depth of shaft 15 -1 mm Depth gauge Installation depth between


seal in output end cover face end of tapered roller
bearing inner ring and front
face of seal ring is set using
device 1X56 136 824.
Verify to check

14. End float of tapered roller 0.02 to 0.07 mm Adjuster 1PO1 136 816, Rotating resistance of output
bearing in output end cover dial gauge and tension end cover set to 0.56 to 0.70
when cold (approx. 20 °C) balance Nm. Setting is made using
spacing washers. Difference
between speedometer worm
and setting ring = distance
“C”.
Thickness of spacing washer
= C + 0.05 + 0.02 to 0.07 mm

15. Total end float between sun 0.4 to 0.6 mm Measuring strips and Setting is made using shims
gear and output depth gauge

16. End float between sun gear 0.4 to 0.6 mm Depth gauge Setting is made using shims
II/III and sun gear shaft

17. Installation depth of needle 2.5 +1 mm Feeler gauge Installation depth between
bearing in planetary carrier IIII running surface of shim and
face end of needle bearing is
set when using device
1X56 137 101

18. End float of planetary 0.5 to 1.2 mm Feeler gauge Play is set, verify to check
gears in planet carrier III

1-13
Adjustment data HP 500 / 590 / 600
“long” version

Description Dimension Measuring device Remarks

19. Tightening torque of M6 5 to 7.5 Nm Torque wrench


studs on output end cover

20. Tightening torque of M10 10 to 15 Nm Torque wrench


studs on output end cover

21. Tightening torque of M5 6 Nm Torque wrench


hex nuts on cover of output

22. Tightening torque of max. 50 Nm Torque wrench Do not exceed specified value
inductive sensor (output speed)

23. Tightening torque of M12 60 Nm Torque wrench Secure with locking plate.
hexagon bolts on output flange Use device 1X56 136 471

24. Tightening torque of ca. 100 Nm Torque wrench Attach new Cu seal ring
speedometer connection piece

Control element

25. Delivery rate of primary ca. 60 l/min Graduated vessel and Measured at pump speed n =
pump in independent test stop watch 1500/min. SAE 10 W oil at
(theoretical value) 80°C. Primary pump is a one
complete unit

26. Distance between spring 1.6 +0.5 mm Measuring gauge Setting is made by removing
guide and guide bolts of stator or attaching the plate springs
ring which are to be installed.
Measurements are made
without preload on the plate
springs

Clutch carrier

27. Test pressure (PÜ) for the 2.5 +0.5 bar Feed guide Pressure test for leaks: fall in
pistons of clutches “A”, “B” 1X56 137 128 pressure from 2.5 +0.5 bar to
and “C” compressed air unit 1.4 bar after locking = 10 sec.
1X56 137 130

28. Disc play of clutch “A” 3.2 to 3.7 mm Depth gauge Deviations can be
compensated for by installing
steel discs or A pistons of
various thicknesses.

1-14
HP 500 / 590 / 600 Adjustment data
“long” version

Description Dimension Measuring device Remarks

29. Disc play of clutch “B” 1.6 to 2.1 mm in Feeler gauge Measurement is taken with
(HP 500) feeler gauge between end
2 to 2.5 mm in washer and outer disc.
(HP 590/HP 600) Deviations are rectified using
steel discs or B pistons of
various thicknesses

30. Disc play of clutch “C” 1.2 to 1.7 mm in Feeler gauge Measurement is taken with
(HP 500) feeler gauge between R-gear
1.6 to 2.1 mm in housing and outer disc.
(HP 590/HP 600) Deviations are rectified using
steel discs of various
thicknesses
31. Concentricity variation of + 0.2 mm Dial gauge The measurement is taken at
inductive sensor ring in the relevant height of the
installed position inductive sensor ring.
Deviations are corrected
carefully using a soft mallet

32. Tightening torque of M8 35 Nm Torque wrench


hex bolts on rotor (retarder)

Mechanical transmission part

33. End float of planetary 0.5 to 1.2 mm Feeler gauge Play is specified, verify to
gears in planet carrier I check

34. Disc play of brake “D” 1.6 to 2.1 mm Feeler gauge Measurement is taken with
feeler gauge between end
washer and outer disc.
Deviations are rectified using
outer discs of various
thicknesses and/or attaching
or removing outer discs

35. Installation depth of needle 4 +1 mm Depth gauge Measured between running


bearing in drive shaft surface of thrust washer and
face end of needle bearing.
The installation depth is set if
you are using device 1X56
137 101

36. End float of planetary 0.5 to 1.2 mm Feeler gauge Play is specified, verify to
gears in planet carrier II check

1-15
Adjustment data HP 500 / 590 / 600
“long” version

Description Dimension Measuring device Remarks

37. Disc play of brake “E” 2.5 to 3 mm in Feeler gauge Measurement is taken with
(HP 500) feeler gauge between pressure
3 to 3.5 mm in ring and outer disc. Deviations
(HP 590/HP 600) are rectified using outer discs
of various thicknesses.

38. Disc play of brake “F” 3.2 to 3.7 mm Depth gauge Deviations are compensated
for using F pistons and discs
of various thicknesses

39. Disc play of brake “G” 2.8 to 3.3 mm / R 12 Depth gauge Disc play depends on the
3.2 to 3.7 mm / R14/16 friction coefficient (R);
3.6 to 4.1 mm / R 18 always set in acc. with parts
list. Deviations are
compensated for using G
pistons or discs of various
thicknesses

Hydraulic control unit

40. Specified distance between 0.6 to 0.8 mm Depth gauge,measuring Distance can be set using
sensing face of inductive rod 1P01 137 833 shims
sensor (in duct plate) and
bulges around circumference
of inductive sensor ring (pulse
sensor)

41. Tightening torque of max. 50 Nm Torque wrench Do not exceed specified value
inductive sensor (turbine
speed)

42. Tightening torque of 80 to 100 Nm Torque wrench


M42x2 screw plug (in duct
plate in conical manner)

Retarder accumulator

43. Tightening torque of M8 7.5 to 10 Nm Torque wrench Studs need only be replaced
studs on rear cover of retarder by new ones if they are
accumulator damaged

44. Tightening torque of M8 15 Nm Torque wrench Attach washers


lock nuts on accumulator cover
of retarder

1-16
HP 500 / 590 / 600 Adjustment data
“long” version

Description Dimension Measuring device Remarks

Miscellaneous
transmission data

45. Tightening torque of 25 Nm Torque wrench Attach new Cu seal ring


M12x1.5 screw plug in
solenoid valve

46. Installation depth of oil fill 40 +1.0 mm Depth gauge Measured between the sealing
pipe face of the transmission
housing (flange surface of oil
pan) and front face of fill
pipe. Seal threads with
sealing tape

47. Tightening torque of approx. 20 Nm Experience


M22x1.5 grooved nut in the oil
pan

48. Tightening torque of 50 Nm Torque wrench Attach new Cu seal ring


M22x1.5 oil drain screw in oil
pan

49. Tightening torque of 12 Nm Torque wrench Attach new Cu seal ring


M10x1 screw plugs at the
pressure measuring points

50. Tightening torque of approx. 20 Nm Torque wrench Attach new Cu seal ring
M10x1 banjo bolts in the cover
plate

1-17
Spring table HP 500 / 590 / 600
“long” version

Wire Outer spring


Part number Point of installation No. of turns diameter diameter Untensionned
in mm in mm length in mm

0732 041 934 Control element, stator ring 13.50 1.40 16.35 56.20

0732 042 114 Control element, 11.50 3.0 22.90 71.14


main pressure valve

0732 041 125 Control element, 4.50 2.50 22.94 22.70


lubrication pressure valve

0732 041 654 Control element, 10.50 2.80 18.70 52.60


converter back pressure valve

0732 041 102 Control element, 10.50 2.80 18.40 48.50


converter back pressure valve

0732 040 786 Control element, 14.50 2.50 17.54 67.40


cooler switch-over valve

0732 041 373 Shift control, 27.50 0.90 5.40 38.40


valve blocks

0732 041 374 Shift control, 13.50 1.30 10.53 37.80


valve blocks

0732 041 148 Shift control, 14.50 2.10 18.95 63.3


valve blocks

0732 041 095 Shift control, 12.50 1.80 18.73 66.90


valve blocks

0732 041 720 Shift control, 13.75 2.20 19.41 60.60


valve blocks

0732 041 357 Shift control, 14.50 1.80 18.80 79.70


valve blocks

0732 041 199 Shift control, 13.50 1.80 18.83 72.90


valve blocks

0732 041 216 Shift control, 14.00 2.10 19.19 60.10


valve blocks

1-18 Index ”a“ 98-04-17


HP 500 / 590 / 600 Spring table
“long” version

Wire Outer spring


Part number Point of installation No. of turns diameter diameter Untensionned
in mm in mm length in mm

0732 041 992 Shift control, 13.50 1.80 19.00 64.80


valve blocks

0732 041 098 Retarder, control valve 12.50 1.40 11.16 36.40

0732 041 142 Retarder, control valve 31.50 1.25 9.21 72.50

0732 041 322 Retarder, control valve 9.50 2.50 14.86 58.90 -0.03

0732 041 847 Disc brake “D” 10.50 1.60 10.10 27.80

0732 041 409 Disc brakes “E” and “F” 50.50 1.60 8.60 123.0

0732 041 846 Disc brake “G” 27.50 1.60 9.00 73.,60

0732 041 421 Clutch carrier, 24.50 2.00 11.60 79.10


R-gear housing

0732 041 269 Clutch carrier, 28.50 1.80 11.50 87.20


B clutch

1-19
Notes HP 500 / 590 / 600 “long” version

1-20
HP 500 / 590 / 600
Special tools
“long” version

Fig. Illustration Order No. Application Qty. Remarks


No

1X56 097 775 2

Assembly hooks
1 for lifting planetary carrier out of
housing

1X56 100 632 1

Adapter with taper


2 for shaft sealing ring (10 x 15 x 3) in
speedo connection piece

1X56 122 205 1

Internal extractor
3 for needle bearing (18x24x16) in
planetary carrier II and in input shaft
(use with 1X56 122 227)

1X56 122 208 1

Internal extractor
4 for needle bearing (45x52x16)
(use with 1X56 122 227)

1X56 122 209 1

Internal extractor
5 for needle bearing (55x63x20)
(use with 1X56 122 227)

1-21
HP 500 / 590 / 600
Special tools
“long” version

Fig. Illustration Order No. Application Qty. Remarks


No

1X56 122 227 1

Counter bracket
6 use with internal extractors
1X56 122 205 and 1X56 122 208

1X56 122 306 1

Base tool
7 use with grip 1X56 136 706

1X56 122 322 1

Extractor
8 for grooved ball bearing
(0635 331 232) in control insert

1X56 124 659 1

Extractor plate
9 for bearing inner race on stator quill
shaft

1X56 126 464 1

Extractor
10 for speedo worm

1-22
HP 500 / 590 / 600
Special tools
“long” version

Fig. Illustration Order No. Application Qty. Remarks


No

1X56 136 260 1

Lifting device
11 for complete output

1X56 136 471 1

Punch
12 for tab washer on output flange

1X56 136 513 (220V) Optional 1


1X56 137 575 (110V)

13 Hot-air blower
for heating various components

1X56 136 594 1

Adapter (LH)
14 for supporting the transmission (use
with assembly stand 1X56 137 450)

1X56 136 595 1

Adapter (RH)
15 for supporting the transmission (use
with assembly stand 1X56 137 450)

1-23
HP 500 / 590 / 600
Special tools
“long” version

Fig. Illustration Order No. Application Qty. Remarks


No

1X56 136 605 1


HP 500
Punch HP 590
for shaft sealing ring conveter
16
(125x150x10) behind torque external
converter diameter
~ 430 mm

1X56 136 612 2

M8 Hook
17 for lifting control insert off clutch
carrier

1X56 136 706 1

Grip
18 for tapered roller bearing
(0635 370 006) on output

1X56 136 815 3

Extractor
19 for cover plate behind torque
converter

1P01 136 816 1

Adjustment device
20 for tapered roller bearing on output

1-24
HP 500 / 590 / 600
Special tools
“long” version

Fig. Illustration Order No. Application Qty. Remarks


No

1X56 136 818 1

Support
21 for oil feed flange when fitting
control insert

1X56 136 820 1

Punch
22 for removal of bush in stator quill
shaft

1X56 136 821 2

M8 guide bolts
23 for installation of control insert and
primary pump

1X56 136 824 1

Inserter
24 for shaft sealing ring (90 x 125 x 10)
on output and bearing outer race in
output cover

1X56 136 850 1

Thread coupling
25 for axle in PTO
(only version with PTO)

1-25
HP 500 / 590 / 600
Special tools
“long” version

Fig. Illustration Order No. Application Qty. Remarks


No

1X56 136 862 1

Lifting device
26 for converter

1X56 137 101 1

Rod
27 for needle bearing (18 x 24 x 16) in
planetary carrier III and input shaft

1X56 137 103 1

Rod
28 for needle bearing (45 x 52 x 16) in
clutch body hub

1X56 137 104 1

Pressure piece
29 for pulling off grooved ball bearing
in control insert
(use with 1X56 122 322)

1X56 137 105 1

Pressure piece
30 for inserting securing rings in front
of “A” piston cup springs

1-26
HP 500 / 590 / 600
Special tools
“long” version

Fig. Illustration Order No. Application Qty. Remarks


No

1X56 137 107 1

Device
31 for inserting spacer rings
7
7 10
1X5
6 13
4139 310 018 in control insert

1X56 137 108 1

Clamping device
32 for removal and installation of main
pressure valve and lubricating
pressure valve and/or converter
pressure back-up valve in control
insert

1X56 137 109 1

Rod
33 for separating clutch carrier from
control insert

1X56 137 126 1

Lifting device
34 for Ecomat transmissions

1X56 137 127 1

Clamping device
35 for inductive sensor ring

1-27
HP 500 / 590 / 600
Special tools
“long” version

Fig. Illustration Order No. Application Qty. Remarks


No

1X56 137 128 1

Insertion bush
36 for leakage check of clutches in
clutch carrier

1X56 137 129 1

Forcing device
37 for converter leak test

1X56 137 130 1

Compressed air unit


38 for leak test of converter and clutch
carrier. Use with insertion bush
1X56 137 128 and forcing device
1X56 137 129

1X56 137 151 1

Punch
39 for knocking in and peening the
pressure control unit orifices

1X56 137 152 2

Support
40 for stator bearing

1-28
HP 500 / 590 / 600
Special tools
“long” version

Fig. Illustration Order No. Application Qty. Remarks


No

1X56 137 153 2

Insert
41 for cleaning oil cooler

1X56 137 156 1

Punch
42 for knocking out orifices

1X56 137 158 1

Holding device
43 for loosening and tightening M16
cap screw in converter

1P01 137 173 1

Plug gauge
44 range 0.03 to 0.12” (0.7 to 3.0 mm),
for measuring orifices

1X56 137 213 1

Lifting device
45 for turbine shaft

1-29
HP 500 / 590 / 600
Special tools
“long” version

Fig. Illustration Order No. Application Qty. Remarks


No

1X56 137 273 1

Inner hex insert


46 for socket head screw
on control insert

1X56 137 357 1

Extractor
47 for output flange

1X56 137 382 1


HP 590
Adaptor HP 600
for radial seal ring (142x162x10) converter
48
behind converter external
diameter
~ 475 mm

1X56 137 387 1

Puller
49 for planet carrier II HP 600

1X56 137 388 1

Puller
50 HP 600
for planet carrier II
(in combination with1X56 137 387)

1-30
HP 500 / 590 / 600
Special tools
“long” version

Fig. Illustration Order No. Application Qty. Remarks


No

1X56 137 432 1

Extractor
51 for pressing off piston ring carrier
from stator quill shaft

1X56 137 450 1

Assembly stand
52 can be swivelled/pivoted

1X56 137 464 1

Support
53 for securing planetary gear pins

1X56 137 465 1

Punch
54 for closing in the planetary gear pins
of planetary carrier I

1X56 137 466 1

Punch
55 for closing in the planetary gear pins
of planetary carriers II and III

1-31
HP 500 / 590 / 600
Special tools
“long” version

Fig. Illustration Order No. Application Qty. Remarks


No

1X56 137 658 1

Brace bracket
56 for loosening and tightening screw
plugs in converter

1X56 137 822 1

Tool
57 for needle bearing (55x63x20)
in planet carrier III and IV

1P01 137 833 1

Measurement rod
58 for measuring inductive sensor
clearance

1X56 150 111 2

M6 threaded pin
59 for control unit

1-32
HP 500 / 590 / 600
Special tools
“long” version

Auxiliary tools for in-house production

Auxiliary mandrel for centring the planetary gears

ø1

mm 4139 333 041 4139 233 049 / 4139 333 667

ø1 24.98 -0.05 29.98 -0.05

ø2 14.98 -0.05 19.98 -0.05


L1

L1 80 80

L2 8 8
L2

ø2

1-33
HP 500 / 590 / 600 “long” version Assembly jig

1 Installing and removing transmission in/from assembly jig

NOTE
Preceding work: removing transmission

7
2 3

7
4 6

004264

1 Lifting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 137 126


2 M16 x1.5x30 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm
3 Adapter “right-hand side” . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 136 595
4 Adapter “left-hand side” . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 136 594
5 Transmission assembly jig . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 137 450
6 M10 hexagon bolt with nut . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Nm
7 M16x1.5 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Nm
8 M10 Allen screw with internal hex . . . . . . . . . . . . . . . . . . . . 46 Nm

2-1
Assembly jig HP 500 / 590 / 600 “long” version

1.1 Installing transmission in assembly jig

1 Fasten adapter (3/4) onto transmission 3


assembly jig (5). 4
2 Tighten M10 hexagon nuts and bolts (6);
torque: 46 Nm
6 5
3 Release Allen screws (8).

4 Set distance “A” to approx. 550 mm by shifting


center cross beam on transmission assembly jig (5).
8
5 Tighten Allen screws (8).

000786

6 Place lifting device 1X56 137 126 (1) on output


end cover.
1
7 Screw in four M16x1.5 hexagon bolts;
torque: 110 Nm

004265

8 Release shackle and insert with ring in the correct


bore.

! DANGER
Take care when inserting shackle. Refer to instructions
on lifting device.

9 Suspend ring in crane hook. Move transmission


over assembly jig, center between adapters and
lower.

004266

2-2
HP 500 / 590 / 600 “long” version Assembly jig

10 Fasten left-hand adapter (4) on transmission. Screw


in four hexagon bolts (7); 7
torque: 225 Nm

004267

11 Swing up right-hand adapter (3) and use four


M16x1.5 hexagon bolts to fasten to transmission;
torque: 225 Nm
3
12 Remove crane hook and lifting device.

13 Unlock assembly jig and swing transmission into


the operating position required.

! DANGER
Avoid hitting and jolting outside of the swivel axle.

004268

! DANGER
Ensure that people cannot access the swivel area
during a swivel process. Once each swivel process
has been completed, lock the assembly jig with bolt.
Secure bolt with a thumb nut.

004269

2-3
Assembly jig HP 500 / 590 / 600 “long” version

1.2 Removing transmission from assembly jig

1 Attach lifting device 1X56 137 126 to output end


cover. Screw in four hexagon bolts;
torque: 110 Nm

004270

2 Hang crane hook in ring.

3 Use lifting device to raise until ring is taut.

! DANGER
Assembly block must not be raised with ring.

004271

! DANGER
Secure right-hand adapter to prevent it swinging.

4 Unscrew hexagon bolts of adapter.

! DANGER
The transmission may lower somewhat, there is a
danger of crushing.

5 Remove transmission from assembly jig.

004272

2-4
HP 500 / 590 / 600 “long” version Pressure reservoir

2 Removing and installing, dismantling and assembling reetarder accumulator


2.1 Removing and installing solenoid valve

NOTE
Preceding work: removing transmission

3
2

4
1 7

8
9
6

004 285
004285

1 Retarder accumulator
2 M10x60 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Nm
3 Washer
4 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace; grease with Vaseline
5 M8 Allen screw with internal hex . . . . . . . . . . . . . . . . . . . . . 23 Nm
6 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace; grease with Vaseline
7 Solenoid valve
8 Washer
9 M8x55 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm

2-5
Pressure reservoir HP 500 / 590 / 600 “long” version

2.1.1 Removing solenoid valve

1 Unscrew M8 hexagon bolts (9) and remove


solenoid valve (7) with O-ring (6) from
accumulator

7
9
003481

2.1.2 Installing solenoid valve

1 Coat new O-ring (6) with Vaseline and insert in


solenoid valve.

003 483
003483

5 Attach solenoid valve (7) to accumulator

6 Screw in two M8x55 hexagon bolts (9) (each with


one washer);
torque: 23 Nm

NOTE
Install the solenoid valve with its electrical connection
at the top.

7
9
003481

2-6
HP 500 / 590 / 600 “long” version Pressure reservoir

2.2 Removing and installing retarder accumulator

NOTE
Preceding work: removing transmission; removing solenoid valve

3
2

4
1

004286

1 Retarder accumulator
2 M10x60 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Nm
3 Washer
4 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace; grease with Vaseline
5 M8 Allen screw with internal hex . . . . . . . . . . . . . . . . . . . . . 23 Nm

2-7
Retarder accumulator HP 500 / 590 / 600 “long” version

2.2.1 Removing retarder accumulator

1 Unscrew hexagon bolts (2) on bracket from output


end cover.

003 484
003484

2 Unscrew Allen screws (5) and remove pressure


reservoir (1) with O-ring from connection piece.

003485

2-8
HP 500 / 590 / 600 “long” version Retarder accumulator

2.2.2 Installing of retarder accumulator

1 Insert new O-ring (4) in reservoir cover.

NOTE
Coat O-ring with Vaseline.

003486

2 Attach retarder accumulator to connection piece.


Use M8 Allen screws (5) (each with one washer) to
fasten this;
torque: 23 Nm

003485

3 Use M10 hexagon bolts (2) (each with one washer)


to fasten bracket onto output end cover;
torque: 46 Nm

NOTE
The accumulator must be fitted to locking plate without
tension. Use shims, if necessary.

003 484
003486

2-9
Retarder accumulator HP 500 / 590 / 600 “long” version

2.3 Removing and installing retarder accumulator


from/in side-mounted oil cooler
2.3.1 Removing retarder accumulator from side-
mounted oil cooler
6 7
1 Unscrew M8 hexagon bolts (7) and take solenoid
valve (6) with O-ring (5) out of reservoir.
5

001558

2 Unscrew hexagon bolts (1) and take retarder


accumulator (2) with gaskets (3) out of
the oil cooler (4).
4
2
3

001565

001565

2.3.2 Installing retarder accumumlator on side-


mounted oil cooler
6 7
1 Attach retarder acumulator (2) with gaskets (3) to 4 5
oil cooler (4).

2 Fit and screw in six hexagon bolts (1) with washers; 3 2


torque: 23 Nm

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


solenoid valve. 1
4 Attach solenoid valve (6) to reservoir and use two
hexagon bolts with washers (7) to tighten;
torque: 23 Nm 001573
001573

2-10
HP 500 / 590 / 600 “long” version Retarder accumulator

2.4 Dismantling and assembling retarder accumulator

10
11
9

8
7
2 6
4
1 3

004287

1 Connecting plate
2 M8 retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm
3 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace; grease with Vaseline
4 Groove ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check; replace
5 Threaded pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
6 Piston
7 Piston guide ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
8 Groove ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check; replace
9 Tube
10 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace; grease with Vaseline
11 Rear cover

2-11
Retarder accumulator HP 500 / 590 / 600 “long” version

2.4.1 Dismantling retarder accumulator

1 Remove M8 retaining nuts (2) with washers.

2 Remove connecting plate (1).

003 487
003487

3 Remove rear cover (11).

4 Press piston (6) fully out of tube (9).

NOTE
If the threaded pins are damaged, unscrew them from
the rear cover.

003 488
003488

5 Use suitable tool to grip rear of groove rings (8/4)


and remove from piston.

6 Take piston guide ring (7) off piston.

003 490
003489

2-12
HP 500 / 590 / 600 “long” version Pressure reservoir

2.4.2 Assembling of retarder accumulator

NOTE
All parts must be cleaned thoroughly prior to assembly.
Groove rings, O-rings, piston guide rings, flange
packings etc. should always be replaced.

1 Insert new groove rings (4/8) in annular groove in


piston.

2 Insert new piston guide ring (7) in piston.

CAUTION
Groove rings must be installed with the open side facing
outwards. 003 490
003490

3 Coat outside of piston (6) and inside of tube with


MIL-G-24 139 grease. (Use between 2 and 4 cm3
of grease).

4 Insert piston (6) in tube.

CAUTION
Ensure that the groove rings are not damaged when
installing the piston.

003 491

003491

5 Place new O-ring (10) on rear cover (11) and coat


with Vaseline.

6 Press tube (9) with piston onto rear cover.

CAUTION
Push on pipe in a manner that the number on the piston
faces the rear cover.

003 492

003492

2-13
Pressure reservoir HP 500 / 590 / 600 “long” version

7 Coat new O-ring (3) with Vaseline and place on


connecting plate (1).

8 Push connecting plate onto threaded pins.

NOTE
The shoulder of the connecting plate (arrow) must point
towards the bracket (arrow) on the rear cover.

003493

9 Tighten M8 retaining nuts (2) with washers;


torque: 12 Nm

NOTE
Use new retaining nuts.

003 487 003487

2.5 Dismantling and assembling of retarder


accumulator from/in side-mounted oil cooler

1 The pressure reservoir should be dismantled and


a
assembled as is described in section 2.4.

NOTE
– The retarder accumulator in connecting plates (a) and
(b) are different.
– Note the site of the connecting plates.
– Assemble pressure reservoir on surface plate.

b
001574

2-14
HP 500 / 590 / 600 “long” version Oil cooler

3 Removing and installing, dismantling and assembling oil cooler


3.1 Removing and installing oil cooler

NOTE
Preceding work: removing retarder accumulator

10
10
8 9

1 10

8
5 3
6 4
2 11

004004310
310

1 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
2 Connector
3 M18x1.5 screw plug (coolant) with seal ring . . . . . . . . . . . . 23 Nm; replace seal ring
4 M12x1.5 screw plug (transmission oil) . . . . . . . . . . . . . . . . . 23 Nm; eal with silicone paste
5 Washer
6 Retaining bolt (hexagon bolt or Allen screw) . . . . . . . . . . . . 23 Nm
7 Oil pipe
8 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace; grease with oil
9 Oil cooler
10 Hexagon nut and washer . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Nm
11 Hexagon nut and washer . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Nm

2-15
Oil cooler HP 500 / 590 / 600 “long” version

3.1.1 Removing oil cooler

1 Unscrew retaining bolts (6) on connector.

003314

2 Drive connector (2) off oil pipes using a plastic


hammer.

3 Remove gaskets (1) from connector or


transmission.

003 315
003315

4 Pull oil pipes (7) and O-rings (8) out of the oil
cooler bores.

003 316

003316

2-16
HP 500 / 590 / 600 “long” version Oil cooler

5 Unscrew M18x1.5 screw plug (3) and drain coolant


from oil cooler.

003317

6 Remove sealant from screw plugs (4) using a


triangular scraper.

7 Unscrew M12x1.5 screw plugs (2) from oil cooler


and drain oil.

NOTE
Transmission version may be one which does not have
screw plugs.

003 318
003318

8 Unscrew M10 hexagon nuts (11) from underside of


oil cooler. Remove washers.

003 31

003319

2-17
Oil cooler HP 500 / 590 / 600 “long” version

9 Unscrew M10 hexagon nuts (10) with washers.

10 Lift off oil cooler (9).

NOTE
If necessary, separate oil cooler from connecting pipes
by lightly tapping it with a plastic hammer.

! DANGER
The oil cooler weighs 25 kg. It should only be raised
and transported by two people or through the use of a
crane.

9 003 320
003320

3.1.2 Installing oil cooler

1 Attach connector (2) with gasket (1) to transmission


and screw in retaining bolts;
torque: 23 Nm

003 315
003315

2 Coat O-rings (8) with Vaseline and push onto oil


pipes. Insert oil pipes (7) in connector.

003321

2-18
HP 500 / 590 / 600 “long” version Oil cooler

3 Position oil cooler (9) on threaded pins on


transmission and in so doing introduce connecting
pipes into oil cooler.

4 Tighten hexagon nuts (10) with washers by hand.

9 003 003320
320

5 Tighten M10 hexagon nuts (11) with washers;


torque: 46 Nm

003 31

003319

6 Thoroughly clean M12x1.5 screw plugs (4) and


their seats.

! DANGER
Refer to the special safety specifications for cleaning
agents.

7 Tighten screw plugs; torque: 23 Nm

8 Seal screw plugs with silicone paste.

NOTE
Transmission may be the version which does not have
screw plugs. 003 318
003318

2-19
Oil cooler HP 500 / 590 / 600 “long” version

10 Tighten M18x1.5 screw plug for water (3) with new


seal ring; torque: 25 Nm

003317

3.2 Removing and installing side-mounted oil


cooler
3.2.1 Removing side-mounted oil cooler 3
1 Unscrew M8 hexagon bolts (2) from connector (1). 4
2 Unscrew hexagon bolts (3) from locking plates (4)
and (5).
6 5
3 Lift off oil cooler with gasket (6).

CAUTION
Take great care when lifting off and transporting the oil 2
cooler. 1
001561
001561

3.2.2 Installing side-mounted oil cooler

1 Place locking plate on transmission.

2 Place oil cooler on locking plate.

3 Coat gaskets (6/7) with Vaseline and position on


transmission or oil cooler. 6
7
4 Screw the pre-assembled connector (with inserted
oil pipes) onto oil cooler; torque: 23 Nm

5 Screw hexagon bolts (2) with washers into connector;


torque: 23 Nm
2
6 Tighten M10 hexagon bolts for locking plate; 001561
001561
torque: 46 Nm

2-20
HP 500 / 590 / 600 “long” version Oil cooler

3.3 Dismantling and assembling oil cooler

004311

1 M8x70 Allen screw with internal hex . . . . . . . . . . . . . . . . . . 23 Nm


2 M8x45 Allen screw with internal hex . . . . . . . . . . . . . . . . . . 23 Nm
3 M8x60 Allen screw with internal hex . . . . . . . . . . . . . . . . . . 23 Nm
4 M8x25 Allen screw with internal hex . . . . . . . . . . . . . . . . . . 23 Nm
5 Washer
6 Cover
7 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
8 Silicone partition
9 Heat exchanger
10 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, grease with oil
11 Oil cooler housing
12 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
13 M8x25 Allen screw with internal hex . . . . . . . . . . . . . . . . . . 23 Nm

2-21
Oil cooler HP 500 / 590 / 600 “long” version

3.3.1 Dismantling oil cooler

1 Unscrew seven M8 Allen screws (13).

003 322

003322

2 Unscrew M8 Allen screws (1/2/3/4) from oil cooler.

003 323

003323

3 Drive out dowel pins (14).

4 Remove cover (6) from oil cooler.

003 324

003324

2-22
HP 500 / 590 / 600 “long” version Oil cooler

5 Remove gasket (12) from oil cooler housing.

6 Remove gaskets (7) from heat exchanger.

7 Pull heat exchanges (9) out of oil cooler housing


and remove silicone partition (8).

NOTE
The heat exchangers have a relatively tight fit in the oil
cooler housing on account of the O-rings fitted on them.

003 325

003325

3.3.2 Assembling oil cooler

1 Check heat exchangers for damage and replace if


necessary.

2 If the old heat exchangers are to be used, install new


O-rings (10).

003 326
003326

3 Insert one heat exchanger (9) into oil cooler


housing, then the other.

4 Insert silicon partition (8) between the heat


exchangers.

003 327

003327

2-23
Oil cooler HP 500 / 590 / 600 “long” version

NOTE
Before installing the gaskets, wipe and clean the sealing
surfaces, e.g. with oil stone.

5 Fit new gaskets (7) on the heat exchangers.

6 Fit new gasket (12) on sealing surface of oil cooler


housing.

003 328

003328

7 Fit cover (6).

8 Drive in dowel pins (14) to align the cover.

NOTE
When fitting the cover, ensure that the gaskets are not
displaced.

003 324

003324

9 Tighten Allen screws (M8) (1/2/3/4) with washers;


torque: 23 Nm

003 323

003323

2-24
HP 500 / 590 / 600 “long” version Oil cooler

10 Turn oil cooler over.

11 Tighten Allen screws (13) with plate springs;


torque: 23 Nm

003 322

003322

3.4 Dismantling and assembling connection parts


for side-mounted oil cooler
3.4.1 Dismantling connection parts for side-mounted 1 2
oil cooler

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


and remove pipe with gaskets (4) from oil cooler.
5
2 Pull oil pipes (2) and (3) out of connector (6) and
4
slip O-rings (5) off oil pipes. 6

3
5
1 001563

001563

3.4.2 Assembling connection parts for side-mounted


oil cooler
2
1 Coat O-rings (5) with Vaseline and insert in groove
of connector.

2 Insert oil pipes (2/3) in connector (6).


6 5

3
5
001564
001564

2-25
Torque converter HP 500 / 590 / 600 “long” version

4 Removing and installing, dismantling and assembling torque converter


4.1 Removing and installing torque converter

NOTE
Preceding work: clamping transmission in assembly jig

Sub-assembly arrangement: torque converter

NOTE
Two torque converter versions are available
(A/B). They can be distinguished from one
another by their different external dimensions.
A = external diameter, approx. 430 mm
B = external diameter, approx. 475 mm
When carrying out repair work, note the
different bolt tightening torques.
A - HP 500 / HP 590 torque converter
B - HP 590 / HP 600 torque converter
003 795
003795

5
4 8
7

3
1 6
9
B
2

004293

2-26
HP 500 / 590 / 600 “long” version Torque converter

Special tools

1X56 137 129 1X56 137 130 1X56 137 152 1X56 137 158 1X56 137 658

1X56 136 862

1 M33x2 screw plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 - 210 Nm


2 Seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
3 Allen screw with internal hex . . . . . . . . . . . . . . . . . . . . . . . . 180 - 190 Nm
5 Torque converter
6 Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gauges 1, 1.1, 1.2, 1.5, 1.7, 1.8, 1.9, 2, 2.5, 2.6 mm
7 Spacer ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . set
8 Rectangular ring
9 Transmission
10 Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 137 158
11 Hexagon socket 1/2”
12 Compressed air supply to holder
13 Wrench socket extension
14 Compressed air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 137 130
15 Shut-off cock
16 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . set to max. 3 bar
17 Regulator
18 Rubber washer for holder
19 Washer
20 Washer
21 Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 137 658

2-27
Torque converter HP 500 / 590 / 600 “long” version

4.1.1 Removing torque converter

1 Turn transmission in assembly jig until torque


converter is pointing upwards.

2 Use suitable tool to lever off the assembly cover


(22).

NOTE
Depending on the version used, there may be an
assembly cover (22) or a screw plug.

22

003 329
003329

3 Measure installation depth of converter.

3.1 Converter is driven on axially, leaving no play.

3.2 Measure installation depth “F” from flange surface


of converter to flange surface of transmission.

3.3 Take measurements at several points around the


circumference and calculate the average from the
various measurements.

3.4 Note installation depth of converter.

003331

CAUTION
The Allen screws around the circumference of the
HP 590 / HP 600 converter must not be unscrewed.

4 Insert brace 1X56 137 658 into transmission


housing and screw onto converter.

003 330

003330

2-28
HP 500 / 590 / 600 “long” version Torque converter

5 Unscrew screw plug (1) and remove with


seal ring (2).

003332

6 Screw holder 1X56 137 158 into converter circuit


cover and tighten by hand.

NOTE
Ensure that the rubber washer is in place on the thread
of the holder.

NOTE
In addition to the pneumatic holder, a ZF mechanical
holder 1X56 138 864 can be supplied and used in
conjunction with the hexagon socket 1X56 136 863.

0
003333

7 Connect compressed air unit 1X56 137 130 (14) to


holder 1X56 137 158.

8 Turn adjusting wheel on regulator (17) a few


revolutions in counter-clockwise direction.

9 Move lever on shut-off cock (15) to the horizontal


position. This opens the shut-off cock.

10 Use regulator to set the pressure to 1.5 bar.

003334

2-29
Torque converter HP 500 / 590 / 600 “long” version

11 Insert socket wrench extension 1/2” (13) into holder


(10) and slacken Allen screw.

12 Close shut-off cock.

13 Unscrew holder 1X56 137 158 from converter


circuit cover.

003335
003 335

14 Unscrew Allen screw (3) and remove from


converter.

15 Remove brace 1X56 137 658.

003 336
003336

16 Screw lifting device 1X56 138 862 (24) into


converter and tighten by hand.

17 Carefully lift converter out of transmission.

NOTE
Before lifting out the converter completely, raise it to
just above the turbine shaft. In this position, tilt the
converter slightly until all the oil has drained from the
converter.

003337

2-30
HP 500 / 590 / 600 “long” version Torque converter

18 Unscrew lifting device.

19 Turn converter over and take shim(s) (6) out of


converter or from turbine shaft.

! DANGER
The converter weighs approx. 60 kg. It must always
be turned over by two people. Only remove lifting
device once the converter has be secured so that it
cannot roll away.

003 338 003338

20 Take spacer ring (8) of stator shaft.

003 339
003339

2-31
Torque converter HP 500 / 590 / 600 “long” version

4.1.2 Installing torque converter, measuring end float


and installation depth of torque converter

1 Screw lifting device 1X56 136 862 into converter


until the turbine wheel in the converter is secured
without play.

3 Turn converter over.

! DANGER
The converter weighs approx. 60 kg. It must always
be turned over by two people and secured so that it
cannot roll away.

003 340
003340

3 Measure converter end float.

3.1 Measure distance “C” between end face of spur


gear and turbine gear stop.

3.2 Note down distance “C”.

003341

3.4 Measure distance “B” between end face of spur


gear to end face of one-way clutch inner ring.

3.5 Note down distance “B”.

003346

2-32
HP 500 / 590 / 600 “long” version Torque converter

3.6 Calculate theoretical distance “D” between end face


of one-way clutch inner ring and face of washer as
follows.

C-B=D
Note down distance “D”.

D B
C

001580 001580

3.7 Check rectangular ring (8) for damage and replace


if necessary.

3.8 Centrally align rectangular ring.

NOTE
Rectangular ring is hooked.

3.9 Push spacer ring (7) onto stator shaft so that there is
no play in the axial direction.

003 003347
347

3.10 Screw lifting device 1X56 137 213 into turbine


shaft.

3.11 Tighten lifting device by hand until the end float of


the turbine shaft is eliminated.

3.12 Place depth gauge on face end of turbine shaft in


recess of lifting device.

3.13Measure distance “A” between end face of turbine


shaft and spacer ring (7) pushed onto stator shaft.

3.14Note down distance “A”.

3.15Unscrew lifting device from turbine shaft.


003348

2-33
Torque converter HP 500 / 590 / 600 “long” version

3.16 Calculate required gauge “S” of washer (6).


D-A=E
Distance “E” plus the specified end float of the
converter, distance “G” (*between 0.3 and 0.4 mm)
produces distance “S” for the washer (6) to be
installed.
E + between 0.3 and 0.4 mm = S

Example calculation:

C = 174.7 mm D = 119.5 mm
-B = 55.2 mm - A = 118.3 mm
D = 119.5 mm E= 1.2 mm
*+G= 0.35 mm
S= 1.55 mm

CAUTION
Dimension ”G” must be added and must not be
subtracted.If it is subtracted, this will result in damage to
the bearing.

Washers are available with the following gauge gradations:

0730 362 123 = 1.0 mm


0730 362 218 = 1.1 mm
0730 362 122 = 1.2 mm
0730 362 121 = 1.5 mm
0730 362 219 = 1.7 mm
0730 362 071 = 1.8 mm
0730 362 220 = 1.9 mm
0730 362 070 = 2.0 mm
0730 362 120 = 2.5 mm
0730 362 067 = 2.6 mm

NOTE
Thicker washers result in more play.

4 Thinly coat washer (6) with grease and stick onto


turbine shaft.

5 Center washer on turbine shaft.

6 Center rectangular ring (8) on turbine shaft.

7 Thinly coat contact surface of seal ring (arrow) with


transmission oil.

003349

2-34
HP 500 / 590 / 600 “long” version Torque converter

8 Screw lifting device 1X56 136 862 into converter.

9 Centrally align converter with turbine shaft and


carefully lower in until there is no play.

CAUTION
Do not damage the seal ring. Washer must be positioned
on turbine shaft.

NOTE
The gears on the turbine shaft and stator shaft must
mesh in the converter. Rotate the converter slightly, if
necessary, to ensure that this is the case. Similarly, gear
on converter must mesh with drive gear of primary 003 350
003350
pump.

10 Slacken lifting device 1X56 136 862 by one


revolution.

003340
11 Measure installation depth of converter

NOTE
The converter must be installed with no end float.

11.1 Measure distance “F” between flange surface of


converter and flange surface of transmission.

11.2 Repeat the measurement at several points around


the circumference and calculate the average from
the various measurements.

NOTE
Converter installation depth “F” must be X ± 0.5 mm.
The Ecomat transmissions are equipped with various
torque converter versions. Depending on the converter
version, installation depth “F” must be one of the
003 331003331
following distances.

2-35
Torque converter HP 500 / 590 / 600 “long” version

Outer diameter Outer diameter


~ 430 mm ~ 475 mm
X = 71.25 mm
X = 77.00 mm X = 77.00 mm
X = 81.25 mm X = 81.25 mm
X = 86.25 mm

Außen Ø
If installation depth “F” is between X + 0.05 mm and X
- 0.05 mm, the setting is correct.

11.3 If the installation depth is less than X - 0.05 mm, a


second spacer ring should be attached to the stator
shaft. F

11.4 If the installation depth is greater than


001581
X + 0.05 mm, remove the spacer ring.

NOTE
The spacer ring thickness is 1 mm.

CAUTION
The thickness of the washer installed must also be
changed by the same amount as the increase or
reduction in the installation depth caused by the addition
or removal of a spacer ring.
If this is not the case, it will result in damage to the
bearing.

12 Unscrew lifting device 1X56 136 862 out of


converter.

13 Screw M16 Allen screw (3) into converter. 003 336


003336

14 Check installation depth again.

15 Insert brace 1X56 137 658 into transmission


housing and screw onto converter.

003330

2-36
HP 500 / 590 / 600 “long” version Torque converter

16 Screw holder 1X56 137 158 into converter circuit


cover and tighten by hand.

NOTE
Ensure that the rubber washer is in place on the thread
of the holder.

003333

17 Connect compressed air unit 1X56 137 130 to


holder 1X56 137 158.

18 Turn adjusting wheel on regulator (17) a few


revolutions in counter-clockwise direction.

19 Move lever (15) on shut-off cock to horizontal


position. This opens the shut-off cock.

20 Set regulator to (17) 2.5 bar using adjusting wheel.

003342

21 Insert wrench socket extension 1/2˝ (13) and tighten


Allen screw;
torque: 18 - 190 Nm

22 Close shut-off cock.

23 Remove holder 1X56 137 158 from converter


circuit cover.

003335

2-37
Torque converter HP 500 / 590 / 600 “long” version

24 Attach new copper seal ring (2) to screw plug (1).

25 Tighten M33x2 screw plug:


torque: 190 - 210 Nm

003332

26 Insert cover (22) in assembly opening.

NOTE
Depending on the version, there will either be an
assembly cover (22) or a screw plug.

22
003329

2-38
HP 500 / 590 / 600 “long” version Torque converter

4.2 Dismantling and assembling torque converter

CAUTION
Torque converter HP 590 / 600 (external diameter 475 mm) with new O-ring seal ; refer to Service Info No.: 06/95

13
44 12 14
11
10
11
10

8 9
7
4
3 5

1
6 26
2
25
19 23 24
21
20

16
15 22 43
38 39 40
*45 41
42
17 18 34

35
30
29 24
27 33
32
36
31

28 37 004309

2-39
Torque converter HP 500 / 590 / 600 “long” version

1 M33x2 screw plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 - 210 Nm


2 Seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
*3 M10x55 Allen screw with internal hex . . . . . . . . . . . . . . . . replace; 60 Nm: only with HP 590/600 converter
4 Circuit cover
5 Grooved ball bearing
6 Rectangular ring
7 Rectangular ring
8 Plate piston
9 Plate spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
10 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
11 Inner disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check lining
12 Roller
13 End disc
*14 M8x25 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm: only with HP 500/590 converter
*14 14 M10x35 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Nm: only with HP 590/600 converter
15 M16 Allen screw with internal hex . . . . . . . . . . . . . . . . . . . 180 - 190 Nm
16 Spacer washer
17 Washer
18 Rectangular ring
19 Turbine wheel
20 Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gauges: 1, 1.2, 1.4, 1.6, 1.8, 2, 2.2 mm
21 Housing washer
22 Thrust roller bearing
23 Shaft washer
24 Grooved ball bearing
25 Thrust washer
26 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support 1X56 137 152
27 Bearing roller
28 One-way clutch inner ring
29 Thrust washer
30 Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm
31 Shaft washer “SW”
32 Roller bearing
33 Housing washer “HW”
*34 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace: only with HP 500/590 converter
35 M8x28 Torx powerlock bolt . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
36 Dowel pin
37 Dowel pin
38 Pump gear
39 Washer
*40 M8x32 Allen screw with internal hex . . . . . . . . . . . . . . . . . 35 Nm: only with HP 500/590 converter
41 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
42 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, grease with Vaseline
43 Spur gear
*44 Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . only with HP 590/600 converter
*45 O-Ring (refer to Service Info No.: 06/95) . . . . . . . . . . . . . . only with HP 590/600 converter

* note converter version


HP 500/590 converter - external diameter approx. 430 mm
HP 590/600 converter - external diameter approx. 475 mm

2-40
HP 500 / 590 / 600 “long” version Torque converter

4.2.1 Dismantling torque converter

1 Lay converter on wooden blocks.

2 Unscrew M8 Allen screws (40) (converter with 430


mm external diameter) or M10 Allen screws (3)
(converter with 475 external diameter) and washer.

3 Force circuit cover off pump gear by screwing in 40


40/3
lifting device 1X56 136 862.

CAUTION
Do not strike the circuit cover or pump gear.

003499

4 Remove roller bearing (22) and shaft washer (23)


from stator.

003500

NOTE
Only remove spur gear (43) if necessary.

5 Unscrew twelve M8 fixing bolts (35).

6 Slightly raise pump gear and drive out spur gear


using a plastic mallet.

NOTE
In transmissions with PTOs, the spur gear and pump
gear are located with four dowel pins. Drive out dowel
pins, if installed.

003003351
351

2-41
Torque converter HP 500 / 590 / 600 “long” version

7 Remove housing washer (33) from spur gear (43).

8 Remove O-ring (42) and gasket from spur gear.

CAUTION
The shaft and housing washers must not be confused
with those of another housing assembly. Mark the
bearing assembly accordingly for identification.

003 352

003352

9 Remove stator (26) assembly from turbine wheel.

10 Remove shaft washer (23) from stator.

11 Remove roller bearing (22) from turbine wheel.

003796

12 Remove housing washer (21) and shim (20) from


turbine shaft.

CAUTION
Bearing assemblies must not be confused during
installation. Mark bearing assemblies accordingly for
identification.

003 353
003353

2-42
HP 500 / 590 / 600 “long” version Torque converter

13 Dismantle stator

13.1 Lay stator on a suitable surface.

13.2 Position a suitable pressure piece on the one-way


clutch inner ring.

13.3 Press one-way clutch inner ring (28) out of stator.

003354

13.4 Remove rollers (27) from one-way clutch inner


ring.

13.5 Remove thrust washer (29) from one-way clutch


inner ring.

003 355

003355

13.6 Press one-way clutch inner ring (28) out of ball


bearing (24).

! DANGER
Do not clean the bearing with compressed air
otherwise the bearing races may no longer remain
attached. This lack of lubrication will cause damage
to the bearing.

003 356

003356

2-43
Torque converter HP 500 / 590 / 600 “long” version

13.7 Lay stator (26) on suitable surface on press.

13.8 Press ball bearing (24) out of stator using suitable


pressure piece.

CAUTION
The diameter of the pressure piece must match the
external diameter of the bearing.

003358

13.9 Remove ball bearing (24) and thrust washer (29)


from stator.

003357

14 Dismantle turbine wheel and circuit cover.

14.1 Lever turbine wheel (19) out of circuit cover (4)


using a suitable pry bar.

003 359

003359

2-44
HP 500 / 590 / 600 “long” version Torque converter

14.2 Remove rectangular ring (18) from annular groove.

! DANGER
The rectangular ring has sharp edges. Wear protective
gloves.

NOTE
Use your thumbs to press the end of the rectangular ring
onto the groove base. Push index finger towards other
end of the ring until it snaps out.

003 360
003360

14.3 Remove ball bearing (5) from turbine wheel using


two pry bars.

14.4 Check washer (17) for damage and replace if


necessary.

003 361
003361

NOTE
If necessary, use a suitable mandrel to drive the washer
out of the turbine wheel from behind.

003362
003 362

2-45
Torque converter HP 500 / 590 / 600 “long” version

14.5 Unscrew twelve hexagon bolts (14) out of end disc


(13) and remove end disc.

003363

Steps 14.6 to 14.8 only apply to torque converter version


HP 500/590 (external diameter 430 mm):

14.6 Remove inner and outer discs (11/10) from circuit


cover.

003797

14.7 Remove plate spring (9).

14.8 Remove rollers (12).

003364
003 3

2-46
HP 500 / 590 / 600 “long” version Torque converter

Steps 14.9 to 14.11 only apply to torque converter


version 590/600 (external diameter 475 mm):

14.9 Remove inner and outer discs (11/10) from circuit 11


cover.

NOTE
There are springs (44) on the last outer disc (10).
Remove the springs with the last outer disc.

14.10 Remove plate spring (9).

14.11 Remove rollers (12).


12
10
9 44 003971

14.12 Grasp plate piston (8) with suitable pliers. Gently


tap the sealing surface of the circuit cover (arrow)
with a plastic mallet to loosen the plate piston and
remove.

003 365

003365

14.13 Use a suitable tool (0.5 - 0.75 mm thick) to grasp


and remove inner rectangular ring (6).

! DANGER
Edge of groove on plate piston may have sharp edges.
Wear protective gloves.

14.14 Press out outer rectangular ring (7) in direction of


arrow by simultaneously pressing on both sides.
Grasp the rectangular ring on the projecting side
and remove from annular groove.
003 366
All outer rectangular rings are removed in the same
way.
003366

2-47
Torque converter HP 500 / 590 / 600 “long” version

4.2.2 Assembling toque converter, measuring end


float of thrust bearing

CAUTION
Torque converter version HP 590/600 (external diameter
475 mm): new O-ring sealing on pump gear: refer to
Service Info. No.: 06/95.
If necessary, work O-ring groove into pump gear.

1 Assemble circuit cover and turbine wheel.

1.1 Check rectangular rings for damage and replace if


necessary.
003 367

003367
1.2 Coat inner rectangular ring (6) and outer rectangular
ring (7) with Vaseline and insert into plate piston.

NOTE
Stretch inner rectangular ring slightly before installation
so that it lies snugly in the base of the groove.

1.3 Insert plate piston (8) into circuit cover without


tilting.

NOTE
The rectangular rings must lie snugly in the base of the
annular groove around their entire circumference.

1.4 Use a plastic mallet to gently tap in the


circumference of the plate piston. The plate piston 003 368
must make axial contact.
003368

1.5 Insert twelve rollers (12) in bores around


circumference of circuit cover.

1.6 Place plate spring on plate piston with the convex


side at the bottom.

003364
003 36

2-48
HP 500 / 590 / 600 “long” version Torque converter

1.7 Lay outer and inner discs on a level surface or on an


end disc and check for unevenness or distortion
with the aid of a straight edge.

CAUTION
– Dished discs with an unevenness of more than 0.3 mm
must be replaced.
– Coated discs with damaged or blackened coating must
be replaced.
– Inner discs with damaged teeth must be replaced.
Permissible wear per tooth edge is 0.2 mm.
003 369

003369

Steps 1.8 to 1.11 only apply to torque converter version


500/590 (external diameter 430 mm):

1.8 Insert outer disc (10) into circuit cover.

1.9 Insert inner disc (11).

1.10 Depending on version, either one, two or three


outer discs must be inserted.

1.11 Insert inner disc.

NOTE
Insert the outer discs (10) so that the bores slip over the
rollers.
003797
Steps 1.12 to 1.1 only apply to torque converter version
590/600 (external diameter 475 mm):

1.12 1.12 Insert first outer disc (10) so that the bores
slip over the rollers.
11
1.13 Slide four springs (44) over the rollers and seat on
outer disc at 90 ° angle. In so doing, note the
position of the springs with regard to recess on
circuit cover.

1.14 Insert inner disc (11).

1.15 Slide two outer discs (10) over remaining rollers


and seat with tooth gaps facing the springs and
bores. 12
10
1.16 Insert inner disc.
9 44 003971

2-49
Torque converter HP 500 / 590 / 600 “long” version

1.17 Insert end disc (13) into circuit cover.

1.18 Align end disc so that the bores in the circuit cover
are in alignment with the bores in the end disc.

1.19 Screw in M8 hexagon bolts (14) (for converter with


430 mm external diameter) and tighten to 35 Nm:
or screw in M10 hexagon bolts (converter with 475
mm external diameter) and tighten to 68 Nm.

NOTE
Before tightening the hexagon bolts, drive the plate
piston fully home with a plastic mallet.

003363

1.20 Use a feeler gauge to measure disc play between


last inner disc and end disc and note down as
distance “A”.

NOTE
Nominal disc play = between 0.5 and 1.1 mm

0
003371
A

NOTE
If the disc play (distance “A”) is less than 0.5 mm or
greater than 1.1 mm, install new outer disc. Measure
distance “A” again.
A
Outer discs can be supplied in the following thicknesses.
004 234

Converter
Converter with 430 mm external diameter
004234
A

with 430 mm external diameter 4139 334 005 = 3.5 mm


4139 334 006 = 4.0 mm
A
Converter
with 475 mm external diameter 4166 338 202 = 3.0 mm
4166 338 206 = 3.5 mm
001 570

Converter
with 475 mm external diameter 001570

2-50
HP 500 / 590 / 600 “long” version Torque converter

1.21 Turn turbine wheel over and drive spacer washer


(16) (if removed) fully home into turbine wheel.

NOTE
Install the spacer washer with the bores (arrow) at the
top.

1.22 Secure spacer washer at four evenly spaced


locations around its circumference using punch.

CAUTION
Do not damage the annular groove.

003 373
003373

1.23 Use suitable pipe to drive ball bearing (5) onto


turbine wheel.

003374

1.24 Insert rectangular ring (18) in annular groove and


hook ring end.

! DANGER
The rectangular ring has sharp edges. Wear protective
gloves.

003375

2-51
Torque converter HP 500 / 590 / 600 “long” version

1.25 Align inner discs so that they are flush with one
another.

1.26 Insert turbine wheel (19) in circuit cover.

CAUTION
– The turbine wheel must mesh in the intervals in the
inner discs.
– To engage, turn the turbine wheel back and forth until
it is fully meshed and makes axial contact.
– If necessary, gently tap the turbine wheel with a plastic
mallet on the edge of the internal gearing to bring it
into axial contact. Do not damage the inner discs.
003 376

003376

2 Assemble stator.

2.1 Install thrust washer (25) in stator.

2.2 Place stator and ball bearing (24) on a suitable


surface in the press.

2.3 Use special tool 1X56 137 152 to press in bearing


until it makes axial contact.

003 377

003377

2.4 Place support 1X56 137 152 in press with the


recess at the top.

2.5 Turn stator over and place on support 1X56 137


152.

2.6 Insert one-way clutch inner ring (28) into stator


with the longer collar at the bottom and press in.

NOTE
The support 1X56 137 152 ensures that the one-way
clutch inner ring is installed at the correct depth.

003 378
003378

2-52
HP 500 / 590 / 600 “long” version Torque converter

2.7 Insert rollers in stator.

NOTE
After inserting, lubricate rollers with transmission oil
and turn the stator several times.

2.8 Install thrust washer (29) in stator.

2.9 Install ball bearing (24).

003 379

003379

2.10 Place support 1X56 137 152 in press and lay stator
assembly on support with inserted ball bearing.

2.11 Place second support 1X56 137 152 on ball


bearing.

2.12 Press ball bearing into stator until it makes axial


contact.

NOTE
The recesses of the two supports 1X56 137 152 must
face towards the stator. These recesses ensure that the
bearing is installed at the correct depth.

003 380
003380

3 Clean spur gear and rub down sealing surface with


an oil stone.

4 Install housing washer (31) in spur gear.

CAUTION
The beveled edge of the housing washer must face
towards the spur gear.

5 Insert new O-ring (42).

6 Place new gasket (41) on sealing surface of spur


gear and align with bores. 41
003 381

003381

2-53
Torque converter HP 500 / 590 / 600 “long” version

7 Prepare bearing assembly for spur gear.

NOTE
The shaft disc (31) is marked ‘WS’ the housing
disc (33) is marked ‘GS’.

003 382

003382

8 Align pump gear with bores in spur gear.

9 Place pump gear on spur gear.

NOTE
In transmissions with PTOs, the spur gear and pump
gear are each located with two dowel pins. Drive in
dowel pins, if necessary.

10 Insert new Torx powerlock bolts (35) and tighten:


torque: 35 Nm

CAUTION
Always use new Torx powerlock bolts. The recesses of
the bolt head bores must be level. Countersink, if 003 351
003351
necessary.

11 Lay roller bearing (32) on housing washer “HW” in


pump gear.

12 Slide washer (30) (0.5 mm thick) over one-way


clutch ring and stick onto bearing inner race (24) in
stator using Vaseline.

13 Slide shaft washer (31) over one-way clutch with


bevel facing washer (30) and stick to stator using
Vaseline.

003 385

003385

2-54
HP 500 / 590 / 600 “long” version Torque converter

14 Insert stator assembly (26) in pump gear.

CAUTION
The longer collar of the one-way clutch inner ring must
point towards the pump gear. When installing the stator,
ensure that the one-way clutch inner ring and bearings
do not fall out of the stator.

003003386
386

15 Place support 1X56 137 152 on bearing of stator.

16 Drive stator and bearing assembly fully home. Do


this by gently tapping them with a plastic mallet.

003 387

003387

17 Prepare marked bearing assembly.

18 Place shaft washer (23) on stator.

19 Place roller bearing (22) on shaft washer.

20 Place housing washer (21) on roller bearing.

003 388
003388

2-55
Torque converter HP 500 / 590 / 600 “long” version

21 Measure and adjust end float of thrust bearing.

NOTE
Step 21.1 only applies to torque converter version
HP 500/590 (external diameter 430 mm)

21.1 Place new gasket (34) on sealing surface.

003389

21.2 Place measuring plates on sealing surface of pump


gear.

21.3 Attach measuring bar.

NOTE
The measuring bar must not rest on the stator.

21.4 Place depth gauge on measuring bar and measure


distance “A” from measuring bar to gasket attached
to sealing surface of pump gear. Note down
distance “A”.

NOTE
Torque converter version HP 590/600 (external diameter
003390
475 mm) with O-ring seal, does not have a gasket fitted.
Measure distance “A” without gasket.

21.5 Move depth gauge to the middle.

21.6 Measure distance “B” from measuring bar to end


face of housing washer (21) and note down
distance “B”.

21.7 Calculate distance “C”:


Distance “A” - distance “B” = distance “C”.

003391

2-56
HP 500 / 590 / 600 “long” version Torque converter

21.8 Place measuring apparatus on sealing surface of


circuit cover.

NOTE
Do not put a gasket on the sealing surface of the circuit
cover for this measurement.

21.9 Use depth gauge to measure distance “D” from


measuring bar to sealing surface of circuit cover.

21.10 Determine distance “E” between measuring bar


and contact surface of shim (arrow). Note down
distance “E”.

21.11 Calculate distance “F”: 003 392


003392
Distance “D” - distance “E” = distance “F”.

21.12 Calculate distance “G”:


Distance “C” - distance “F” = distance “G”.

21. 13 Calculate the required gauge “S” of the shim to


be installed, proceed as follows:
Distance “G” - distance “H” = shim gauge “S”.

Nominal end float of thrust bearing = between 0.1 and


0.3 mm (Average distance “H” = 0.2 mm)

Example calculation: G = 1.4 mm


– H = 0.2 mm
S = 1.2 mm

CAUTION
003393
The distances in the example calculation are only
theoretical.

Shims are available with the following gauges:


0630 000 219 = 1.0 mm
0630 004 152 = 1.2 mm
0630 004 154 = 1.4 mm
0630 004 156 = 1.6 mm
0630 004 158 = 1.8 mm
0630 004 127 = 2.0 mm
0730 000 982 = 2.2 mm

2-57
Torque converter HP 500 / 590 / 600 “long” version

22 Insert shim (20) (with previously determined


gauge) into turbine wheel.

23 Remove upper housing washer (21) from stator.

24 Insert housing washer (21) into turbine wheel


with the beveled edge facing the shim (arrow).

25 Remove roller bearing from stator and install in


turbine wheel.

003394

26 Remove stator assembly from pump gear.

27 Install stator in turbine wheel.

NOTE
The short collar of the one-way clutch inner ring must
point towards the turbine wheel.
Coat all bearings with transmission oil prior to
installation.

28 Remove shaft washer (31) from pump gear.

29 Place shaft washer on one-way clutch ring. The


beveled edge must face the stator.

003 395
003395

30 Remove roller bearing (32) from pump gear and


place on shaft washer (31) in stator.

003501

2-58
HP 500 / 590 / 600 “long” version Torque converter

Steps 31 to 35 only apply to torque converter version


HP 500/590 (external diameter 430 mm):

31 Place gasket (34) on circuit cover and align with


bores.

32 Screw two M8 threaded pins 1X56 136 821 into


opposite sides of the flange of the circuit cover.

003 396
003396

33 Place pump gear on circuit cover.

34 Unscrew threaded pins.

003397

35 Screw in M8x32 Allen screws (40) with washers


and tighten.
Torque: 35 Nm

40

003499

2-59
Torque converter HP 500 / 590 / 600 “long” version

Steps 35 to 41 only apply to torque converter version


HP 590/600 (external diameter 475 mm):
38
NOTE
– Service Info. No.: 06/95 –
note repair instructions for O-ring seal on pump gear.
Ensure that the O-ring groove has been worn into the
13
pump gear.

38 Pump gear 45
13 End disc
45 O-ring
4 Circuit cover
4
36 Place O-ring (45) on sealing surface of
005272
circuit cover (4).

37 Insert two M10 threaded pins into opposite sides of


the flange of the pump gear.

38 Place pump gear on circuit cover.

004288

39 Unscrew threaded pins.

CAUTION
Allen screws (3) are coated.
Always use new Allen screws (3).

40 Screw four M10x55 Allen screws (3) into opposite


sides and tighten by hand.

41 Turn converter over and place on two wooden 3


blocks. Screw in the remaining M10 Allen screws
(3) and tighten;
torque: 60 Nm

004289

2-60
HP 500 / 590 / 600 “long” version Torque converter

41 Check end float of one-way clutch inner ring (28).

41.1 Grasp inside of one-way clutch inner ring with both


hands and move in axial direction. End float must
be detectable.

003 398
003398

2-61
Torque converter HP 500 / 590 / 600 “long” version

4.3 Checking torque converter for leaks

NOTE
Preceding work; removing torque converter

8 17 2

6 1 3
5
4
9 003126

1 Compressed air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 137 130


2 Shut-off cock
3 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . set to max. 3 bar
4 Water tank
5 Torque converter assembly
6 Pressurizing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 137 129
7 Regulator
+0.5
8 Compressed air supply to converter . . . . . . . . . . . . . . . . . . . 2.5 bar
9 Retaining nut

2-62
HP 500 / 590 / 600 “long” version Torque converter

1 Insert pressurizing unit 1X56 137 129 in spur gear


side of converter.

2 Turn converter over.

! DANGER
The converter weighs approx. 60 kg. Two people are
required to turn it over and it must be secured to
prevent it falling.

003 343
003343

3 Screw retaining nut (9) into pressurizing unit.

003344

4 Lower converter into water tank using lifting tackle


and keep lowering until sealing surface between
pump gear and spur gear is underwater.

CAUTION
The water in the tank must be at a temperature of 20 °C
and be mixed with antifreeze in the ration 1:120.

5 Connect compressed air line to pressurizing unit


1X56 137 130.

003 127
003127

2-63
Torque converter HP 500 / 590 / 600 “long” version

6 Turn regulator (7) in counter-clockwise direction.

7 Open shut-off cock (2).


71 2
2
8 Set regulator (7) to 2.5 +0.5 bar using adjusting
wheel.

NOTE
The torque converter must be absolutely airtight.

003126

9 Close compressed air unit 1X56 137 130 and


remove pressurizing unit 1X56 137 129.

10 Raise converter out of water tank using lifting


tackle and place on work surface.

11 Unlock converter from lifting tackle and turn over.

! DANGER
The converter weighs approx. 60 kg. Two people are
required to turn it over and it must be secured to
prevent it falling.

12 Unscrew retaining nut (9).


003344

13 Lay converter on circuit cover and remove


pressurizing unit 1X56 137 129 from converter.

NOTE
Use compressed air to dry converter. Lightly lubricate
spur gear with transmission oil.

003 343
003343

2-64
HP 500 / 590 / 600 “long” version Cover plate

5 Removing and installing cover plate

NOTE
Preceding work; removing converter

7 8 9 3

6
5
4
16 10
14 15
2 13
1
12
11

31
1 2 30

24 25
22 23
18 26 27
24
29 23
20 25
27
28
17
27
21 29
19

19 20
003798

Diagram showing PTO gears.

2-65
Cover plate HP 500 / 590 / 600 “long” version

Special tools

1X56 122 227 1X56 136 605 1X56 136 815 1X56 136 850 1X56 137 382

* 1 M10x40 Allen screw with internal hex . . . . . . . . . . . . . . . . 32 Nm;


* 2 Clamping plate
* 3 Thrust washer
* 4 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
* 5 Shaft
* 6 Roller bearing
* 7 Drive gear
* 8 Circlip
* 9 Circlip
*10 Thrust washer
*11 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
*12 Shaft
*13 Roller bearing
*14 Drive gear
*15 Circlip
*16 Circlip
17 Radial seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, insert with detergent
*18 Oil pipe
*19 Banjo bolt with seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Nm; replace seal ring
20 Banjo bolt with seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Nm; replace seal ring
21 Oil pipe
*22 M8x40 Allen screw with internal hex . . . . . . . . . . . . . . . . . 23 Nm;
22 M8x35 Allen screw and seal ring . . . . . . . . . . . . . . . . . . . . 23 Nm; replace seal ring
*23 Lug
*24 Retainer
*25 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
26 M8x20 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
27 Seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
28 M8x85 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
29 M8x130 Allen screw with internal hex . . . . . . . . . . . . . . . . 23 Nm
30 Cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 136 815
31 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace

* only for version with PTO gears

2-66
HP 500 / 590 / 600 “long” version Cover plate

5.1 Removing cover plate

NOTE
Before removing the cover plate, swivel up transmission
and drain oil. Only remove oil pipe (21) if necessary.

1 Unscrew banjo bolts (20).

2 Remove banjo bolts with seal rings and oil pipe


(21) from cover plate.

003502

Steps 3 to 6 only apply for version with PTO


29 22
23
3 Unscrew Allen screw (22) with lug (23), retainer 24
(24) and O-ring (25). 23
24 25
4 Unscrew Allen screw (29) with lug (23), retainer
(24) and O-ring (25).

5 Unscrew banjo bolts (19).


25
6 Remove banjo bolts with seal rings and oil pipe
(18) from cover plate.
18
19
003503

7 Unscrew M8 hexagon bolts (26/28) with seal rings


from cover plate.

8 Unscrew M8 Allen screws (22/29) with seal rings.

003799

2-67
Cover plate HP 500 / 590 / 600 “long” version

Step 9 only applies for version with PTO

9 Unscrew Allen screw (1) and take off clamping


plates (2).
2

003504

10 Screw three threaded rods of puller 1X56 136 815


into M10x1 threaded bores.

003505

11 Place square bars of puller 1X56 136 815 on


threaded rods and screw on thumb nuts.

12 Extract cover plate by uniformly turning the thumb


nuts one after another.

13 Loosen and remove puller 1X56 136 815 from


cover plate.

003506

2-68
HP 500 / 590 / 600 “long” version Cover plate

14 Check shaft seal ring (17) for damage.

15 If necessary, force shaft seal ring out of cover plate


by pressing from behind.

003507

16 Remove O-ring (31) from cover plate.

003512

Steps 17 to 27 only apply to version with PTO

17 Remove O-rings (4/11) from shafts (5/12).

003800

2-69
Cover plate HP 500 / 590 / 600 “long” version

18 Screw threaded element 1X56 136 850 into shaft


(5) of drive gear (7).

19 Screw steady 1X56 122 227 onto threaded element


and pull out shaft.

20 Remove drive gear.

21 Shaft (12) of drive gear (14) is removed in the same


way.

22 Remove thrust washers (3/10).

003508

23 Remove inner bearing race (7a) and washer (7b)


from drive gear.

24 Remove circlip (9) from drive gear (7).

003509

25 Press out roller bearing (6) using suitable drift


press.

003510

2-70
HP 500 / 590 / 600 “long” version Torque converter

26 Remove circlip (8) from outer bearing race.

27 Drive gear (14) is dismantled in the same way.

003511

5.2 Installing cover plate

Steps 1 to 10 only apply to version with PTO

1 Install circlip (8) in outer bearing race.

003511

2 Press roller bearing (6) into drive gear using a


suitable drift press.

003510

2-71
Cover plate HP 500 / 590 / 600 “long” version

3 Insert inner bearing race (7a) and disc (7b) into


drive gear.

4 Install circlip (9).

5 Drive gear (14) is assembled in the same way.

003509

6 Attach thrust washers (3/10) and align centrally


with bearing bores.

7 Lie assembled drive gears (7/14) and roller bearing


on top of thrust washers.

NOTE
The circlips and disc must face towards the control
element.

8 Align drive gears centrally to bearing bores.

9 Heat inner bearing race to approx. 85 °C and drive


in shafts (5/12) with the threaded bore pointing
towards the drive end and continuing driving in
003800
until they are fully home.

10 Coat O-rings (4/11)with Vaseline and insert in


shafts.

11 Install new O-ring (31) in cover plate.

12 Thinly coat O-ring and sealing surface of cover


plate with Vaseline.

003512

2-72
HP 500 / 590 / 600 “long” version Torque converter

13 Screw stud bolts into control element to locate it


and insert cover plate in the correct radial position.

14 Drive cover plate fully home. Drive on by tapping


with a plastic mallet at evenly spaced intervals.

CAUTION
At each of the three screw bores with threads, the Allen
screws are subject to a special sealing combination
which takes the following order: new Cu seal ring,
washer, new Cu seal ring.

003505

15 Tighten fourteen M8x130 Allen screws (29) and


new Cu seal rings;
torque: 23 Nm

16 Tighten one M8x40 Allen screw (22) and new Cu


seal rings;
torque: 23 Nm

17 Tighten eight M8x85 hexagon bolts (28) and new


Cu seal rings;
torque: 23 Nm

18 Tighten eleven M8x20 hexagon bolts (26) and new


Cu seal rings;
torque: 23 Nm
003799

19 Insert oil pipe (21) with banjo bolts (20) and new
seal rings.

CAUTION
Insert one new Cu seal ring between banjo head and
connector in each banjo bolt connection.

20 Tighten banjo bolts;


torque: 18 Nm

003502

2-73
Cover plate HP 500 / 590 / 600 “long” version

Steps 21 to 24 only apply to version with PTO

21 Insert clamping plates (2) into intermediate gear


shafts and tighten M10x40 Allen screws (1);
torque: 32 Nm

NOTE
The beveled side must be at a tangent to the turbine
shaft.

003399

22 Install oil pipe (18) with banjo bolts (19) and new
seal rings. 29 22
23
24
CAUTION 23
Insert one new Cu seal ring between banjo head and
connector in each banjo bolt connection.
24 25

23 Insert Allen screws (22/29) each with a lug (23), 25


retainer (24) and O-ring (25) and tighten;
torque: 23 Nm

24 Tighten banjo bolts (19); 18


torque: 18 Nm 19
003503

25 Coat outer edge of shaft seal ring with lubricant.

NOTE
The lubricant used should be a water-soluble detergent
concentrate.

26 Pack sealing lip(s) with Vaseline.

27 Fit shaft seal ring on bore with sealing lip(s) facing


towards cover plate.

28 Drive in shaft seal ring until it is fully home. Use


attachment 1X56 136 605 (HP 500/590) or
attachment 1X56 137 382 (HP 590/600).

003513

2-74
HP 500 / 590 / 600 “long” version Oil pan

6 Removing and installing oil pan

NOTE
Preceding work; draining transmission oil

This description only applies to the standard version; different oil pan versions are also possible

13
13

11
11
10
10

55
66 12

99

7
3 2
1 1
2
004308
4 8

1 M8x60 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm


2 Washer (steel)
3 Washer (copper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
4 M8x80 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
5 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
6 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . clean, replace if necessary
7 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coat with Vaseline
8 Cover
9 Oil pan
10 Oil filler pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . installation depth 40 =1 mm; coat with sealing tape
11 Sealing tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
12 M30x1.5 grooved nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
13 Oil dipstick

2-75
Oil pan HP 500 / 590 / 600 “long” version

6.1 Removing oil pan

1 Unscrew four M8 hexagon bolts (4) and take off


with washers.

2 Take cover (8) off filter housing.

004304

3 Pull filter (6) off suction pipe.

004302

4 Unscrew thirty three M8 hexagon bolts (1) from


circumference of oil pan and remove with washers.

5 Take oil pan (9) and gasket off transmission. 1

004295

2-76
HP 500 / 590 / 600 “long” version Oil pan

NOTE
Only remove oil pipe, if necessary.

6 Loosen grooved nut (12) on oil filler pipe and


unscrew oil pipe (10).

10

12
004305

6.2 Installing oil pan

1 Screw M30x1.5 grooved nut (12) onto oil filler pipe


(10), do not tighten last thread. 11 12
2 Wrap sealing tape (11) around thread of oil filler
pipe (10).

3 Screw oil filler pipe (10) into transmission by


turning it a few revolutions and check installation
depth.
10

004306

NOTE
The installation depth of the oil filler pipe is measured
from the sealing surface of the transmission housing (oil
pan flanged surface) to the face end of the oil filler pipe
and should be 40 + 1 mm.

4 Adjust installation depth of oil filler pipe and tighten


grooved nut (12);
torque: 80 Nm.

004307

2-77
Oil pan HP 500 / 590 / 600 “long” version

5 Attach new gasket (5) to sealing surface.

004294

6 Place oil pan on transmission.

NOTE
The gasket must remain in the same position when the 1
oil pan is attached.

7 Tighten hexagon bolts (1) and washers;


torque: 23 Nm

CAUTION
Attach new Cu seal rings (2) to the two hexagon bolts
(arrow) to assist the sealing.

004295

8 Lightly coat O-ring in suction filter with Vaseline.

004296

2-78
HP 500 / 590 / 600 “long” version Oil pan

9 Slide suction filter (6) onto suction pipe until it


makes axial contact.

004302

10 Insert new O-ring (7) in cover (8).

11 Lightly coat O-ring with Vaseline.

004303

12 Place cover (8) on oil pan.

13 Tighten M8x80 hexagon bolts (4) and washers;


torque: 23 Nm

004304

2-79
Inductive sensor HP 500 / 590 / 600 “long” version

7 Removing and installing inductive sensor, determining installation depth

NOTE
Preceding work; removing oil pan

1
2

3
4

004291

1 M42x2 screw plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100 Nm


2 Inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm, between 0.6 and 0.8 mm play
3 Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gauges of 0.2 mm, between 3 and 0.6 mm
4 Cable connector

Special tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . measuring rod 1PO1 137 833

2-80
HP 500 / 590 / 600 “long” version Inductive sensor

7.1 Removing inductive sensor

1 Unscrew screw plug (1).

004298

2 Use flat pliers to pull two cable connectors (4) off


inductive sensor.

3 Unscrew inductive sensor (2) with socket wrench


attachment and extension.

2
4

004297

4 Remove inductive sensor (2) and shim(s) (3).

NOTE
Shim(s) may stick to retaining plate in transmission.
Remove shim(s) with care.

004301

2-81
Inductive sensor HP 500 / 590 / 600 “long” version

7.2 Installing inductive sensor; establishing set


distance

1 Attach small screwdriver to inductive sensor ring.

2 Rotate torque converter (arrow). At the same time,


use small screwdriver to locate the bulge on the
pulse generator ring.

3 Stop rotating output flange when one of these


bulges is located under the screw-in bore of the
inductive sensor.

003306

4 Push circlip (A) to approx. 5 mm from the end of


measuring rod 1PO1 137 833.

5 Insert measuring rod 1PO1 137 833 into bore of


inductive sensor until rod rests against bulge of
pulse generator ring.

NOTE
The highest point of the pulse generator ring should be
measured. The measuring rod must be at right angles to A
the threaded bore.

003307

CAUTION
When this measurement is taken, one of the bulges of
the pulse generator ring must be located directly below
the threaded bore for the inductive sensor. If a
5 6 7 8
measurement is taken at a deeper point of the impulse
sensor ring, the inductive sensor will be damaged by the
sensor ring bulges when the engine is started.

5 = Impulse sensor ring


6 = retaining plate
7 = circlip
8 = measuring rod 1PO1 137 833

001571

2-82
HP 500 / 590 / 600 “long” version Inductive sensor

6 Pull the measuring rod 1PO1 137 833.

7 Measure distance ”B” from end face of measuring


rod to circlip (7) and note down.

CAUTION
Circlip (7) must remain in the same position when the
measuring rod is pulled.

003303

8 Measure distance “C” from sensing face of


inductive sensor to contact surface of shim.

9 Subtract distance “B” from distance “C”.


C -B = D

10 Note down distance “D”.

003304

NOTE
Distance “A” must be between 0.6 and 0.8 mm.
Set distance “A” using relevant shim (3).
5 6 3 2
5 = impulse sensor ring
6 = retaining plate
2 = inductive sensor (speed sensor)
3 = shim

11 Calculate required shim gauge, as follows:

12 D + A = shim gauge “S”

A 001572

2-83
Inductive sensor HP 500 / 590 / 600 “long” version

Example calculation: Shims (3) are available in the following gauges:

B = 23 mm 0730 003 049 = 0.6 mm


C = 25 mm 0730 003 050 = 0.8 mm
A = 0.6 to 0.8 mm 0730 002 069 = 1.0 mm
0730 002 068 = 1.2 mm
D=C-B 0730 002 067 = 1.4 mm
D = 25 mm - 23 mm 0730 002 066 = 1.6 mm
D = 2 mm 0730 002 065 = 1.8 mm
0730 002 064 = 2.0 mm
S=D+A 0730 002 063 = 2.2 mm
S = 2 + 0,6 bis 0,8 mm 0730 002 062 = 2.4 mm
S = 2.6 to 2.8 mm 0730 002 061 = 2.6 mm
0730 003 299 = 2.8 mm
0730 003 300 = 3.0 mm
NOTE
The distances used in the example calculation are only
theoretical.

13 Screw in inductive sensor (2) with shim(s);


torque: 50 Nm

CAUTION
Do not exceed torque.

14 Connect cable connector (4) to inductive sensor. Do


not worry about the positive and negative pins on
the flat connector.
2
4

004297

15 Use Allen wrench to tighten M42x2 screw plugs (1);


torque: between 80 and 100 Nm

004298

2-84
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

8 Removing and installing hydraulic transmission control unit, dismantling and assembling
8.1 Removing and installing hydraulic transmission control unit

NOTE
Preceding work; removing oil pan, removing inductive sensor

2
2
3
3
4

3
1

7
6 5

8
9
003794

1 M8x35 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm; screw into recesses


2 M8x45 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
3 Washer
4 Transmission control unit
5 Lug
6 “Output inductive sensor” socket connection
7 Cannon connector
8 Washer
9 M8x28 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm

2-85
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

8.1.1 Removing hydraulic transmission control unit

1 Unscrew M8 hexagon bolts (9) and remove with


washers.

2 Push cannon connector (7) into transmission


housing.

003 462
003462

3 Use a screwdriver to snap plug connection out of


teeth and separate plug connection (6).

NOTE
If necessary, unfasten lug (5) and unscrew plug
connection until it disconnects from lug.

003 463

003463

4 Unscrew M8 hexagon bolts (1/2) and take out with


washers.

CAUTION 1
Do not loosen M6 hexagon bolts.

7 Take entire hydraulic transmission control unit (4)


out of transmission. In so doing, note the cable
connections.

! DANGER
Hydraulic transmission control unit weighs 18 kg.
Two people will have to lift it. In so doing, note that it
has sharp edges. 2
003515

2-86
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

8.1.2 Installing hydraulic transmission control unit

1 Insert hydraulic transmission control unit in


transmission.

NOTE
Cannon connector must slide into seat of transmission
housing. Locating nose of connector bush must face
towards input. Do not clamp cable to inductive sensor.

003462

2 Screw nine M8x45 hexagon bolts (2) and washers


into recesses, do not however tighten.

3 Screw in thirty M8x45 hexagon bolts (2) and 1


washers and tighten;
torque: 23 Nm
Tighten the hexagon bolts as is described in step 2;
torque: 23 Nm

NOTE
Tighten hexagon bolts starting from inside and working
outwards

2
003515

4 Connector plug connection (6) for inductive sensor.


Plug connection is encoded.

5 Align cannon connector (7) with bores.

6 Tighten M8x28 hexagon bolts (9) and washers;


torque: 23 Nm

003 463

003463

2-87
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

8.2 Dismantling and assembling hydraulic transmission control unit

Valve block “B”


5
5 6 7 8

Valve block “A”


11 22 3 4

30
9

29
10

004351

Special tools

1X56 137 151 1X56 137 156 1P01 137 173 1X56 150 111

2-88
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

13
12
11 13
12
14 14
17
13
15 16
17 18
19
22
32 20
24 23
25 21
32 26

30 27

31
28
29

003 801

003801

2-89
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

Valve block “A”:


1 Solenoid valve clutch “A”
2 Solenoid valve clutch “C”
3 Solenoid valve clutch “WK”
4 Solenoid valve brake “F”

Valve block “B”:


5 Solenoid valve clutch “B”
6 Solenoid valve brake “E”
7 Solenoid valve brake “D”
8 Solenoid valve brake “G”

11 Wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for damage


12 Clamp
13 Cable connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
14 M6x70 hexagon bolt with washer . . . . . . . . . . . . . . . . . . . . 9.5 Nm
15 Retaining plate for inductive sensor
16 Spacer ring
17 M6x60 hexagon bolt with washer . . . . . . . . . . . . . . . . . . . . 9.5 Nm
18 Cover plate
19 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
20 Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace if necessary
21 Valve block “A”
22 Cover plate
23 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
24 Retainer
25 Valve block “B”
26 Intermediate plate
27 Duct plate
28 Circlip
29 Converter safety valve
30 Throttle valve
31 M6x45 hexagon bolt with washer . . . . . . . . . . . . . . . . . . . . 9.5 Nm
*32 Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . item number: 4139 306 673

* Fitted as standard as of transmission no. 078844. If not fitted - fit four items.

2-90
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

8.2.1 Dismantling hydraulic transmission control


unit in sub-assemblies

1 Pull flat connector out of solenoid valves (1 to 8).

CAUTION
Observe the markings and assignment of the individual
cables to the solenoid valves. If necessary, mark the cable.

003 400

003400

2 Pull flat connector off solenoid switch on throttle


valve (arrow).

3 Unscrew clamp (12) from valve block.

003 401

003401

4 Remove ground/earth cable from solenoid valve.

003516

2-91
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

5 Unscrew ground/earth cable (arrow) from valve


block “A”.

6 Unscrew remaining clamps (12/24) from wiring


harness (11) and remove wiring harness.

003802

7 Remove retaining plate (15) and spacer ring (16).

003 402
003402

8 Turn over transmission control unit.

9 Unscrew hexagon bolts (31) and remove throttle


valve (30).

003803

2-92
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

10 Unscrew hexagon bolts (17).

11 Remove valve block “A” (21).

003403

12 Remove two solenoid washers (32).

NOTE
18
22
Fitted as standard as of transmission no. 078844.

13 Use plastic mallet to unfasten cover plate (18) from


valve block “A” and take off.

14 Remove gasket (19).


19
23
CAUTION
Do not prize off cover plate with peening tool, the
sealing surfaces may be damaged.
32
32
003805

15 Take valve ball (20) out of “WK” duct.

20

003 461

003461

2-93
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

16 Unscrew hexagon bolts (17) and remove valve


block “B” (25).
25 17

003404

17 Take off two solenoid washers (32).

NOTE
22
22
Fitted as standard as of transmission no. 078844.

18 Use plastic mallet to unfasten cover plate (22) and


take off valve block “B”.

19 Remove gasket (23).


23
23
CAUTION
Do not prize off cover plate with peening tool, the
sealing surfaces may be damaged.
32
32
004390

20 Take off intermediate plate (26).

26

003 407
003407

2-94
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

NOTE
Only remove converter safety valve (29), if necessary.

21 Use plastic mallet to drive converter safety valve


(29) into duct plate until circlip (28) is accessible.

22 Snap out circlip.

23 Take converter safety valve out of duct plate.

003405

8.2.2 Assembling hydraulic transmission control unit


in sub-assemblies

NOTE
Check duct plate for damage and replace if necessary.

1 Insert converter safety valve (29) in duct plate.

003406

2 Insert circlip (28) into converter safety valve.

3 Press in converter safety valve (29) and continue


doing so until circlip makes axial contact with duct
plate.

003505

2-95
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

4 Attach intermediate plate (26) on duct plate.

003 407
003407

5 Screw in threaded pins 1X56 150 111 as shown to


center the duct plate.

003 408

003408

6 Place valve block “A” (21) above threaded pins.

7 Insert valve ball (20) for ventilation valve in ”WK”


duct.

CAUTION
Check valve ball for wear. It must have a diameter of 5
mm. If necessary, replace valve ball.

003 461

003461

2-96
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

8 Attach new gasket (19) with printed side on top.


18
18
9 Place cover plate (18) on valve block.
oben
CAUTION
Printed wording “top” (arrow) must remain visible. The
cover plates must not be confused.

10 Attach two solenoid washers (32) on cover plate, as


19
19
shown.

NOTE
Solenoid washers (item no.: 4139 306 673) are fitted as 32
32
standard as of transmission no. 078844.
003806

CAUTION
If the solenoid washers are not fitted as volume
production, they must be fitted afterwards.
21 17
11 Unscrew threaded pins 1X56 150 111 and tighten
valve block “A” (21) and hexagon bolts (17);
torque: 9.5 Nm

003403

12 Screw threaded pins 1X56 150 111 into duct plate


to center valve block “B”. 22
22
13 Place valve block (21) on threaded pins.
oben

14 Attach new gasket (21) with printed side on top.

15 Place cover plate (22) on valve block. Printed


wording “top” (arrow) must remain visible. 23
23
16 Place two solenoid washers (32) on cover plate.

32
32
003806

2-97
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

NOTE
Solenoid washers (item no.: 4139 306 673) are fitted as
standard as of transmission no. 078844. 25 17 32
CAUTION
If the solenoid washers are not fitted as volume
production, they must be fitted afterwards.

17 Unscrew threaded pins 1X56 150 111 and tighten


valve block (25).
Torque: 9.5 Nm

003404

18 Tighten throttle valve (30) and six M6x45 hexagon


bolts and washers;
torque: 9.5 Nm

003803

19 Place two spacer rings (16) on valve blocks.

20 Attach retaining plate (15) for inductive sensor, as


shown.

003 402
003402

2-98
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

21 Screw wiring harness (11) and clamps (12/24) onto


valve blocks.
Torque: 9.5 Nm

22 Screw ground/earth cable (arrow) onto


valve block “A”;
torque: 9.5 Nm

003802

23 Screw on clamp (12) for inductive sensor line.

24 Set up screw connection (arrow) on throttle valve.

003 401

003401

25 Screw ground/earth cable to solenoid valve bars.


Torque: 5.5 Nm

003516

2-99
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

26 Set up screw connection on solenoid valves (1 to 6).

CAUTION
Note the markings and assignment of the individual
cables to the solenoid valves.

003 400

003400

2-100
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

8.3 Dismantling and assembling throttle valve

NOTE
Preceding work; dismantling hydraulic transmission control unit in sub-assemblies

6
1 5
2
3

9
14

10 15
12 16
13
11

17

003804

1 M5x16 Allen screw with internal hex . . . . . . . . . . . . . . . . . . 5.5 Nm


2 Washer
3 Shift solenoid
4 Piston
5 Washer
6 M6x18 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Nm
7 Cover
8 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
9 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace if necessary
10 Housing
11 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace if necessary
12 Ball
13 Piston
14 Piston
15 Piston
16 Cover
17 M6x18 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Nm

2-101
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

8.3.1 Dismantling throttle valve


6
1 Unscrew Allen screws (1) and remove shift
solenoid (3).

2 Unscrew hexagon bolts (6) and remove cover (7)


with gasket.

003807

3 Unscrew hexagon bolts (17) and remove cover (16).

003 413

003413

4 Remove ball (12) and pistons (13/14/15) from valve


housing.

003 411

003411

2-102
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

5 Remove piston (4).

003 412

003412

6 Clean filters (9/11), check and replace if necessary.

003 410

003410

8.3.2 Assembling throttle valve

1 Install ball (12) and pistons (13/14/15) in valve


housing.

003411

2-103
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

2 Install piston (4) in valve housing with bore facing


towards housing.

003 412

003412

3 Screw down cover (16) and two M6x18 hexagon


bolts (17);
torque: 9.5 Nm

003 413

003413

4 Insert shift solenoid (3) and screw down with two


M5x16 hexagon bolts (1); 6
torque: 5.5 Nm

5 Attach new gasket (8) and screw down cover (7)


with six M6x18 hexagon bolts (6);
torque: 9.5 Nm

003807

2-104
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

8.4 Dismantling and assembling valve block B

NOTE
Preceding work; dismantling hydraulic transmission control unit in sub-assemblies

1 9
2 10
11
5
4 6
3
16 (B) (E) (D) (G)
15 18 23 24 25
22
20 7 12
17 8
19 26
21
13
14
32 (G)
31 (D)
B E D G 30 (E)
27 29 (B) 35
28
36
33
34 38
37
39 37
38
003808

Special tools

1X56 137 151 1X56 137 156 1P01 137 173 1X56 150 111

2-105
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

1 Retainer
2 Cover plate
3 Washer
4 M6x18 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Nm
5 M6x65 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Nm
6 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
7 Compression spring
8 Vent piston
9 M5x12 Allen screw with internal hex . . . . . . . . . . . . . . . . . . 5.5 Nm
10 Washer
11 Solenoid valve
12 Valve strip
13 Ball
14 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, insert with Vaseline
15 Compression spring
16 Control piston
17 Pin
18 Washer
19 Circlip
20 Bush
21 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, insert with Vaseline
22 Orifice “B” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
23 Orifice “E“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
24 Orifice “D“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
25 Orifice “G“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
26 Housing
27 Piston
28 Stop ring
29 Compression spring “B” . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
30 Compression spring “E“ . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
31 Compression spring “D“ . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
32 Compression spring “G“ . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
34 Piston
35 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
36 Cover plate
37 Washer
38 M6x16 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Nm
39 Valve block “B”

2-106
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

8.4.1 Dismantling valve block B

1 Unscrew Allen screws (9) and take out solenoid


valves (11).

003 414

003414

2 Unscrew hexagon bolts (38).

NOTE
Leave one hexagon bolt (arrow) in the valve block.

3 Press cover plate (36) against the valve block and


unscrew hexagon bolt (arrow).

! DANGER
The cover plate is spring-loaded. Remove the cover
plate carefully.

4 Remove cover plate.


003 415
003415

5 Remove gasket (35).

003 416

003416

2-107
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

6 Pull pistons (34) out of valve block.

34 003809

7 Mark installation positions of compression springs


(29/30/31/32).

8 Remove compression springs from valve block.

CAUTION
Because of the risk of confusion, the compression
springs must be marked and stored with the
corresponding letter in accordance with their installation
position.

003417

9 Unscrew hexagon bolts (4/5).

NOTE
Leave one hexagon bolt (arrow) in the valve block.

! DANGER
The cover plate is spring-loaded.

003 418

003418

2-108
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

10 Press cover plate (2) against valve strip. Unscrew


hexagon bolt and remove plate with retainer (1).

! DANGER
The cover plate is spring-loaded. Remove the cover
plate carefully.

003 419

003419

11 Remove valve strip from valve block.

12 Remove gasket (6).

003 443

003443

13 Remove compression springs (7) of control piston.

14 Pull vent piston (8) with compression springs out of


valve block.

003 428

003428

2-109
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

15 Remove bush (20) and O-ring (19) from valve strip

16 Remove O-ring (14) from valve strip.


19
14
20

003853

17 Remove control pistons (16) from valve strip.

16

003420

18 Remove pistons (27) and stop rings (28) from valve


strip. 27

28

003 421
003421

2-110
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

8.4.2 Assembling valve block B


G D E B
NOTE
Check valve block for damage.
25 24 23 22
1 Check that orifices (22/23/24/25) are correctly
seated.

2 Check bore diameter of orifices using plug gauge


1PO1 137 173 and replace orifices if necessary.

003422
003 422

3 If necessary, use peening tool 1X56 137 156 to


knock out liners.

CAUTION
The peening tool must be ground off before removing
the orifices.

003 423

003423

4 Insert new orifices using peening tool


1X56 137 151.

NOTE
Peen orifices twice at right angles.

003 424 003424

2-111
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

5 Insert stop rings (28) into valve block with the


collars pointing downwards. G D E B
6 Push pistons (27) into valve block, as shown. 27
NOTE
The pistons may fall out when the valve block is turned 28
over.

003 425
003425

7 Insert pressure control pistons (16) in valve strip.

16

003420

8 Insert bushes (20) with collars facing the valve


strip.
19
9 Coat new O-rings (19) with Vaseline and insert in 14
bushes (20). 20
10 Coat new O-ring (14) with Vaseline and insert in
valve strip.

003853

2-112
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

11 Insert vent pistons (8), each with one compression


spring.

12 Insert compression springs (7) for control piston.

7
8 003 428

003428

13 Screw threaded pin 1X56 150 111 into valve block


and push on valve block until it makes axial
contact.

14 Place new gasket (6) on valve block.

003 429

003429

15 Attach cover plate (2) and press onto valve block.

16 Screw down cover plate with two M6x65 hexagon


bolts (5).

! DANGER
The cover plate is spring-loaded. The cover plate must
be secured until the hexagon bolts are screwed in.

17 Unscrew threaded pin.

003 430
003430

2-113
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

18 Install retainer (1) and tighten remaining hexagon


bolts (4/5);
torque: 9.5 Nm

003 431
003431

19 Insert marked compression springs (29/30/31/32)


into the corresponding piston bores.

CAUTION
The compression springs must not be confused.
Fractured springs must be replaced, refer to spare parts
catalogue.

29 30 31 32
B E D G
003417

NOTE
If a new compression spring is used, the wire diameter
(d), the length (L) and the coil diameter (D) of the
uncompressed spring must be measured. Compare these
measurements with the values specified in the
compression spring table. D

dd

L
L
004283

2-114
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

20 Insert piston (34).

34 003809

21 Fit new gasket (35).

003 416

003416

22 Attach cover plate (30), press onto valve block and


tighten one M6x16 hexagon bolt (arrow) by hand.

! DANGER
Cover plate is spring-loaded. The cover plate must be
secured until the hexagon bolt is screwed in.

23 Screw down cover plate (30) using the remaining


hexagon bolts (38);
torque: 9.5 Nm

30 003 415

003415

2-115
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

24 Insert solenoid valves (11) and screw down each


with two M5x12 Allen screws.
Torque: 5.5 Nm

003 414

003414

2-116
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

8.5 Dismantling and assembling valve block A

NOTE
Preceding work; dismantling hydraulic transmission control unit in sub-assemblies

1 2
3
4 A C WK
F
9
8
7
6
9 5
37
10 15 16
11 13 14
29 12
18 28
20 27
17
19 22 24
21 26
23
32

25 33
30 34
31 35

34 36
004348

Special tools

1X56 137 151 1X56 137 156 1P01 137 173 1X56 150 111

2-117
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

1 M6x16 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Nm


2 Washer
3 Cover plate
4 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
5 Compression spring “A” . . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
6 Compression spring “C” . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
7 Compression spring “WK” . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
8 Compression spring “F” . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
9 Piston
10 Stop ring
11 Piston
12 Housing
13 Orifice “A” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
14 Orifice “C” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
15 Orifice “WK” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
16 Orifice “F” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check, replace, if necessary
17 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, insert with Vaseline
18 Bush
19 Circlip
20 Washer
21 Pin
22 Control piston
23 Compression spring
24 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, insert with Vaseline
25 Ball
26 Valve strip
27 Solenoid valve
28 Washer
29 M5x12 Allen screw with internal hex . . . . . . . . . . . . . . . . . . 5.5 Nm
30 Vent piston
31 Compression spring
32 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
33 Cover plate
34 Washer
35 M6x65 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Nm
36 M6x18 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Nm
37 Valve block “A”

2-118
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

8.5.1 Dismantling valve block A

1 Unscrew Allen screws (29) and take out solenoid


valves (27).
F
WK
C
A

003432

2 Unscrew hexagon bolts (1).

NOTE
Leave one hexagon bolt (arrow) in valve block.

3 Press cover plate (3) against valve block and


unscrew hexagon bolt (arrow).

! DANGER
Cover plate is spring-loaded. Remove the cover plate
carefully.

4 Remove cover plate. 003 433

003433

5 Remove gasket (4).

003 434

003434

2-119
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

6 Pull pistons (9) out of valve block.

9 003809

7 Mark installed positions of compression springs


(5/6/7/8).

8 Remove compression springs from valve block.

CAUTION
Because of the risk of confusion, the compression
springs must be marked and stored with the corresponding
letter in accordance with their installation position.

8 7 6 5 003 435

F WK C A
003435

9 Unscrew hexagon bolts (35/36).

NOTE
Leave one hexagon bolt (arrow) in the valve block.

! DANGER
The cover plate is spring-loaded.

003 436

003436

2-120
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

10 Press cover plate (33) against valve strip and


unscrew hexagon bolt.

! DANGER
The cover plate is spring-loaded. Remove the cover
plate carefully.

003 437

003437

11 Remove valve strip from valve block.

12 Remove gasket (32).

003 442

003442

13 Remove compression springs (23) of control piston.

14 Pull vent piston (30) with compression springs out


of valve block.

003 438

003438

2-121
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

15 Remove bush (18) and O-ring (17) from valve strip.

16 Remove O-ring (24) from valve strip.


17
24
18

003853

17 Remove control pistons (22) from valve strip.

22

003 439
003439

18 Remove pistons (11) and stop rings (10) from valve


block. 11

10

003440
003 440

2-122
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

8.5.2 Assembling valve block A

NOTE A C WK F
Check valve block for damage. 13 14 15 16
1 Check that orifices (13/14/15/16) are correctly
seated.

2 Check bore diameter of orifices using plug gauge


1PO1 137 173 and replace orifices if necessary.

003 441
003441

3 If necessary, use peening tool 1X56 137 156 to


knock out liners.

CAUTION
The peening tool must be ground off before removing
the orifices.

003423

4 Insert new orifices using peening tool


1X56 137 151.

NOTE
Peen orifices twice at right angles.

003 424 003424

2-123
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

5 Insert stop rings (10) into valve block with the


collars pointing downwards. 11
6 Push pistons (11) into valve block, as shown.

10

003440

003 440

7 Insert pressure control piston assemblies (22) in


valve strip.

003 439
003439

8 Insert bushes (18) with collars facing the valve


strip.

9 Coat new O-rings (17) with Vaseline and insert in


bushes (18).

10 Coat new O-ring (24) with Vaseline and insert in


valve strip.

003853

2-124
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

11 Insert vent pistons (30), each with one compression


spring.

12 Insert compression springs (23) for control piston.

003 438

003438

13 Screw threaded pin 1X56 150 111 into valve block


and push on valve block until it makes axial
contact.

14 Place new gasket (32) on valve block.

003 446

003446

15 Attach cover plate (33) and press onto valve block.

16 Screw down cover plate with two M6x65 hexagon


bolts (35).

! DANGER
The cover plate is spring-loaded. The cover plate must
be secured until the hexagon bolts are screwed in.

17 Unscrew threaded pin.

003 447
003447

2-125
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

18 Tighten remaining hexagon bolts (35/36);


torque: 9.5 Nm

003 448

003448

NOTE
The pistons may fall out when the valve block is turned
over.

19 Insert marked compression springs (5/6/7/8) into


the corresponding piston bores.

CAUTION
The compression springs must not be confused.
Fractured springs must be replaced, refer to spare parts
catalogue.
8 7 6 5
F WK C A
003 459
003459

NOTE
If a new compression spring is used, the wire diameter
(d), the length (L) and the coil diameter (D) of the
uncompressed spring must be measured. Compare these
measurements with the values specified in the
compression spring table. D

dd

L
L
004283

2-126
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit

20 Insert piston (9).

9 003809

21 Fit new gasket (4).

4 003 416

003416

22 Attach cover plate (3), press onto valve block and


tighten one M6x16 hexagon bolt (arrow) by hand.

! DANGER
Cover plate is spring-loaded. The cover plates must
be secured until the hexagon bolt is screwed in.

23 Screw down cover plate (3) using the remaining


hexagon bolts (1);
torque: 9.5 Nm

003 433

003433

2-127
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version

24 Insert solenoid valves (27) and screw down each


with two M5x12 Allen screws.
Torque: 5.5 Nm 29
27
F
WK
A C

003432

2-128
HP 500 / 590 / 600 “long” version Retarder valve

9 Removing and installing retarder valve

NOTE
Preceding work; removing transmission control unit

CAUTION
New housing (as of volume production no.: 99196) must be fitted with new retarder valve. The new retarder valve
can also be installed in older housings.
Pistons from the new and old retarder valves must not be mixed during installation, never change individual items,
always the entire set.

8
7
6
4
3
1

20
5
2
18 19
17
16
15
13 14
12
10 11
9

003810

1 M8x55 hexagon bolt with washer . . . . . . . . . . . . . . . . . . . . . 23 Nm


2 M12x1.5 screw plug with seal ring . . . . . . . . . . . . . . . . . . . . compressed air connection
3 Solenoid valve
4 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, grease with transmission oil
5 M8x25 hexagon bolt with washer . . . . . . . . . . . . . . . . . . . . . 23 Nm
6 Cover
7 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, grease with transmission oil
8 Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3; 0.4; 0.5; 0.6; 0.8; 1.0 mm
9 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, grease with transmission oil
10 Bush
11 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, grease with transmission oil
12 Piston
13 Shim
14 Spring
15 Spring
16 Stop
17 Piston
18 Spring
19 Piston

2-129
Retarder valve HP 500 / 590 / 600 “long” version

9.1 Removing retarder valve

1 Remove solenoid valve (3) and take out O-ring (4).

003449
003 449

2 Remove cover (6), take out O-ring (7) and shims (8).

003450

3 Pull piston (12) out of valve housing.

4 Remove compression springs (14/15) from piston.

5 Remove shim (13).

003 451
003451

2-130
HP 500 / 590 / 600 “long” version Retarder valve

6 Screw threaded bolt or M18x1.5 screw into


stop (16).

7 Pull out stop (16) and bush (10) using threaded bolt
or screw.

003 452
003452

8 Press both pistons (17/19) out of valve housing.

003 453 003453

9 Remove piston (19) and compression spring (18)


from piston (17).

003 454

003454

2-131
Retarder valve HP 500 / 590 / 600 “long” version

9.2 Installing retarder valve

1 Install compression spring (18) and piston (19) in


piston (17).

003 454

003454

2 Insert assembled pistons (with piston (17) pointing


outwards) and compression springs into valve seat
until they reach the stop.

003455

3 Screw stop (6) onto screw or M18x1.5 threaded bolt


and push onto valve seat until it makes axial
contact.

4 Unscrew threaded bolt or screw.

003456
003 45

2-132
HP 500 / 590 / 600 “long” version Retarder valve

5 Push new O-ring (9) onto bush (10).

6 Push bush into valve housing until it makes axial


contact.

NOTE
The bores (arrow) in the bush must point vertically
upwards.

003 457

003457

7 The play between bush and cover must be between


0 and 0.1 mm. Adjust play as follows:

7.1 Attach depth gauge to end face of housing, as


shown, with measuring leg above the threaded
bores.

7.2 Press on bush (10) until it makes axial contact and


measure distance “A” to end face of bush.

003458

7.3 Place depth gauge on shoulder of cover and


measure distance “B” to flange.

7.4 Calculate distance “C” between bush and cover


Distance “C” = between 0 and 0.1 mm

Distance “C” = distance “A” - distance “B”

Shims (8) are available in the following gauges:


0730 004 295 = 0.3 mm B
0730 004 296 = 0.4 mm
0730 004 297 = 0.5 mm
0730 002 566 = 0.6 mm
0730 002 565 = 0.8 mm
0730 004 298 = 1.0 mm 001579
001579

2-133
Retarder valve HP 500 / 590 / 600 “long” version

8 Check seal ring (11) for damage. If necessary, cut


through old seal ring and push new seal ring onto
piston (12).

NOTE
Push on the seal ring with open side pointing towards
the piston crown.

9 Install shim (13) of same thickness as that removed


from piston.

10 Install compression springs (14/15) into piston and


insert assembly in valve housing.

003451

11 Coat new O-ring (7) with Vaseline and install in


cover.

12 Install shims (8) of gauge previously determined.

7
8

003464

13 Push cover into bore of valve housing.

14 Tighten M8x25 hexagon bolts (1);


torque: 23 Nm

003 465
003465

2-134
HP 500 / 590 / 600 “long” version Retarder valve

15 Coat new O-ring (4) with Vaseline and install in


solenoid valve.

003 466

003466

16 Tighten solenoid valve (3) using two M8x55


hexagon bolts (1);
torque: 23 Nm

003449
003 449
Output HP 500 / 590 / 600 “long” version

10 Removing and installing, dismantling and assembling output


10.1 Removing and installing “output speed” inductive sensor; establishing set distance
10.2 Removing and installing speedo connection piece; vent valve and screw plug
10.3 Removing and installing output flange
10.4 Removing and installing output end cover;
Measuring end float of sun gear shaft;
Setting disc play of brake G

Arrangement of sub-assembly:
output

003814

19 18 16
21 20

17
10
13
10 12

11

4
3
2 5
1 22 14 15

003 813 003813

2-136
HP 500 / 590 / 600 ”long” version Output

Special tools

1X56 136 260 1X56 136 471 1X56 137 213 1P01 137 833 1X56 100 632

1X56 137 357

1 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
2 Thrust needle bearing
3 Thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 -190 Nm
4 Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gauges: 1.15, 1.20, 1.50, 1.80 mm
5 Piston G
6 Lip-type seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, lubricate with transmission oil
7 Rectangular ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, lubricate with transmission oil
8 Output housing
9 Output flange
10 M22x1.5 screw plug and seal ring . . . . . . . . . . . . . . . . . . . . 60 Nm; replace seal ring; old version
11 Thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coat with transmission oil
12 M12 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
13 Locking plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 136 471
14 M10 hexagon bolt with washer . . . . . . . . . . . . . . . . . . . . . . . 46 Nm
15 Speedo connection piece and seal ring . . . . . . . . . . . . . . . . .replace seal ring, if nec., fit shaft seal ring
16 M6 hexagon nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm
17 Washer
18 Cover
19 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, grease with Vaseline
20 Inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm; play between 0.5 and 0.7 mm
21 Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grades of 0.2 mm between 3 and 0.6 mm
22 M18x1.5 screw plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm

2-137
Output HP 500 / 590 / 600 “long” version

10.1 Removing and installing “output” inductive


sensor; establishing set distance

1 Unscrew two M6 hexagon nuts (16) and take off


with washers.

2 Remove cover (18).

18
16

004352

3 Use pliers to remove cable connector.

5 Unscrew inductive sensor (20) with socket wrench


attachment.

6 Remove inductive sensor with shim(s).

CAUTION
Ensure that all remaining shims are removed from the
output end cover.

004353

7 Establish installation depth

7.1 Turn output flange until the teeth of the planetary


gears (23) are visible in the threaded bore.

004354

2-138
HP 500 / 590 / 600 “long” version Output

7.2 Establish specified distance ”a” (between 0.5 and


0.7 mm) between contact surface of inductive
sensor and face end of gear, proceed as follows:
8
8 = output end cover
20 = inductive sensor
21 = shim 23
23 = planet carrier gear

20

21
a
001566
005273

7.3 Push circlip to approx. 5 mm in front of face end of


measuring rod 1PO1 137 833.

m
5m

1P01 137 833

7.4 Feed measuring rod 1PO1 137 833 into bore of


inductive sensor until face end of measuring rod
stands on face side of gear.

NOTE
Measuring rod must be at right angles to gear.

7.5 Carefully pull out measuring rod.

NOTE
The circlip must not move.

004355

2-139
Output HP 500 / 590 / 600 ”long” version

7.6 Measure distance “b” between face end of


measuring rod and circlip.

003303

7.7 Measure distance “c” between contact surface of


inductive sensor and locating surface of shim.

7.8 Determine gauge “S” for shim.

Distance “c” - distance “b” = distance “d”

Distance “d” - distance “a” = gauge “S”

003304
003 304

NOTE
The distances used in the example calculation are Shims are available for installation in the following
theoretical. gauges:

Example calculation 0730 003 049 = 0.6 mm


0730 003 050 = 0.8 mm
b = 23 mm 0730 002 069 = 1.0 mm
c = 25 mm 0730 002 068 = 1.2 mm
a = 0.5 until 0.7 mm 0730 002 067 = 1.4 mm
0730 002 066 = 1.6 mm
d=c-b 0730 002 064 = 2.0 mm
d = 25 mm - 23 mm 0730 002 063 = 2.2 mm
d = 2 mm 0730 002 062 = 2.4 mm
0730 002 061 = 2.6 mm
S=d+a 0730 003 299 = 2.8 mm
S = 2 + 0.5 until 0.7 mm 0730 003 300 = 3.0 mm
S = 2.5 until 2.7 mm

2-140
HP 500 / 590 / 600 “long” version Output

8 Screw in inductive sensor (20) and shims;


torque: max. 50 Nm

20

004356

9 Use flat pliers to attach both cable connectors to


inductive sensor.

NOTE
The flat connectors can be attached in any way.

004357

10 Insert cover (18) and O-ring in bore.

NOTE
Lightly lubricate O-ring.

11 Screw on two M6 hexagon nuts (16) and washers;


torque: 6 Nm

18
16
004352

2-141
Output HP 500 / 590 / 600 “long” version

10.2 Removing and installing speedo connection


piece and screw plugs.

1 Unscrew speedo connection piece (15).


10
2 Only unscrew screw plugs (10/22) if necessary.

22 15
004 349
004349

NOTE
If leaks are detected on the speedo connection piece
(15), fit new shaft seal ring as follows:
second shaft seal rings can only be assembled in old
versions of the speedo connection piece.
15 a b c
3 Push cone (b) onto speedo shaft.

4 Coat external diameter of shaft seal ring (a) with


sealing compound.

5 Fill gap on reverse of sealing lip with grease.

6 Use attachment 1X56 100 632 (c) to push seal ring 001578

(sealing lip facing pinion) over cone and to drive it


into the speedo connection piece.
001578

7 Coat thread of speedo input (15) with oil.

8 Push new Cu seal ring onto speedo input.

9 Screw in speedo input;


torque 120 Nm 10
10 Check backlash of speedo pinion. The backlash
(between 0.1 and 0.2 mm) must be detectable by
hand.

11 Insert screw plug (10) and new seal ring;


torque: 50 Nm

12 Insert screw plug (22) and new seal ring;


torque: 50 Nm 22 15
004 349
004349

2-142
HP 500 / 590 / 600 “long” version Output

10.3 Removing and installing output flange

1 Use chisel to remove locking plate (13).

! DANGER
Wear protective glasses: risk from flying metal
splinters. 12

2 Unscrew two hexagon bolts (12).

NOTE 13
Counter output flange using flange retainer.
11

3 Loosen thrust washer (11) by gently tapping it with 003 312


003312
a plastic mallet and remove.

4 Attach puller 1X56 137 357 or three-arm puller.

5 Insert pressure piece and pull output flange (9) off


output shaft.

CAUTION
Never use puller or three-arm puller without a pressure
piece. Otherwise the thread in the output shaft may be
damaged.

NOTE
When pulling off output flange, counter it with a flange 9
retainer.
003 309
003309

6 Coat sealing surfaces of thrust washer (11) with


sealing compound and place on output flange.

NOTE
Beveled side of thrust washer must be facing outwards.

7 Screw in two M12 hexagon bolts (12); counter with


flange retainer, and tighten. 12
Torque: 60 Nm

13 11
003312

2-143
Output HP 500 / 590 / 600 “long” version

8 Place attachment 1X56 136 471 and new locking


plate (13) on hexagon bolts.

9 Drive locking plate onto hexagon bolts.

! DANGER
A surface with a sharp edge may be formed when
driving in the locking plate. Remove this surface with
a file.

13

003310
003 310

2-144
HP 500 / 590 / 600 “long” version Output

10.4 Installing and removing output end cover;


Measuring end float of sun gear
10.4.1 Removing output end cover

CAUTION
If the torque converter is removed, lifting device
1X56 137 213 must be screwed into the turbine shaft to
prevent it falling out.

003467
003 467

1 Use a chisel to remove locking plate (13).

! DANGER
Wear protective glasses: risk from flying metal
splinters.

2 Unscrew two hexagon bolts (12).

NOTE
To unscrew the two hexagon bolts, counter output flange
with flange retainer.

3 Remove thrust washer (11).

NOTE
004361
If necessary gently tap thrust washer with plastic mallet
to remove it.

4 Swivel transmission and output upwards.

5 Tightly screw lifting device 1X56 136 260 onto


output shaft. Unscrew all M10 hexagon bolts from 14
circumference of output end cover.

NOTE
Cable connector for inductive sensor must have been
pulled off.
Refer to Chapter 10.1, step 3 on page 2-138

003468

2-145
Output HP 500 / 590 / 600 “long” version

6 Grip output end cover with lifting tackle and


carefully lift off transmission.

CAUTION
When lifting off the output end cover, carefully guide
the cable for the inductive sensor through the housing
bore.

7 Remove gasket (1).

8 Remove lifting device 1X56 136 260.

004358

10.4.2 Measuring end float of sun gear.

1 Use three hexagon bolts to make axial contact with


intermediate housing.

CAUTION
Place washers underneath. The sealing surface must not
be damaged.

003517

2 Set up measuring apparatus on intermediate flange


with measuring plates and measuring rod.

3 Place thrust needle bearing and a thrust washer (3)


(1 mm gauge) on sun gear shaft.

4 Measure distance between measuring rod and thrust


washer on sun gear shaft = distance “A”.

003518

2-146
HP 500 / 590 / 600 “long” version Output

5 Measure distance between measuring rod and


mounting face (without gasket) = distance “M”.

6 Calculate theoretical distance “C” between


mounting face and thrust washer:
distance “M” - distance “A” = distance “C”

M
B

003519

7 Attach gasket to output end cover.

8 Place measuring rod on planet carrier III. Measure


distance between measuring rod and locating face
for shim = distance “B”.

9 Measure distance between measuring rod and


locating face of gasket = distance “Y0”
Y1 Y2
NOTE
Perform check measurements “Y1” and “Y2” and find
average value “Y0” finden.

Distance “Y1” + distance “Y2”: 2 = distance “Y0”

005218
10 Calculate gauge “X” of the shim required.

Distance “B” - distance “Y0” = distance “D”


Distance “D” - distance “C” = distance “E”
Distance “E” - (between 0.4 and 0.6 mm) = gauge ”X”
of the shim required

NOTE
End float of sun gear = between 0.4 and 0.6 mm.

2-147
Output HP 500 / 590 / 600 “long” version

Example calculation

NOTE
The distances in the example calculation are only
theoretical.

Distance “A” = 195.15 mm


Distance “M” = 199.95 mm
Distance “B” = 207.55 mm
Distance “Y1” = 200.00 mm
Distance “Y2” = 199.90 mm

Distance “M” = 199.95 mm


- Distance “A” = 195.15 mm
Distance “C” = 4.80 mm

Distance “Y1” = 200.00 mm


+ Distance “Y2” = 199.90 mm
399.90 mm : 2
Distance “Y0” = 199.95 mm

Distance “B” = 207.55 mm


- Distance “Y0” = 199.95 mm
Distance “D” = 7.60 mm

Distance “D” = 7.60 mm


- Distance “C” = 4.80 mm
Distance “E” = 2.80 mm

Distance “E” = 2.80 mm


- 0.4 until 0.6 mm

Distance “X” = 2.20 until 2.40 mm

The shim gauges must be between 2.2 and 2.4 mm


4
Shims are available in the following grades: 3
1.15, 1.20, 1.50, 1.80 mm 2
NOTE
Do not grind the shims.

11 Place shim(s) (of gauge established above)


(from out example calculation, two items, both of
1.15 mm) on thrust washer on sun gear shaft.

12 Unscrew the three hexagon bolts.

003568

2-148
HP 500 / 590 / 600 “long” version Output

10.4.3 Adjusting disc play of brake G

1 Move intermediate housing into axial contact using


three hexagon bolts.

CAUTION
Use washers. The sealing surface must not be damaged.

003517

2 Use depth gauge to measure from measuring rod to


end disc. Repeat measurement at several points
around the circumference and determine average
value, distance “A” and note this down.

NOTE
The end disc must be an outer disc.

004994

3 Use depth gauge to measure between measuring rod


and locating surface on intermediate housing. Note
down as distance “B”.

4 Calculate “C”:
Distance “A” - distance “B” = distance “C”.

003519

2-149
Output HP 500 / 590 / 600 “long” version

5 Place gasket (1) on output end cover.

6 Press on piston G until it makes axial contact.

7 Use depth gauge to measure from “piston G” to


gasket on output flange.
Note down as distance “D”.

8 Disc play = C - D

NOTE
The disc play of brake G depends on the friction
coefficient. The setting is made using outer discs of
various gauge sizes. Discs are available in the gradations
2 mm and 2.5 mm. For friction coefficient, see parts list
003 520003520
or spare parts catalogue.

Friction coefficient 12 14 16 18
Disc play: mm 2.8-3.3 3.2-3.7 3.2-3.7 3.6-4.1

2-150
HP 500 / 590 / 600 “long” version Output

10.4.4 Installing output end cover

NOTE
Before attaching the output end cover, ensure that brake 1
“G” has been installed correctly.

1 Place gasket (1) on intermediate housing.

004359

2 Tightly screw lifting device 1X56 136 260 onto


output shaft.

3 Grip output end cover with lifting device and place


above transmission and align with threaded pins.

004358

4 Slowly lower output end cover.

5 While lowering cover, cable (arrow) for inductive


sensor must be fed into bore of output end cover.

6 Complete lowering of output end cover and


disconnect lifting tackle.

CAUTION
While lowering output end cover, the planetary gears
must mesh in the gears of the disc carrier or the ring
gear and sun gear. You may have to turn the
transmission a little to do this. Do not damage cable for
inductive sensor.

004360

2-151
Output HP 500 / 590 / 600 “long” version

7 Insert six M10x65 pin bolts.


Torque: 13 Nm

8 Place M10 nuts with washers on the pin bolts.


14
9 Screw in fourteen M10x155 hexagon bolts and
washers.

10 Screw in two M 10x155 hexagon bolts and


washers.

11 Alternatively tighten the hexagon bolts and nuts


crosswise and place output end cover on
transmission.

003468
12 Tighten all hexagon bolts (14) and nuts.
Torque: 46 Nm

NOTE
Ensure that the two bolt bores (arrow) for the retainer of
the retarder accumulator are left free.
10
9 11 12
11 12

13 Unscrew lifting device 1X56 136 260.

14 Coat sealing surface of thrust washer (11) with


sealing compound and attach on output flange.

15 Tighten two M12x30 hexagon bolts (12). Counter


13
13
output flange with flange retainer; torque: 60 Nm

NOTE
Beveled side of thrust washer must be facing outwards.
003817

16 Attach attachment 1X56 136 471 to hexagon bolts


with new locking plate.

17 Drive on locking plate with hexagon bolts.

! DANGER
A surface with a sharp edge may be formed when
driving in the locking plate. Remove this surface with
a file.

NOTE
Adjust inductive sensor output:
refer to Chapter 10.1, page 2-138 13

003310

2-152
HP 500 / 590 / 600 “long” version Output

10.5 Dismantling and assembling output end cover

11

16 17
15
14 19
12
23

13 25
24
22
18 20 21

1
2

3
4
5
6
7

9
10

004 315 004315

2-153
Output HP 500 / 590 / 600 “long” version

Special tools

1X56 122 209 1X56 122 227 1X56 122 306 1X56 126 464 1X56 136 706

1P01 136 816 1X56 136 824 1X56 137 818 1X56 137 822

1 Shaft seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, coat with Vaseline


2 Tapered roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
3 Output end cover
4 Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gauges: 0.4, 0.6, 0.8, 0.9, 0.95, 1, 1.1, 1.2 mm
5 Speedo worm
6 Spacer bush
7 Tapered roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
8 Piston “G”
9 Rectangular ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, lubricate with transmission oil
10 Lip-type seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, lubricate with transmission oil
11 Thrust ring
12 Thrust washer or thrust plate
13 Planetary gear set
14 Roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
15 Bearing bolt
16 5x20 dowel pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
17 Thrust washer or thrust plate
18 Needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
19 Planet carriers III and IV
20 Thrust washer
21 Bearing bolt
22 5x20 dowel pin
23 Planetary gear set
24 Roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
25 Thrust washer

2-154
HP 500 / 590 / 600 “long” version Output

10.5.1 Dismantling output end cover

1 Place output end cover in press and place blocks


under it so that the planet carrier cannot be pressed
out.

! DANGER
Do not put fingers under planet carrier to lift it.

2 Press planet carrier out of output end cover.

CAUTION
Place soft material under planet carrier.
003527

3 Place output cover on wooden blocks.

4 Grip piston G (8) with pliers and drive out of output


end cover with even blows from plastic mallet.
8
NOTE
All piston Gs on the circumference are driven out in the
same way.

005401
005401

5 Press shaft seal ring out of output end cover.

NOTE
To ease the installation of the shaft seal ring, drive it
deeper into one side than the other and then prize out
using pry bars.
1

003528

2-155
Output HP 500 / 590 / 600 “long” version

6 Remove tapered roller bearing (2) from output end


cover.
2

NOTE
003529
Only remove outer bearing races, if necessary

7 Use hot air blower 1X56 136 513 to heat output end
cover to approx. 85 °C.

! DANGER
Output end cover is hot, only handle if wearing
protective gloves.

8 Drive out both outer bearing races (2a/7a) using a 2a / 7a


plastic mandrel.

NOTE
Always insert the plastic mandrel in the grooves
(arrows). Drive out the outer bearing race on the drive
side from the output side and the outer bearing race on
003530
the output side from the drive side.

9 Remove shim (4) from speedo worm (5).


4

003531

2-156
HP 500 / 590 / 600 “long” version Output

10 Fit puller 1X56 126 464 on speedo worm.

CAUTION
Do not damage the thread of the speedo worm when
fitting the puller.

11 Fit two-arm puller into recesses in rear of puller.

CAUTION
Attach pressure piece to face end of output shaft.

12 Pull speedo worm off output shaft.

003532

13 Pull spacer bush (6) off output shaft.

003533

NOTE
Only remove tapered roller bearing if necessary.

14 Push grip (b) 1X56 136 706 onto inner bearing


race.
a
15 Use threaded ring on grip to move pulling edge
until the pulling ring grips the tapered roller bearing
from behind.

16 Screw basic unit (a) 1X56 122 306 onto grip (b)
1X56 136 706. b
17 Pull off inner race (7) of tapered roller bearing.

003534

2-157
HP 500 / 590 / 600 “long” version Output

18 Remove thrust ring (11) from planet carrier.

11

003535

CAUTION
Only remove needle bearing if necessary. The bearing
should be destroyed once removed.

19 Insert internal extractor 1X56 122 209 into bearing


bore and grip needle bearing from behind.

20 Screw steady 1X56 122 227 onto internal extractor.

21 Pull needle bearing (18) out of planet carrier. 18


18

003536

22 Release planet gear shafts (15/21) To do this,


carefully drive dowel pins (16/22)into the center of
the planet gear shafts.

CAUTION
Never drive the dowel pins in as far as their stops.

003540

2-158
HP 500 / 590 / 600 “long” version Output

23 Drive out planet gear shafts (15).


16 17
24 Remove planet gears (13), roller bearings (14) and 15
14
thrust washers (12/17) from planet carrier. 19
12
25 Drive dowel pins (16) out of planet gear shafts.

13

18
003819

26 Drive out planet gear shafts (21).

27 Remove planet gears (23), roller bearings (24) and


thrust washers (20/25) from planet carrier.
19
29 Drive dowel pins (22) out of planet gear shafts.
23

25
24
22
20 21
003820

2-159
HP 500 / 590 / 600 “long” version Output

10.5.2 Assembling output end cover

1 Insert outer lip-type seal ring (10) in piston G with


8
its sealing lip facing the pressure side.
9
2 Insert inner rectangular ring (9).
10
NOTE
Stretch inner rectangular ring (9) before installation so
that it snugly fits the base of the groove.

3 Insert piston G (8) in output end cover.

NOTE
005401
Piston G must make axial contact and must slide in 005401
easily.

4 Use attachment 1X56 137 822 to drive new needle


bearing (18) into planet carrier. 1
18
NOTE
When using attachment 1X56 137 822, the installation
depth is always specified. Fit attachment to bearing side
with reinforced casing. Lubricate needle bearing with
transmission oil.

19

003819

5 Secure needle bearing so that it cannot move


axially. To do this, use peening tool 1X56 137 822
to peen the collar on the planet carrier (displaced by
120 °C three times).

CAUTION
During the peening process, collar of planet carrier must
not cur in or become dislodged.

004366

2-160
HP 500 / 590 / 600 “long” version Output

NOTE
Grease bearing bore of planet gears and roller bearing
with Vaseline before installation.
19
6 Insert roller bearing (24) in planet gears (23).

CAUTION 23
Always replace planet gears as sets.

7 Push planet gears (28), roller bearings and thrust


25
washers into planet carrier (19) and align centrally 24
with shaft bores.
22
20 21
8 Align bores for dowel pins and push in planet gear
shafts (21) until they make axial contact.
003820

9 Drive in new dowel pins (22) on planet carrier until


they are flush and secure by peening.

003540

10 Install planet gear set III as was described in


steps 6 to 8. 16 17
15
14
19
12

13

18
003819

2-161
Output HP 500 / 590 / 600 “long” version

11 Measure end float of planet gears between thrust


washer (thrust plate) and planet carrier.

NOTE
The end float must be between 0.5 and 1.2 mm.
Take measurement on all planet gears.

003548

12 Adjust tapered roller bearings (2/7).

12.1 Clamp adjuster 1PO1 136 816 in vice.

NOTE
Both tapered roller bearings must be washed and thinly
lubricated with transmission oil. a
12.2 Push inner race (7) of tapered roller bearing onto 6
drive side on adjuster. 7
12.3 Beforehand drive dowel pins (arrow) out of
adjuster ring by at least 5 mm.

12.4 Push spacer bush (6) and adjuster ring (a) onto
003550
adjuster 1PO1 136 816.

CAUTION
The dowel pins (arrow) must point upwards.

12.5 Use hot air blower 1X56 136 513 to heat output
end cover to approx. 85 °C. 7a
12.6 Insert outer bearing race (7a) on drive side into
output end cover (ensuring that the wider collar is
facing upwards) and use attachment
1X56 136 513 to drive in until fully home.

! DANGER
Only handle heated output end cover when wearing
protective gloves.
003551

2-162
HP 500 / 590 / 600 “long” version Output

12.7 Turn over output end cover.

12.8 Insert outer bearing race (2a) on output side into


output end cover as is described in step 9.6.

CAUTION
The output end cover must not be allowed to cool
below 85 °C.
2a

003552

12.9 Lay output end cover on adjuster 1PO1 136 816;


the output end cover must make axial contact.

12.10 Insert inner race (2) of tapered roller bearing on


output side until it makes axial contact.

2
003553

12.11 Attach washer of adjuster with recess facing


towards adjuster.

12.12 Screw in M12 hexagon bolt until it makes axial


contact.

NOTE
During the following adjustment procedure, the parts on
the adjuster must be at a temperature of approx. 20 °C.

003554

2-163
Output HP 500 / 590 / 600 “long” version

12.13 Wind a cord several times around neck (arrow) of


output end cover and hook into spring balance.

12.14 Pull evenly on the spring balance to start the


output end cover turning. The pulling force when
the output end cover is turning must be between 8
and 10 N.

CAUTION
- If the pulling force is less than 8 N, the hexagon bolts
must be tightened and set to provide a pulling force of
between 8 and 10 N.
- If the pulling force is greater than 10 N, the adjusting
device must be prepared again from the start for
another measurement.
003555

12.15 After adjusting, unscrew hexagon bolt and


remove washer.

12.16 Remove output end cover from adjuster.

CAUTION
Do not displace the dowel pins when unscrewing the
hexagon bolt.

003554

12.17 Remove adjuster ring.

12.18 Lay adjuster ring on flat surface with dowel pins


at bottom.

12.19 Use depth gauge to measure distance “A”


between end face of adjuster ring and end face of
dowel pin.

NOTE
Repeat measurement at several points and determine
average value.

003556

2-164
HP 500 / 590 / 600 “long” version Output

12.20 Measure width of speedo worm (distance “B”)


using a micrometer and note distance down.

12.21 Distance “A” minus distance “B” gives you


distance “C”.

Calculate required gauge “S” of shim to be installed,


proceed as follows:

S = C + 0.05 mm + (between 0.02 and 0.07 mm)


0.05 mm = constant overmeasure factor
between 0.02 and 0.07 mm = nominal end float

003557

12.22 Check calculated gauge of shim to be installed


using a micrometer.

Shims are available in the following gauges:

0730 103 586 = 1.20 mm


0730 103 587 = 1.10 mm
0730 106 668 = 1.05 mm
0730 103 588 = 1.00 mm
0730 106 667 = 0.95 mm
0730 106 666 = 0.90 mm
0730 103 589 = 0.80 mm
0730 103 590 = 0.60 mm
0730 103 591 = 0.40 mm

003558

13 Use hot air blower 1X56 136 513 to heat inner


race (7) of tapered roller bearing on drive side to
approx. 140 °C and press onto output shaft until it
makes axial contact.

CAUTION
Do not strike the rollers. Drive tapered roller barring 66
fully home after it has cooled.

14 Push spacer bush (6) onto output shaft. 77

003559

2-165
Output HP 500 / 590 / 600 “long” version

15 Use hot air blower 1X56 136 513 to heat speedo


worn (5) to approx. 140 °C and push onto drive
shaft.
5
CAUTION
Collar of speedo worm must face the output.

003560

16 Once cool, use attachment 1X56 136 824 to press


on inner bearing race (7), spacer bush (6) and
speedo work (5) until they make axial contact and
there is no play.

7 5
6

003 560
003561

17 Fit shim (4) (of gauge previously determined).


4

003531

2-166
HP 500 / 590 / 600 “long” version Output

18 Place thrust washer (11) on planet carrier with


collar (arrow) at top.

11

003562

19 Fit output cover end on planet carrier.

20 Use hot air blower 1X56 136 513 to heat output 2


side of inner bearing race (2) to approx. 140 °C.

21 Insert inner bearing race in output end cover until it


makes axial contact.

003563
22 Coat circumference of shaft seal ring (1) with
detergent.

23 Push shaft seal ring onto attachment 1X56 136 824


with the sealing lip pointing towards the output end.

24 Use attachment 1X56 136 824 to press shaft seal


ring into output end cover.

NOTE
The use of attachment 1X56 136 824 ensures that seal
ring is installed at the correct installation depth of 1
15 -1 mm between face end of inner bearing race and
face end of seal ring.

CAUTION
Coat sealing and dust lips of shaft seal ring with Vaseline.
003564

2-167
Output HP 500 / 590 / 600 “long” version

NOTE
If necessary, attach hexagon bolts before assembly.

25 Use hot air blower to heat output flange to approx.


140 °C.

26 Press output flange onto output shaft until it makes


axial contact.

NOTE
If the output flange cannot be pressed fully home at the
temperature specified, place the planet carrier on
support 1X56 137 154 and use a drift press to press on
the output flange until it makes axial contact.

003565
27 Fit lifting device 1X56 136 260 with two hexagon
bolts and tighten to 60 Nm.

2-168
HP 500 / 590 / 600 “long” version Intermediate housing

11 Removing and installing intermediate housing

NOTE
Preceding work; removing output end cover

67 8 15
5
4
1 2 3
13

10 11 12
9

14

14

16
17 24
22
21 23
20
19
18 22

23
22

003821

2-169
Intermediate housing HP 500 / 590 / 600 “long” version

Arrangement of sub-assembly:
intermediate housing

004365

1 Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gauges: 1.8, 1.6, 1.4, 1.2, 1 mm


2 Angle ring
3 Split ring
4 Inner ring
5 Sun gear shaft
6 Thrust needle bearing
7 Thrust washer
8 Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gauges: 1.15, 1.2, 1.5, 1.8 mm
9 Piston F
10 Lip-type seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, lubricate with transmission oil
11 Rectangular ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, lubricate with transmission oil
12 Rectangular ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, lubricate with transmission oil
13 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
14 16x40 dowel pin
15 Intermediate housing
16 Seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
17 Screw plug
18 Guide pin
19 Spring
20 Tube
21 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration; gauge 2, 2.5, 3 mm
22 Inner disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check lining, lubricate with transmission oil
24 Ring gear

2-170
HP 500 / 590 / 600 “long” version Intermediate housing

11.1 Removing intermediate housing

1 Remove thrust needle bearing (6), thrust washer (7) 8


and shims (8) from sun gear shaft.
7
6

003568

2 Remove ring gear (24) from intermediate housing.


24

003569

3 Remove guide pin (21), compression spring (19)


and tube (20).
21
19
20

003570

2-171
Intermediate housing HP 500 / 590 / 600 “long” version

4 Remove entire disc assembly.

NOTE
Mark the order of the discs and tie together.

003571

5 Remove three outer discs (22) last.

22

005399

6 Pull guide pins (18) out of housing bores.

18

003573

2-172
HP 500 / 590 / 600 “long” version Intermediate housing

7 Pull sun gear shaft (5) and inner ring (4) out of
gearing on sun gear.
5

003574

8 Remove split ring (3), angle ring (2) and shim (1)
from sun gear.

33
2
21
1

003575

9 Loosen intermediate housing (15) by tapping gently


and evenly around the entire circumference and
remove.

CAUTION 15
Carefully guide cable for inductive sensor through
housing bore.

13
003576

2-173
Intermediate housing HP 500 / 590 / 600 “long” version

10 Remove piston F (9) from intermediate housing.


9

003577

11 Remove lip-type seal ring (10) and rectangular


rings (11/12) from piston.

12

10 11
003578

2-174
HP 500 / 590 / 600 “long” version Intermediate housing

11.2 Adjusting end float of sun gear

1 Insert sun gear shaft (5), inner ring (4), split ring (3) 5
and angle ring (2) into sun gear but do not insert
shim (1).

003574

2 Measure distance “A” from end face of sun gear


shaft to contact face of sun gear.

3 Pull sun gear up until it makes axial contact with


sun gear shaft and measure distance “B” from end
face of sun gear shaft to contact face of sun gear.

4 Distance “A” - distance “B” must equal between 0.4


and 0.6 mm.
End float of sun gear = between 0.4 and 0.6 mm

5 Correct difference with shim (1) and repeat


measurement.

Shims are available in the following gauges:

0730 105 596 = 1.80 mm


0730 105 597 = 1.60 mm
0730 105 598 = 1.40 mm
0730 105 599 = 1.20 mm
0730 105 600 = 1.00 mm

6 Place shim (1) (of gauge just determined) on sun


gear and insert sun gear shaft. 003822
003822

2-175
Intermediate housing HP 500 / 590 / 600 “long” version

11.3 Adjusting disc play of brake F

1 Place gasket (13) on sealing surface of housing.

NOTE
The end disc must be an outer disc.

2 Use depth gauge to measure from measuring rod to


end disc (22). Repeat measurement at several points
around the circumference and note down the
average value as distance “A”.

003815

3 Use depth gauge to measure from measuring rod to


gasket. Note down as distance ”B”.

4 A-B=C Note down distance “C”.

003816

5 Insert piston F into intermediate housing without


lip-type and rectangular rings.

6 Use depth gauge to measure from “piston F” to


sealing surface of intermediate housing (without
gasket). Note down as distance “D”.

7 Disc play = C - D
Disc play must be between 3.2 and 3.7 mm
Adjustment is made using outer discs. Discs are
available in the following gauges:
2 mm 2.5 mm 3 mm

CAUTION
The last outer disc of piston F has wider teeth and must
not be used for play compensation.
003579

2-176
HP 500 / 590 / 600 “long” version Intermediate housing

11.4 Installing intermediate housing

1 Coat the lip-type seal ring (10) and rectangular


rings (11/12) with Vaseline and insert into relevant
groove in piston.

NOTE
The sealing lip on the outer lip-type seal ring (10) must 12
be facing the pressure side.
Stretch the inner rectangular ring (12) before installing
so that it lies snugly in the base of the groove.

10 11
003578

2 Install piston F in intermediate housing.


9
NOTE
Piston F must make axial contact and must slide in
easily.

003577

3 Fit new gasket (13) on transmission housing.

NOTE
Install dowel pin (14) in transmission housing, if 15
removed.

CAUTION
Carefully guide cable for inductive sensor through
housing bore (arrow).

4 Place intermediate housing (15) above dowel pin


(14) on transmission housing and drive on using a
plastic mallet. 13
003576

2-177
Intermediate housing HP 500 / 590 / 600 “long” version

5 Insert three hexagon bolts (25) and tighten


alternately until axial contact is made.
25
CAUTION
Insert discs under them. The sealing surface must not be
damaged.

003580

6 Insert guide pins (18) into housing bores.

18

003573

7 Insert ring gear (24).

24

003569

2-178
HP 500 / 590 / 600 “long” version Intermediate housing

NOTE
Check outer and inner discs for wear. Use a straight-
edge to check that all discs are flat. Uneven, dished and 22
damaged discs must be replaced.

8 Install three outer discs (22) by slipping bores over


guide pins.

005399

9 Insert alternately one inner and one outer disc.

NOTE
Install outer discs so that the recesses lie over the guide
pins.

003571

NOTE
For the number of inner and outer discs required, please
refer to the relevant spare parts catalogue.

The outer discs are available with the gauges


2 and 2.5 mm

NOTE 22 23
Adjust the disc play of brake G; refer to Chapter 10.4.3,
page 2-149
22

003829

2-179 2-179
Intermediate housing HP 500 / 590 / 600 “long” version

10 Install tube (20), compression spring (19) and guide


pins (21) on lower guide pins in recesses of discs.
21
19
20

003570

11 Place thrust needle bearing (6), thrust washer (7)


and shims (8) (of gauge previously determined) on 8
sun gear shaft.
7
6

003568

2-180
HP 500 / 590 / 600 “long” version Mechanical transmission part

12 Removing and installing, dismantling and assembling mechanical transmission part.

NOTE
Preceding work; removing output end cover and intermediate housing
Diagram: transmission version - HP 500 / HP 590

2
4

003839

1 Brake D 6 Planet carrier I


2 Drive shaft 7 Piston F
*3 Quill shaft 8 Planet carrier II
4 Disc carrier 9 Sun gear
5 Brake E * only in transmission version with clutch C

2-181
Mechanical transmission part HP 500 / 590 / 600 “long” version

Sub-assembly arrangement:
planet carriers I and II

003840

Special tools

1X56 097 775 1X56 122 205 1X56 122 227 1X56 136 612 1X56 136 821

1X56 137 101 1X56 137 387 1X56 137 388 1X56 137 464 1X56 137 465

2-182
HP 500 / 590 / 600 “long” version Mechanical transmission part

12.1 Removing, dismantling and assembling planet carriers II and I, brakes F and E

NOTE
Diagram: transmission version HP 600

10 11
9
8
7

2 5
4
2
1

20
18
19
6 18
3
17
15
13 14 16 21
12
10

30
29
28
27
26 33
25 32
31
24
23
22

003823

2-183
Mechanical transmission part HP 500 / 590 / 600 “long” version

1 Planet gear shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 137 464, 1X56 137 465
2 Thrust plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . two parts needed, 1 mm and 2 mm
3 Thrust washer
4 Needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
5 Planet carrier I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 097 775
6 Planet gear
7 Circlip
8 Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 137 387, 1X57 137 388
9 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
10 Inner disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check lining, lubricate with transmission oil
11 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
12 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
13 Thrust ring
14 Ring gear
15 Circlip
16 Thrust washer
17 Planet carrier II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 1097 775
18 Thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . two parts needed
19 Needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
20 Planet gear shaft
21 Planet gear set
22 Circlip
23 Ring gear
24 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
25 Inner disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check lining, lubricate with transmission oil
26 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
27 Pin
28 Spring
29 Guide tube
30 Pin
31 Thrust washer
32 Sun gear
33 Thrust washer

2-184
HP 500 / 590 / 600 “long” version Mechanical transmission part

12.1.1 Removing planet carriers II and I, brakes F


and E

1 Remove cable (36) for inductive sensor from trans-


mission.

003698

2 Pull sun gear (32) with thrust washer (33) off drive
shaft.

003699

3 Pull thrust washer (31) off drive shaft.

NOTE
The thrust washer may be stuck to the back of the sun
gear.

003842

2-185
Mechanical transmission part HP 500 / 590 / 600 “long” version

NOTE
Steps 4 to 13 only apply to version HP 500 / HP 590

4 Grasp planet carrier II (17) with assembly hooks


1X57 097 775 and lift out of transmission.

! DANGER
Secure planet carrier so that it cannot tilt.
Planet carrier is unstable when suspended by hooks.

003700

5 Remove disc assembly of brake F from


transmission.

NOTE
Mark disc assemblies for identification. The discs of the
various assemblies must not be confused.

003844

6 Remove thrust washer (16) from transmission.

NOTE
The thrust washer may be stuck on the back of planet
carrier II.

003701

2-186
HP 500 / 590 / 600 “long” version Mechanical transmission part

7 Remove compression springs (28) with pins (30)


and guide tubes (29) from transmission.

NOTE
The pins (27) are removed together with the last discs
(refer to step 13).

003848

8 Grasp planet carrier I (5) with assembly hooks


1X57 097 775 and lift out of transmission.

! DANGER
Secure planet carrier so that it cannot tilt.
Planet carrier is unstable when suspended by hooks.

003702

9 Remove thrust washer (3) from transmission.

NOTE
The thrust washer may be stuck on the back of planet
carrier I.

003703

2-187
Mechanical transmission part HP 500 / 590 / 600 “long” version

10 Turn thrust ring (13) until the teeth of the thrust


ring are between the gaps in the gearing and the
transmission housing.

11 Remove thrust washer from transmission.

003704

12 Remove disc assembly from transmission.

NOTE
The disc assembly must be marked for identification.
The discs of the various assemblies must not be
confused.

004924

13 Remove centering pins (27) and the last disc.

NOTE
The centering pin must not be dropped into the trans-
mission.

003705

2-188
HP 500 / 590 / 600 “long” version Mechanical transmission part

12.1.2 Removing planet carriers II and I;


version HP 600

1 Lift disc assembly of brake F out of transmission


housing using assembly hooks 1X56 097 775.

2 Remove last outer disc from transmission housing.

NOTE
Wire the disc assembly together and mark for identifica-
tion. The discs of the various assemblies must not be
confused.

004989

3 Remove compression springs (28) with pins (30)


and guide tubes (29) from transmission.

003707

4 Screw guide bolts 1X56 136 821 into


thrust ring (13).

5 Turn thrust ring in radial direction until the teeth of


the thrust ring are between the gaps in the gearing
and the transmission housing.

6 Remove thrust ring from transmission housing.

003788

2-189
Mechanical transmission part HP 500 / 590 / 600 “long” version

7 Screw hooks 1X56 136 612 into planet carrier II


and lift planet carriers II and I out of transmission
together with the discs of brake E.

003709

8 Remove disc assembly from planet carrier.

NOTE
Wire disc assembly together and mark for identificati-
on. The discs of the various assemblies must not be
confused.

003710

2-190
HP 500 / 590 / 600 “long” version Mechanical transmission part

12.1.3 Diversion HP 600smantling planet carrier II:


version HP 500 / HP 590

1 Disengage circlip (15) at all four recesses.

NOTE
Ensure that the circlip does not slip back into the annu-
lar groove.

003711

2 Pull ring gear (14) on output end off planet


carrier II (17) and remove circlip.

NOTE
If necessary, separate the ring gear from the planet car-
rier by tapping gently with a plastic mallet.

003712

3 Release planet gear shafts (20) with suitable


peening tool.

003713

2-191
Mechanical transmission part HP 500 / 590 / 600 “long” version

4 Drive out planet gear shafts (20) downwards.

5 Remove planet gears (21) from planet carrier II.

003714

6 From each planet gear, remove two needle


bearings (19).

003715

7 Remove thrust plate from planet carrier.

003716

2-192
HP 500 / 590 / 600 “long” version Mechanical transmission part

8 Press circlip (22) out of groove by inserting a suita-


ble mandrel through the bore (arrow).

9 Grip circlip and snap out.

003717

10 Position a suitable plastic mandrel on shoulder of


ring gear (23).

11 Drive ring gear off planet carrier.

003718

2-193
Mechanical transmission part HP 500 / 590 / 600 “long” version

12.1.4 Dismantling planet carrier II:


version HP 600.

1 Remove thrust washer (16) from planet carrier.

003745

2 Snap out circlip (15) at the four recesses using a


suitable screwdriver.

NOTE
Ensure that the circlip does not slip back into the annu-
lar groove once disengaged.

003744

3 Pull ring gear off gearing of planet carrier II.

4 Remove ring gear (23) from planet carrier II.

NOTE
Further dismantling is similar to version
HP 500 /HP 590, refer to Chapter 12.1.3, page 2-191.

003742

2-194
HP 500 / 590 / 600 “long” version Mechanical transmission part

12.1.5 Dismantling planet carrier I.


version HP 500 / HP 590

1 Press out circlip (7) by inserting a suitable mandrel


through the bore (arrow) and snap out circlip.

003719

2 Drive ring gear (8) off planet carrier using a suita-


ble plastic mandrel.

003720

3 Release planet gear shafts (1) using a suitable


peening tool.

! DANGER
Wear goggles when peening the planet gear shafts.

4 Drive out planet gear shafts downwards.

003721

2-195
Mechanical transmission part HP 500 / 590 / 600 “long” version

5 Remove planet gears (6) with thrust plates (2) from


inside of planet carrier.

003722
003 722

6 Remove needle bearing (4) from planet carrier.

003723

2-196
HP 500 / 590 / 600 “long” version Mechanical transmission part

12.1.6 Dismantling planet carrier I;


version HP 600.

1 Press out circlip (7) by inserting a suitable mandrel


through bore.

2 Snap out circlip using a screwdriver.

003719

3 Press planet carrier I (5) off ring gear.

4 Remove planet carrier I.

NOTE
Further dismantling is similar to version
HP 500 /HP 590, refer to Chapter 12.1.5, page 2-195.

003746

2-197
Mechanical transmission part HP 500 / 590 / 600 “long” version

12.1.7 Assembling planet carrier I

1 Insert lower thrust plate (2) into planet carrier I


with curved side on the outside.

NOTE
The thrust plates have one steel and one aluminum sur-
face. The steel surface is shiny and the aluminum surfa-
ce is matt. The steel surface must always face towards
the planet carrier.

NOTE
Two thrust plates (2) are fitted in transmission version
HP 600.

003724

2 Install one needle bearing (4) in each planet


gear (6).
4
NOTE
Lubricate the bearing bores in the planet gears and the
needle bearing with Vaseline prior to installation.

003723

3 Fit planet gears in planet carrier assembly.

4 Insert upper thrust plate (2) with the steel side


facing towards the planet carrier.

NOTE
Two thrust plates (2) are fitted in transmission
version HP 600.

003725

2-198
HP 500 / 590 / 600 “long” version Mechanical transmission part

5 Align planet gears with needle bearings and thrust


plates with bores in planet carrier.

6 Guide in mandrel until it makes axial contact.

NOTE
Do not push in mandrel with force or knock in.

7 Carefully pull out mandrel and drive in planet gear


shaft (1) until they are fully home.

NOTE
Use new planet gear shafts.
Always replace entire sets of planet gears.
All the planet gears are installed in the same way.
003726

8 Place support 1X56 137 464 in the press.

CAUTION
The lug (arrow) must engage in the bore of the planet
gear shaft. The planet gear shaft to be secured must rest
on the lug.

003728

9 Place planet carrier on support.

10 Secure all planet gear shafts by peening the collar


with the peening tool 1X56 137 465.

003727

2-199
Mechanical transmission part HP 500 / 590 / 600 “long” version

11 Measure end float of planet gears in planet carrier I


by inserting a depth gauge between thrust washer
and planet carrier.

NOTE
Do not take measurement at the recess (arrow). End
float is between 0.5 and 1.2 mm. Take measurement on
all planet gears.

003729

12 Place ring gear (8) in press with the annular groove


pointing upwards.

13 Place planet carrier I (5) on ring gear.

14 Align gearing.

15 Position pressing tool of suitable diameter on pla-


net carrier and press ring gear onto planet carrier.

003730

16 Snap in circlip (7).

NOTE
Install circlip with the gap at the bore (arrow). The circ-
lip must be fully engaged in the annular groove.

003731

2-200
HP 500 / 590 / 600 “long” version Mechanical transmission part

12.1.8 Assembling planet carrier II.


version HP 500 / HP 590.

1 Install lower thrust plate (18).

NOTE
Firstly fit the thrust plate with three apertures.

003732

CAUTION
The thrust plates have one steel and one aluminum sur-
face. The steel surface is identified with a punch mark
(arrow). This punch mark must always face towards the
planet carrier.

003733

2 Install two needle bearings (19) in each planet gear.

NOTE
Lubricate the bearing bore in the planet gears and the
roller bearing with Vaseline prior to installation.

003715

2-201
Mechanical transmission part HP 500 / 590 / 600 “long” version

3 Fit planet gears (21) in planet carrier assembly (17).

4 Install upper thrust plate (18) with steel side facing


the planet carrier.

NOTE
First fit the thrust plate with three apertures.

003734

5 Align bore, thrust plate and planet gear with bores


in the planet carrier.

6 Insert mandrel until it makes axial contact.

NOTE
Do not push in the mandrel with force or knock it in.

7 Carefully pull out mandrel and drive in planet gear


shaft (20) until it is fully home.

NOTE
Use new planet gear shafts. All the planet gears are
installed in the same way. Always replace entire sets of
planet gears.
003735

8 Place support 1X56 137 464 in press.

CAUTION
The lug (arrow) must engage in the bore of the planet
gear shaft. The planet gear shaft to be secured must rest
on the lug.

003728

2-202
HP 500 / 590 / 600 “long” version Mechanical transmission part

9 Place planet carrier on support.

10 Secure all planet gear shafts by peening the collars


with peening tool 1X56 137 465.

003736

11 Measure end float of planet gears in planet carrier


II by inserting a feeler gauge between thrust washer
and planet carrier.

NOTE
End float is between 0.5 and 1.2 mm
Take measurement of all planet gears.

003737

12 Place output side ring gear (23) in press with the


annular groove pointing upwards.

13 Place planet carrier II (17) on ring gear.

14 Align gearing.

15 Position pressing tool of suitable diameter on


planet carrier and press ring gear (23) onto planet
carrier.

003738

2-203
Mechanical transmission part HP 500 / 590 / 600 “long” version

16 Snap in circlip (22).

NOTE
Install circlip with the gap at the bore (arrow).
The circlip must be fully engaged in the annular groove.

003739

17 Place planet carrier II in press.

18 Fit circlip.

19 Place input side ring gear (14) in press with the


annular groove pointing towards the planet carrier.

20 Position pressing tool of suitable diameter on


planet carrier.

21 Press ring gear onto planet carrier so that the


circlip still has a little play.

003740

22 Snap circlip (15) into annular groove in ring using


screwdriver.

23 Press ring gear fully home and press circlip into


annular groove through all recesses (arrow).

CAUTION
Install circlip with the ring end at the recess (arrow).
The circlip must be fully engaged into the annular groove.

003741

2-204
HP 500 / 590 / 600 “long” version Mechanical transmission part

12.1.9 Assembling planet carriers II and I;


version HP 600

NOTE
Preceding work as is described under Chapter 12.1.8.
However, only one roller bearing (19) is attached to each
planet gear and rather than using thrust plates, fit two
thrust washers (18) for each gear.

1 Place ring gear (23) on planet carrier.

003742

2 Push ring gear (14) onto gearing of planet carrier.

003743

3 Install circlip (15) in annular groove in planet


carrier.

NOTE
The circlip must be fully engaged in the annular groove.

003744

2-205
Mechanical transmission part HP 500 / 590 / 600 “long” version

4 Place thrust washer (16) on planet carrier II.

003745

5 Install planet carrier I (5) and snap in circlip (7).

003746

2-206
HP 500 / 590 / 600 “long” version Mechanical transmission part

12.2 Removing piston E and disc carrier

NOTE
Preceding work; removing output end cover, intermediate housing and mechanical transmission part

Arrangement of sub-assembly:
E piston and disc carrier

003845

9
8
7

6
3 4

1 *2

5
*** 11

* 10
003846

1 Thrust washer
*2 Circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . only with HP 500 / HP 590
3 Disc carrier
4 Needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
5 Sun gear
6 Thrust washer
7 Lip-type seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, grease with Vaseline
8 Lip-type seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, grease with Vaseline
9 Piston E
*10 Circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . only with HP 500 / HP 590
**11 Circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . only with HP 600

2-207
Mechanical transmission part HP 500 / 590 / 600 “long” version

1 Remove piston E (9) from transmission housing.

004999

NOTE
If piston E is stuck, blow compressed air into one of the
oil ducts (arrow) to loosen the piston.

! DANGER
Before blowing compressed air into the oil ducts,
cover the transmission housing with a cloth. Protect
your eyes from transmission oil.

003747

2 Remove lip-type seal rings (7/8) from piston E.

003778

2-208
HP 500 / 590 / 600 “long” version Mechanical transmission part

3 Lift disc carrier (3) out of transmission.

003777

4 Remove needle bearing (4) and thrust washer (6)


from drive shaft.

003748

NOTE
The needle bearing (4) and thrust washer (6) may also
be stuck on the back of the disc carrier.

003749

2-209
Mechanical transmission part HP 500 / 590 / 600 “long” version

5 Remove upper needle bearing (4) from disc carrier.

003750

NOTE
Step 6 only applies to version HP 500 / HP 590

6 Snap outer circlip (2) and inner circlip (10) out of


sun gear.

NOTE
To do this, turn each circlip until one end appears in the
groove (arrow).

2 10
003774
003774

NOTE
Step 7 only applies to version HP 600

7 Snap circlip (11) out of sun gear.

8 Drive sun gear (5) out of disc carrier using suitable


mandrel.

003751

2-210
HP 500 / 590 / 600 “long” version Mechanical transmission part

12.3 Removing and installing quill shaft and drive shaft

NOTE
Preceding work; removing output end cover, intermediate housing and mechanical transmission part

Arrangement:
quill shaft and drive shaft

003845

6
5
5
3 4

2
004990

1 Thrust washer
2 Needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
3 Drive shaft
4 Thrust washer
*5 Needle washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
*6 Quill shaft

* only in transmission version with clutch C

Special tools: 1X56 122 227, 1X56 122 205, 1X56 137 101

2-211
Mechanical transmission part HP 500 / 590 / 600 “long” version

12.3.1 Removing quill shaft and drive shaft

NOTE
Steps 1 and 2 only apply to version with clutch C

1 Lift quill shaft out of transmission.

NOTE
To lift out, turn the quill shaft until it is in alignment
with the gearing of the inner discs of clutches B and C.

003752

2 Remove both needle bearings (5).

3 Remove thrust washer (4) from drive shaft and/or


6
quill shaft. 5

4 5

003854

4 Remove drive shaft (3) from transmission.

003772

2-212
HP 500 / 590 / 600 “long” version Mechanical transmission part

5 Remove thrust washer (1) from turbine shaft.

NOTE
The thrust washer may stick on the drive shaft.

003754

NOTE
Only remove needle bearing (2) if required.

3 Insert internal extractor 1X56 122 205 in bearing


bore and grip needle bearing (2) from behind.

4 Screw steady 1X56 122 227 onto extractor.

5 Tighten lock nut by hand and pull needle bearing


out of drive shaft.

003755

NOTE
Removing and installing brake D;
refer to Chapter 14, page 300

2-213
Mechanical transmission part HP 500 / 590 / 600 “long” version

12.3.2 Installing quill shaft and drive shaft

1 Use attachment 1X56 137 101 to drive new needle


bearing fully home into drive shaft.

NOTE
The installation depth of the needle bearing is 4+1 mm
and attachment 1X56 137 101 is used to ensure that
the needle bearing is installed at the correct depth. The
thick coating of the needle bearing must be visible
and/or be facing outwards. To do this, place attachment
on bearing side which has the thicker coating.

003769

2 Stick thrust washer (1) into drive shaft using


Vaseline.

003770

3 Use a screwdriver to align outer discs (arrow) of


clutch A so that they are flush and central.

003771

2-214
HP 500 / 590 / 600 “long” version Mechanical transmission part

4 Insert drive shaft (3).

CAUTION
The drive shaft must make axial contact.

5 Place thrust washer (4) on drive shaft.

NOTE
Coat thrust washer with Vaseline.

003772

NOTE
Steps 6 to 8 only apply to transmission version with
clutch C.
6
6 Coat both needle bearings (5) with Vaseline and 5
install in quill shaft (6).

4 5

003854

7 Align inner discs of clutches B and C.

8 Install quill shaft (6) above drive shaft until it


makes axial contact.

003752

2-215
Mechanical transmission part HP 500 / 590 / 600 “long” version

12.4 Installing piston E and disc carrier

Arrangement of sub-assembly:
piston E and disc carrier

003845

9
8
7

6
3 4

1 *2

*** 11
5

* 10
003846

1 Thrust washer
*2 Circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * only in version HP 500 / HP 590
3 Disc carrier
4 Needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
5 Sun gear
6 Thrust washer
7 Lip-type seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace; grease with Vaseline
8 Lip-type seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace; grease with Vaseline
9 Piston E
*10 Circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * only in version HP 500 / HP 590
**11 Circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * only in version HP 600

2-216
HP 500 / 590 / 600 “long” version Mechanical transmission part

12.4 Installing piston E and disc carrier

NOTE
Steps 1 to 3 only apply to version HP 600. 2
1 Insert circlip (11) in the groove on the sun gear.

2 Insert sun gear (5) into disc carrier with the long
collar at the top and let circlip (11) snap into disc
carrier.

3 Coat output side needle bearing (4) with Vaseline


and insert in sun gear (5).

005400

NOTE
Steps 4 to 6 only apply to version HP 500 / HP 590

4 Insert sun gear (5) into disc carrier with the long
collar at the top.

5 Coat output side of needle bearing (4) with


Vaseline and insert into sun gear (5).

003773

6 Install inner circlip (10) and outer circlip (2).

2 10
003774
003774

2-217
Mechanical transmission part HP 500 / 590 / 600 “long” version

7 Coat lower needle bearing (1) with Vaseline and


insert into sun gear (2).

003775

8 Coat thrust washer (1) with Vaseline and stick into


disc carrier.

9 Place assembled disc carrier (3) on quill shaft


and/or drive shaft.

CAUTION
When fitting the disc carrier, take care of the lower
needle bearing. The disc carrier must make axial
contact. If necessary, move disc carrier into axial
contact by rocking back and forth.

003777

10 Install inner lip-type seal ring (7) and outer lip-type


seal ring (8) in piston E.

CAUTION
Check lip-type seal ring and replace if necessary. The
grooves of both lip-type seal rings must face towards
the pressure side. Stretch the lip-type seal ring before
installing so that is lies snugly in the base of the groove.

003778

2-218
HP 500 / 590 / 600 “long” version Mechanical transmission part

11 Thinly coat sealing surface of piston E (9) and


lip-type seal rings with Vaseline.

12 Insert piston E (9) into transmission and carefully


drive fully home using a plastic mallet.

CAUTION
Do not damage the lip-type seal ring when installing.
The piston E must slide in tightly.

004999

2-219
Mechanical transmission part HP 500 / 590 / 600 “long” version

12.5 Installing planet carriers I and II, brakes E and F

Diagram: version HP 600

10 11
9
8
7

2 5
4
2
1

20
18
19
6 18
3
17
15
13 14 16 21
12
10

30
29
28
27
26 33
25 32
31
24
23
22

003823

2-220
HP 500 / 590 / 600 “long” version Mechanical transmission part

1 Planet gear shaft


2 Thrust washer
3 Thrust washer
4 Needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
5 Planet carrier I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 097 775
6 Planet gear
7 Circlip
8 Ring gear
9 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
10 Inner disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check coating, lubricate with transmission oil
11 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
12 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
13 Thrust ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 136 821
14 Ring gear
15 Circlip
16 Thrust washer
17 Planet carrier II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 097 775
18 Thrust washer
19 Needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
20 Planet gear shaft
21 Planet gear set
22 Circlip
23 Ring gear
24 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
25 Inner disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check coating, lubricate with transmission oil
26 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
27 Pin
28 Spring
29 Guide tube
30 Pin
31 Thrust washer
32 Sun gear
33 Thrust washer

Transmission version HP 600 . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 136 612

2-221
Mechanical transmission part HP 500 / 590 / 600 “long” version

12.5 Installing planet carriers I and II, brakes E


and F

1 Measure first outer disc of brake E.

CAUTION
The outer disc must be 3 mm thick.

2 Check all outer and inner discs for wear and une-
venness

003780

NOTE
Uneven, dished and damaged discs must be replaced.

CAUTION
The brake E is available as first and second versions.
In the first version, the first disc to be inserted is a 3
mm outer disc with bores. The lower pins on this disc
are shorter than the pins of brake F.
In the second version, the first disc to be inserted in a
3 mm outer disc without bores. The lower pins on this
disc are the same length as the pins on brake F.

003781

NOTE
Install the discs of brake E as follows.

A) First version

3 Mark the deeper housing bores with an arrow.

003779

2-222
HP 500 / 590 / 600 “long” version Mechanical transmission part

4.1 Install the first outer disc so that the bores (arrow)
in the outer disc are flush with deeper housing
bores (marked).

5.1 Install one inner disc.

6.1 Install second outer disc so that the recesses lie


above the bores of the first outer disc.

003782

B) Second version

3 Mark the deeper housing bores with an arrow.

4.2 Install first outer disc so that the central tooth


(arrow) of each disc segment is over the marked
housing bores (arrow).

5.2 Install one inner disc.

6.2 Install second outer disc so that the recesses lie


above the central tooth (arrow) of each disc seg-
ment of the first outer disc.
99
003783

7 Install the remaining discs in the specified sequence.

NOTE
The number of outer and inner discs depends on the
version, refer to spare parts list.

004924

2-223
Mechanical transmission part HP 500 / 590 / 600 “long” version

8 Install thrust ring. In so doing, note the recesses for


spring elements on the thrust ring.

9 Lift thrust ring slightly and turn so that the gears of


the thrust ring slide under the housing gears.

003704

10 10 Use a feeler gauge to measure the disc play of


brake E.

NOTE
Permissible disc play in transmission HP 500 is
between 2.5 and 3 mm. Permissible disc play in
transmission HP 590 / HP 600 is between 3 and 3.5 mm.
Variations must be corrected by installing different
gauges of outer ring.

Outer discs used for compensation have the following


gauges: 2, 2.5, 3 mm.

11 Remove thrust ring (13) and entire disc assembly


from transmission.
003784

12 Stick thrust washer (3) into disc carrier with


Vaseline.

003703

2-224
HP 500 / 590 / 600 “long” version Mechanical transmission part

NOTE
Steps 13 to 25 only apply to transmission
version HP 500 / HP 590

13 Grasp planet carrier (5) with assembly hooks


1X56 097 775 and install in transmission.

! DANGER
Counter the planet carrier I when lifting to prevent it
from slipping off the assembly hooks.

14 Install the E brake disc pack as already described.

003702

CAUTION
The first outer disc must be 3 mm thick.

15 Install thrust ring (13).

CAUTION
Install the thrust ring so that the round recesses
(arrow A) are over the housing bores.

16 Install pins (27), springs (28), guide tubes (29) and


pins (30) in the round recesses.

NOTE
The guide tunes are conical. Always install the guide
tubes with the longer bevels pointing upwards.
003843

17 Stick thrust washer (16) onto drive side of planet


carrier II with Vaseline.

003785

2-225
Mechanical transmission part HP 500 / 590 / 600 “long” version

18 Turn planet carrier II over. Grasp planet carrier II


with assembly hooks 1X56 097 775 and install in
transmission.

! DANGER
Counter planet carrier II when lifting to prevent it
from slipping off the assembly hooks.

CAUTION
Ensure that the thrust washer on the drive side does not
fall off the planet carrier.

003700
003 700

19 Stick thrust washer (31) onto drive side contact sur-


face of sun gear with Vaseline.

NOTE
The drive side contact surface of the sun gear can be
identified by the two recesses.

20 Push sun gear (32) onto drive shat and fit thrust
washer (33).

21 If necessary, drive on sun gear by tapping gently


with a plastic mallet.

003699
003 698

22 Check outer and inner discs for wear.

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

NOTE
Uneven, dished and damaged discs must be replaced.

003781

2-226
HP 500 / 590 / 600 “long” version Mechanical transmission part

24 Measure and install discs of brake F.

CAUTION
The first outer disc must be 3 mm thick.

NOTE
Refer to the spare parts catalogue for the number of
outer and inner discs required.

003780

25 Alternately install one inner and one outer disc.

CAUTION
Install outer discs so that the recesses (arrow) are over
the compression springs (28).

NOTE
The last outer disc of piston F has no bores and its teeth
are slightly larger.

003786

24 Outer disc
25 Inner disc
26 Last outer disc

Outer discs of the following gauges are used:


2, 2.5 3 mm

CAUTION
The last outer disc must not be used for compensating
play.

Disc play = between 3.2 and 3.7 mm


Adjust disc play of brake F,
refer to Chapter 11.3, page 2-176

003851

2-227
Mechanical transmission part HP 500 / 590 / 600 “long” version

12.6 Installing planet carriers I and II;


version HP 600

1 Coat thrust washer with Vaseline and fit on disc


carrier in transmission.

2 Screw two hooks 1X56 136 612 into planet carrier


and lower assembled planet carrier into housing.

003787

3 Install disc assembly of brake E as is described in


Chapter 12.5.
9
CAUTION
The first outer disc must be 3 mm thick.

003704

4 Screw two guide bolts 1X56 136 821 into thrust


ring (13) and install thrust ring in groove on
housing.

NOTE
The round recesses in the thrust ring must be over the
housing bores.

003788

2-228
HP 500 / 590 / 600 “long” version Mechanical transmission part

5 Install disc assembly of brake F as is described in


Chapter 12.5.

CAUTION
The first outer disc must be 3 mm thick.

003789

6 Insert guide tubes (29) in recesses.


30
NOTE
The guide tubes (29) are conical. Always install the
guide tubes with the longer bevels pointing upwards.

7 Install pins (27) in guide tubes with heads facing


downwards. 29
28
8 Insert compression springs (28) in guide tubes
above the pins (27).

9 Insert pins (30) in compression springs.


27
003790

10 Install cable (36) for inductive sensor output in


transmission housing.

CAUTION
Insert cable for inductive sensor in the correct housing
duct.

Adjust end float of sun gear


- refer to Chapter 11.2; page 2-175

Adjust disc play of brake F


- refer to Chapter 11.3; page 2-176

Install intermediate housing


- refer to Chapter 11.4; page 2-177
003698

2-229
Mechanical transmission part HP 500 / 590 / 600 “long” version

12.7 Measuring and adjusting inductive sensor ring

NOTE
The inductive sensor ring only needs to be measured in
version “without clutch C”.

1 Swivel transmission so that the mounting face for


the transmission control unit is pointing upwards.

2 Use dial gauge to measure deviation from


roundness.

NOTE
The roundness refers to each raised area of the induc-
tive sensor ring. The inductive sensor ring may have a
004991
maximum deviation from roundness of + 0.2 mm.

3 Carefully rectify any deviations using a soft plastic


mallet.

Install hydraulic transmission control unit


- refer to Chapter 8.1.2, page 2-87 Maximale Rundlaufabweichung
+ 0,2 mm

Induktivgeberring

001572

2-230
HP 500 / 590 / 600 “long” version Control unit

13 Removing and installing, dismantling and assembling control unit

NOTE
Preceding work;
removing torque converter, output end plate, shift control unit and intake pipe, as well as quill shaft and drive
shaft

Sub-assembly arrangement:
control unit

003824

2
1
8
4

12 9
11 7
3
10
5
14
13 *15

*16

004955

2-231
Control unit HP 500 / 590 / 600 “long” version

Special tools

1X56 122 208 1X56 122 227 1X56 136 612 1X56 136 821 1X56 137 109

1X56 137 213 1X56 137 273

1 M8x65 Allen screw with internal hex . . . . . . . . . . . . . .5 pieces, 23 Nm, 1X56 137 273
2 Washer
3 Turbine shaft
4 Tube
5 Control element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 137 213, 1X56 136 513, 1X56 136 612
6 Intermediate plate
7 Clutch body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 136 821
8 Circlip
9 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, lubricate with transmission oil
10 Intake pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 122 208, 1X56 122 227
11 M8x55 Allen screw with internal hex . . . . . . . . . . . . . . 4 pieces, 23 Nm, 1X56 137 273
12 Washer
13 M8x70 Allen screw with internal hex . . . . . . . . . . . . . . 3 pieces, 23 Nm, 1X56 137 273
14 Washer
*15 Locking plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . as of vol prod. no.: 96173 (new housing)
*16 M8x18 hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . as of vol. prop. no.: 96173 (new housing); 23 Nm

2-232
HP 500 / 590 / 600 “long” version Control unit

13.1 Removing control unit

NOTE
Step 1 only applies to transmissions with new housing
(as of vol. prod. no.: 96173)

1 Unscrew M8 hexagon bolts (16) and remove


locking plate (15).
- refer to Annex 15

2 Remove intake pipe (10) from transmission hou-


sing using internal extractor 1X56 122 208 and
steady 1X56 122 227.

003581

3 Remove O-ring (9) from intake pipe (10).

003582

4 Swivel the transmission so that the drive side is at


the top.

5 Unscrew all M8 hexagon bolts (1/11/13) from aro-


und the circumference using Allen insert 1X56 137
273 and remove with washers.
13 11
CAUTION 003598
Ensure that the sealing surface is not damaged.
003 598

003597

2-233
Control unit HP 500 / 590 / 600 “long” version

6 Hook lifting tackle into lifting device


1X56 137 213.

7 Use hot air blower 1X56 136 513 to heat transmis-


sion housing at same level as control unit to
approx. 85 °C.

! DANGER
Only handle transmission housing when wearing
protective gloves.

003583

8 Lift control unit out of transmission housing and


place on wooden blocks.

! DANGER
Do not remove lifting drive 1X56 137 213 or the
turbine shaft will fall down through the control unit.

003593

2-234
HP 500 / 590 / 600 “long” version Control unit

13.1.1 Dismantling control unit

1 Unscrew lifting device 1X56 137 213 from turbine


shaft.

CAUTION
Whilst the lifting device is being unscrewed, the turbine
shaft must be held (by hand) to prevent it falling out.

2 Lower turbine shaft out of control unit until the


circlip (8) is easily accessible.

3 Use circlip pliers to snap out circlip (8).

003584

4 Pull turbine shaft (3) up and out of stator shaft.

5 Screw hooks 1X56 136 612 into control unit.

6 Hook up lifting tackle.

003585

7 Lift control unit slightly off wooden blocks.

8 Use attachment 1X56 137 109 to drive clutch


carrier off control unit.

9 Remove clutch carrier and lower control unit onto


wooden blocks.

! DANGER
When detaching the clutch carrier from the control
element, do not hold under the clutch carrier.

003586

2-235
Control unit HP 500 / 590 / 600 “long” version

13.1.2 Assembling control unit

1 Fit intermediate plate (6).

CAUTION
The lug (arrow) on the intermediate plate must engage
in the recess (arrow) in the sealing washer.

003587

2 Screw two hooks 1X56 136 612 into opposite sides


of the control element.

3 Hook lifting tackle into hooks and move control


element over clutch carrier.

003588

4 Use hot air blower 1X56 136 513 to heat grooved


ball bearing (17) to approx. 85 °C.

! DANGER 17
Grooved ball bearing is hot. Wear protective gloves.

003589

2-236
HP 500 / 590 / 600 “long” version Control unit

5 Lower control element into clutch carrier.

6 Bring control unit into axial contact by tapping


gently with a plastic mallet.

003590

CAUTION
Before introducing the turbine shaft, ensure that the
three pins (15) are fully inserted and do not project out
into the hub (arrow).

003591

8 Remove lifting tackle and insert turbine shaft (3)


into control unit.

003585

2-237
Control unit HP 500 / 590 / 600 “long” version

9 Push in turbine shaft until annular groove is


accessible.

10 Snap circlip (8) into annular groove of turbine


shaft.

003592

11 Screw lifting tackle 1X56 137 213 into turbine


shaft.

CAUTION
When turning and/or lifting the control unit, be sure not
to damage the oil tube in the turbine shaft. Place blocks
under control unit so that the turbine shaft does
not project.

003593

2-238
HP 500 / 590 / 600 “long” version Control unit

13.1.3 Installing control unit

1 Align bore pattern of intermediate plate with bore


pattern of control unit.

NOTE
The lug on the intermediate plate must be engaged in
the recess of the sealing washer.
- refer to Chapter 13.1.2, page 2-236

2 Screw in two Allen screws for centering.

003594

3 Screw M8 guide pins 1X56 136 821 into transmis-


sion housing to center the control unit.

003595

4 Use hot air blower 1X56 136 513 to heat seat for
control unit in transmission housing
to approx. 140 °C.

5 Use lifting tackle to move control unit over trans-


mission, align with guide blots and lower into
transmission.

! DANGER
Housing is hot. Wear protective gloves.

NOTE
The control unit must be brought into axial contact
immediately. If necessary, drive in with plastic mandrel. 003583
003 583

2-239
Control unit HP 500 / 590 / 600 “long” version

6 Unscrew guide bolts.

7 Screw in M8x70 Allen screw (13) with washers


and tighten by hand.

8 Screw in M8x55 Allen screw (11) with washers


and tighten by hand.

13 11
003598

9 Screw five M8x65 Allen screws (1) with washers


into control unit and tighten by hand.

003597

10 Attach control unit to housing bore without play


using two M8 bolts and a wide shim and or wide
washers (17).

CAUTION
If this measure is not performed, this may result in 17
leaks on the transmission.

NOTE
– This measure prevents a drop in lubricant pressure.
– Use a wide shim.
– Do not damage the sealing surface.

003596

2-240
HP 500 / 590 / 600 “long” version Control unit

11 Tighten all Allen screws using insert 1X56 137


273.
Torque; 23 Nm

CAUTION
When screwing in and tightening the Allen screws,
ensure that the sealing surface is not damaged.
13 11
003598

12 Unscrew the M8 screws required for auxiliary mea- 003

sure (step 10) and remove with shim.

003597

13 Install O-ring (9) in transmission housing.

14 Grease O-ring with Vaseline.

003599

15 Install intake pipe (10) in transmission housing and


use Vaseline.

NOTE
If the intake pipe is difficult to install, drive it in
carefully using a plastic mallet.

16 Insert locking plate for intake pipe (15) using two


M8x18 hexagon bolts (16).
Torque: 23 Nm, refer to Annex 15

NOTE
Step 16 only applies to transmissions with new housing
(as of transmission no.: 97173).

003600

2-241
Control unit HP 500 / 590 / 600 “long” version

13.2 Removing and installing valves of control element.

NOTE
Preceding work; removing control unit

12
1
2
1
3
4 13
4
14
5 5
15 16
17 21
6 6
7 7 18
8 8 19 22
9 20
9 10
10 11 24 23
11
2 3 4
*2

003826/2

CAUTION 1 1 Spacer element


The primary pressure valve is available in various ver-
sions, P1 to P4. This manual describes version P1. You 2 2 Primary pressure valve (*new valve P4)
can find more information in the spare parts list, parts
list and Service Info. 3 3 Lubricant pressure and converter pressure
maintenance valve
4 4 Cooler switch-over valve

2-242 Index ”a“ 98-04-17


HP 500 / 590 / 600 “long” version Control unit

Special tools

107
137
1X56

1X56 137 107 1X56 137 108

1 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
2 Spacer element
3 Spacer tube
4 Compression spring (* valve parts)
5 Compression spring
6 Piston
7 Piston
8 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
9 Spacer element (*bush) . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 137 108
10 Washer
11 Circlip
12 Control element
13 Piston
14 Compression spring
15 Spacer ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 137 107
16 Cylinder pin
17 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 137 108
18 Compression spring
19 Washer
20 Circlip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 137 108
21 Piston
22 Compression spring
23 Cylinder pin
24 Spacer ring

Index ”a“ 98-04-17 2-243


Control unit HP 500 / 590 / 600 “long” version

13.2.1 Removing valves from control element

CAUTION
The pistons and other individual parts of the control
element must be handled with great care and kept clean.

1 Remove cooler switch-over valve.

1.1 Counter spacer ring (24) and pull out cylinder pin
(23).

1.2 Remove spacer ring.

! DANGER
Spacer ring is spring loaded.
003601

1.3 Remove compression spring (22) and piston (21).

003602

2 Attach clamping device 1X56 137 108 to control


element.

003603

2-244
HP 500 / 590 / 600 “long” version Control unit

3 Screw in spindles of clamping device until the


circlips (11/20) are free.

4 Snap out circlips (11/20).

5 Unscrew spindles. Remove sealing washers (10/19)


and circlips (11/20).

! DANGER
The washers are spring-loaded. When relieving the
spindles, ensure that the sealing washers do not jump
out.

003604

6 Remove primary pressure valve.

6.1 Remove spacer element (9) with O-ring (8), pistons


(6/7) compression springs (4/5) and spacer tube (3).

7 Remove lubricant pressure valve and converter


pressure maintenance valve.

7.1 Remove compression spring (18) and piston (17).

003832

7.2 Screw clamping device 1X56 137 107 into spacer


ring (15), counter device and pull out cylinder
pin (16).

! DANGER
Spacer ring is spring-loaded.

7.3 Use device 1X56 137 107 to pull out spacer ring.

003605

2-245
Control unit HP 500 / 590 / 600 “long” version

7.4 Remove piston (13) and compression spring (14).

! DANGER
Do not touch the housing with bare hands. The hou-
sing has sharp edges.

003606

8 Remove spacer element (2) and take of O-ring.

003607

2-246
HP 500 / 590 / 600 “long” version Control unit

13.2.2 Installing valve in control element

CAUTION
The pistons and other individual parts of the control
element must be handled with great care and kept clean.
When installing the pistons, check that they can move
easily.

1 Fit new O-ring (1) in groove of spacer element (2).

2 Thinly grease O-ring (1) with Vaseline and install


in housing bore with spacer element (2).

NOTE
When installing spacer element, turn it so that it does
003608
not protrude over the coat side of the control element.

3 Install primary pressure valve.

3.1 Assemble compression springs (4/5) and spacer


tube (3) and push into piston (6). Insert piston (7)
into piston (6).

003609

3.2 Install fully assembled piston (6) of primary pres-


sure valve in control element.

3.3 Fit new O-ring (8) in groove of spacer element (9)


and thinly grease with Vaseline.

003610

2-247
Control unit HP 500 / 590 / 600 “long” version

3.4 Attach clamping device 1X56 137 108 to control


element.

3.5 Unscrew spindles of clamping device until the spa-


cer element can be installed.

3.6 Fit circlip (11) and washer (10) on spindle.

3.7 Insert spacer element (9) into housing bore and


press in with spindle until circlip (11) and washer
(10) can be installed.

003604

! DANGER
Before unscrewing the spindles, ensure that the circlip
is correctly engaged.

3.8 Remove clamping device.

4 Install lubricant pressure valve and converter pres-


sure maintenance valve.

4.1 Insert piston (13) and compression spring (14) in


housing bore.

4.2 Screw spacer ring (15) onto device 1X56 137 107.
003611

4.3 Push device with spacer ring into housing bore, ali-
gning the spacer ring so that the cylinder pin (16)
can be inserted.

4.4 Remove device 1X56 137 107.

003605

2-248
HP 500 / 590 / 600 “long” version Control unit

4.5 Install piston (17) and compression spring (18) of


converter pressure maintenance valve.

003612

4.6 Attach clamping device 1X56 137 108 to control


element. Unscrew spindles of clamping device until
circlip (20) and washer (19) can be inserted.

4.7 Press in washer (19) with spindle without tilting


until the circlip (20) can be snapped in.

! DANGER
Before unscrewing the spindles, ensure that the circlip
is correctly engaged.

003613

5 Install cooler switch-over valve.

5.1 Insert piston (21) and compression spring (22) into


bore of collar switch-over valve.

003602

2-249
Control unit HP 500 / 590 / 600 “long” version

5.2 Install spacer ring (24) and insert cylinder pin (23).

003601
003 601

2-250
HP 500 / 590 / 600 “long” version Control unit

13.3 Dismantling and assembling control element.

NOTE
Preceding work; dismantling control unit

7
6
5 8 9
4
3
2
1
21 22

15 16 19 20
36
17
18
11
23 24
12
16

13

10
14
25
27 34 35
28 33
26 29
30

32
31

004953

1 Circlip
2 Rectangular ring
3 Piston ring carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 137 432
4 Needle bearing
5 Inner bearing race . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 134 659
6 Dowel pin
7 Dowel pin
8 Stator shaft
9 Bush with rectangular ring . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 136 820
10 Washer
11 M8x45 Allen screw with washer . . . . . . . . . . . . . . . . . . . 3 pieces, 23 Nm

2-251
Control unit HP 500 / 590 / 600 “long” version

12 M8x40 Allen screw with washer . . . . . . . . . . . . . . . . . . 3 pieces, 23 Nm


13 M8x55 Allen screw with washer . . . . . . . . . . . . . . . . . . 4 pieces, 23 Nm
14 M8x70 Allen screw . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 pieces, 23 Nm
15 Control element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 137 104; 1X56 122 322
*16 Banjo bolt with two seal rings . . . . . . . . . . . . . . . . . . . 15 Nm; replace seal rings
17 Allen screw with washer . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm; special tool 1X56 137 273
*18 Oil tube
19 Allen screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Nm
20 Washer
21 Oil supply flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 136 818
22 Thrust ring
23 Washer
24 Hexagon bolt
25 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
26 Intermediate plate
27 Stator ring
28 Spring seat
29 Compression spring
30 Spring guide
31 Plate spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 pieces
32 Guide pin
33 Rectangular ring
34 Grooved ball bearing
35 Turbine shaft
36 Primary pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . special tool 1X56 136 821
* only in version with PTO

Special tools

1X56 122 322 1X56 124 659 1X56 136 818 1X56 136 820 1X56 136 821

1X56 137 213 1X56 137 273 1X56 137 432

2-252
HP 500 / 590 / 600 “long” version Control unit

13.3.1 Dismantling control element.

1 Turn control unit over.

2 Fit thrust piece 1X56 137 104 on oil supply flange.

003614

3 Insert puller 1X56 122 322 in grooved ball bearing


(34) tighten clamping ring.

NOTE
Use SW 46 open end wrench to counter puller on lock
nut.

4 Pull grooved ball bearing off oil supply flange.

003615

5 Remove the four rectangular rings (33).

003616

2-253
Control unit HP 500 / 590 / 600 “long” version

! DANGER
The rectangular rings have sharp edges. Risk of injury.
To press out, always place pieces of leather around
rectangular ring or wear gloves.

003617

NOTE
Remove rectangular ring (33) with hooked gap as
follows:

– Press rectangular ring at base of groove (arrow A)


and on opposite side of groove (arrow B). B A
– Push rectangular ring forwards (arrow C) and snap
out.

C
001582
001582

6 Unscrew all M8 hexagon bolts (24) in oil supply


flange.

003618

2-254
HP 500 / 590 / 600 “long” version Control unit

7 Remove spring guide (30) with compression spring


(29), plate spring (31) and guide pin (32) on stator
ring.

! DANGER
The springs are spring-loaded. Do not let them spring
out.

CAUTION
The spring guide pins are each fitted with 48 plate
spring. Ensure that the guide pin does not spring out.

003619

8 Remove compression spring (29), spring guide (30)


and plate springs (31) from guide pin (32).

003620

9 Remove spring seat (28) from stator ring.

NOTE
The spring seat (28) may stick to the compression
spring (29).

003621

2-255
Control unit HP 500 / 590 / 600 “long” version

10 Turn control element over.

11 Unscrew Allen screws (11/12).

003637

12 Unscrew Allen screws (13/14).

003636

13 Unscrew Allen screw (17) of primary pump (36)


using Allen insert 1X56 137 273.

003622

2-256
HP 500 / 590 / 600 “long” version Control unit

14 Lift control element (15) and remove from oil


supply flange.

003623

15 Screw two M8 hexagon bolts into the stator shaft.


They should be screwed in from the reverse side
and should be at an angle of 180 °.

16 Loosen stator shaft by gently tapping hexagon bolts


with plastic mallet.

17 Unscrew hexagon bolts from stator shaft.

003624

18 Remove stator shaft (8) from control element.

NOTE
The two dowel pins can remain in place.

003625

2-257
Control unit HP 500 / 590 / 600 “long” version

19 Remove plain compression spring (2).

! DANGER
The rectangular rings have sharp edges. Risk of injury.
To press out, always place pieces of leather around
rectangular ring or wear gloves.

003626

NOTE
Remove rectangular ring (2) with hooked gap as
follows:

– Press rectangular ring at base of groove (arrow A)


and on opposite side of groove (arrow B). B A
– Push rectangular ring forwards (arrow C) and snap
out.

C
001582
001582

20 Use a screwdriver to snap out circlip (1).

003627

2-258
HP 500 / 590 / 600 “long” version Control unit

21 Insert puller 1X56 137 432 in annular groove of


piston ring carrier.

22 Place thrust piece on stator shaft.

23 Use puller 1X56 137 432 to pull piston ring carrier


off stator shaft.

24 Remove needle cage (4).

003628

25 Check inner bearing race (5) for damage and repla-


ce with needle cage if necessary.

26 Fit pulling device 1X56 124 659 on inner bearing


race with the stamped numbers at top and screw
down equally with two hexagon bolts.

CAUTION
The stamped numbers must match on the two halves of
the pulling device.

003629

27 Place thrust piece on stator shaft.

28 Use pulling device to place stator shaft in press and


press inner bearing race off stator shaft.

003630

2-259
Control unit HP 500 / 590 / 600 “long” version

29 Check bush (9) and rectangular rings (arrow) in


stator shaft for damage.

30 Only if damage is found: use attachment


1X56 136 820 to drive out bush.

NOTE
The bush (9) and rectangular rings form a single part.

003631

NOTE
Only remove primary pump, if necessary.

31 Place control element assembly on blocks in the


furnace and heat to approx. 150 °C.

32 Leave control element in the furnace until the pri-


mary pump (36) falls out under its own weight.

CAUTION
Lay the control element on blocks and place in the fur-
nace so that the drive gear (arrow) points upwards.
Do not strike the primary pump.

003632

33 Unscrew three M8 Allen screws (19) on rear side


of oil supply flange.

19

003633

2-260
HP 500 / 590 / 600 “long” version Control unit

34 Turn oil supply flange over and remove thrust


ring (22).

35 Remove stator ring (27) from oil supply flange.

003634

13.3.2 Assembling control element

1 Insert stator ring (27) into oil supply flange so that


the oblong holes are in alignment.

2 Insert thrust ring (22) into stator ring and align


with the threaded bores.

NOTE
The recess in the thrust ring must point towards the sta-
tor ring.

003634

3 Turn oil supply flange over and tighten M8 Allen


screws (19) with washers (20);
torque: 16 Nm
19
NOTE
The stator ring must turn easily.

003633

2-261
Control unit HP 500 / 590 / 600 “long” version

4 Place oil supply flange on device 1X56 136 818.

5 Place control element (15) on oil supply flange


(21) and align with the bores.

003635

6 Screw in three M8x70 Allen screws (14) with


washers and tighten by hand.

7 Screw in four M8x55 Allen screws (13) with


washers and tighten by hand.

003636

8 Screw in three M8x40 Allen screws (12) and three


M8x45 Allen screws (11) with washers and tighten
all Allen screws (11/12/13/14);
torque: 23 Nm

003637

2-262
HP 500 / 590 / 600 “long” version Control unit

9 Screw guide bolt 1X56 136 821 into threaded bore


for fastening the primary pump.

10 Heat control element in furnace to approx. 150 °C.

! DANGER
Only handle hot control element when wearing pro-
tective gloves.

NOTE
Before installing the primary pump, check the
tightening torque of the M8x50 Allen screws on the
primary pump;
003638
torque: 24 Nm

11 Push primary pump (36) over guide bolt and insert


in pump seat without hooking it.

CAUTION
When the control element is heated to 150 °C the
primary pump will drop into the pump seat under its
own weight. Do not strike the primary pump.
Ensure that the primary pump makes axial contact.

12 Remove guide pin.

13 Tighten M8x40 Allen screw (17) and washer of pri-


mary pump by hand.

003639
NOTE
Only tighten the Allen screw (17) after the control ele-
ment has cooled to room temperature;
torque: 23 Nm

14 Use hot air blower 1X56 136 513 to heat stator


shaft (8) to approx. 150 °C.

NOTE
Align the lubrication bore (arrow) in the bore with the
bore in the stator shaft.

15 Push bush into stator shaft until it makes axial


contact.

003640

2-263
Control unit HP 500 / 590 / 600 “long” version

16 Use hot air blower 1X56 136 513 to heat inner


bearing race (5) to approx. 140 °C and push onto
stator shaft until it makes axial contact.

! DANGER
Only handle hot inner bearing race when wearing
protective gloves.

003641

17 Lubricate needle cage (4) with transmission oil and


push onto stator shaft.

18 Use hot air blower 1X56 136 513 to heat piston


ring carrier (3) to approx. 140 °C and push on until
it makes axial contact.

! DANGER
Only handle hot piston ring carrier when wearing pro-
tective gloves.

CAUTION
Never strike the piston ring carrier.

003642

19 Snap circlip (1) into annular groove in stator shaft.

20 Insert rectangular ring (2) into piston ring carrier


and hook up ring gap.

NOTE
The piston ring gap must be correctly engaged and
hooked.

003643

2-264
HP 500 / 590 / 600 “long” version Control unit

! DANGER
Ensure that the control element has cooled completely
before installing the stator shaft.

21 Center stator shaft (8) over dowel pins (arrow) and


insert.

22 Drive stator shaft fully home by tapping gently


with plastic mallet.

003644

Arrangement of stator shaft: 8


1 Circlip
2 Rectangular ring
3 Piston carrier
4 Needle cage
3
2
4

5 Inner bearing race 2 3 1


5

5
6 Dowel pin 4

6
7 Dowel pin
8 Stator shaft
15 Control element

8
6/7
7 15

003828

23 Turn control element over.

24 Screw M8x45 hexagon bolts (24) with washers into


stator shaft;
torque: 23 Nm

003645

2-265
Control unit HP 500 / 590 / 600 “long” version

25 Install four rectangular rings (3) one after the other.

NOTE
Always install the lowest rectangular ring first.
The rectangular ring gap must be correctly engaged
and hooked.

CAUTION
All rectangular rings must be fully engaged in the
annular groove. The rectangular rings are fragile.

003616

26 Use hot air blower 1X56 136 513 to heat bearing


bore of oil supply flange to approx. 85 °C.

27 Insert grooved ball bearing (34) into bearing bore


and drive fully home by tapping gently with a
plastic mallet.

! DANGER
Do not touch hot surface.

NOTE
Do not tilt the grooved ball bearing when driving it in.

003646

28 Push stator ring to open position and insert spring


seat (28).

003621

2-266
HP 500 / 590 / 600 “long” version Control unit

29 Fit spring guide pin (32) with 48 plate springs (31).

NOTE
Push six plate springs in one direction onto the guide
pin. Install the next six the other way round etc.

30 Push spring guide (30) and compression spring


(29) over fitted guide pin (32).

31 Measure distance between spring guide and guide


pin.

32 The distance must measure between


1.6 and 0.5 mm.
Adjust the distance if necessary by adding or
removing plate springs.

NOTE
All threes spring guides are measured and adjusted in
the same way.
1,6 ± 0,5

003831

33 Install spring assembly in stator ring.

NOTE
The spring guide pin (arrow) must rest exactly on the
oil supply flange.

003647

2-267
Clutch carrier HP 500 / 590 / 600 “long” version

13.4 Dismantling and assembling clutch carrier

NOTE
Preceding work; removing and dismantling control unit

5 9
8 10
2
4 6 3
1

7 11

20 21
18 19
16 17
14 15
12 13 46

45

22 23
25
28 30 31 32
29
27 29 28
24
21
26

43 44
42
41
39 40
36 37 38
34 35
33

003 830
003830

2-268
HP 500 / 590 / 600 “long” version Clutch carrier

1 Hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Nm
2 Rotor
* 3 Rectangular ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
4 Rectangular ring
5 Disc seal
6 Needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil: 1X56 122 208;
1X56 122 227; 1X56 137 103
7 Dowel pin
8 Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 136 821
9 Pin
10 Circlip
11 Pin
**12 Circlip
**13 Lip-type seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, grease with Vaseline
**14 Piston C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . retrofit; new piston item no.: 4139 270 016
**15 Lip-type seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . replace, grease with Vaseline
16 Clutch carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 137 127; 1X56 137 128; 1X56 137 130
17 Rectangular ring
18 Piston B
19 Rectangular ring
20 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
21 Inner disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check coating; lubricate with transmission oil
22 Pin
23 Compression spring
24 Retaining pin
**25 Pin
26 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
27 End disc
**28 Inner disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check coating; lubricate with transmission oil
**29 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
**30 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
**31 O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
**32 Reverse gear housing
33 Lip-type seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
34 Lip-type seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . replace
35 Piston A
36 Plate spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1X56 137 105; 1X56 137 127
37 Retaining plate
38 Circlip
39 Plate spring
40 Retaining plate
41 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
42 Inner disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check coating, lubricate with transmission oil
43 End disc
44 Split ring
* 45 Inductive sensor ring
* 46 M6x16 hexagon bolt

* version without clutch C


** version with clutch C

2-269
Clutch carrier HP 500 / 590 / 600 “long” version

Special tools

1X56 122 208 1X56 122 227 1X56 136 821 1X56 137 103 1X56 137 105

1X56 137 127 1X56 137 128 1X56 137 130 1X56 150 111

13.4.1 Dismantling clutch carrier

1 Unscrew M8 hexagon bolts (1) and remove rotor


(2) from clutch carrier.

003648

2-270
HP 500 / 590 / 600 “long” version Clutch carrier

2 Remove disc seal (5) from clutch carrier.

3 Remove rectangular ring (4) from disc seal.

003649

NOTE
Steps 4 to 16 only apply to version with clutch C.

4 Turn clutch carrier over.

5 Insert end of clamping device 1X56 137 127 into


clutch carrier.

6 Attach pressure plate and screw on hand wheel.

7 Put clutch carrier together by tightening hand


wheel.

003650

8 Compress circlip (12) to release and remove.

NOTE
Tapping piston C gently helps to release the circlip.

9 Remove circlip and piston C from the clutch carrier.

003651

2-271
Clutch carrier HP 500 / 590 / 600 “long” version

10 Turn clutch carrier over.

11 Remove clamping device 1X56 137 127.

12 Remove reverse gear housing (32).

003652

13 Remove O-ring (31) from reverse gear housing.


32
31

003837

14 Lift last outer disc (30) off clutch carrier.

003653

2-272
HP 500 / 590 / 600 “long” version Clutch carrier

15 Pull pins (25) and compression springs (23) out of


bores.
25

003654

16 Remove entire disc assembly for clutch C from


clutch carrier.

003685

NOTE
Steps 17 to 23 only apply to version without clutch C.

17 Insert end of clamping device 1X56 137 127 into


clutch carrier.

18 Attach pressure plate and screw on hand wheel.

19 Press inductive sensor ring (45) against clutch


carrier by tightening hand wheel.

20 Unscrew hexagon bolts (46).

21 Unfasten and remove clamping device.

003694

2-273
Clutch carrier HP 500 / 590 / 600 “long” version

22 Lift off inductive sensor ring (45).


45
45

004952

23 Remove compression springs (23) from the bores.

NOTE 23
The version without clutch C has no bolts fitted on
the inductive sensor ring side of the compression
springs (23).

003692

24 Pull two retaining pins (24) out of clutch using a


bar magnet.

24

003655

2-274
HP 500 / 590 / 600 “long” version Clutch carrier

25 Turn end disc (27) so that the teeth point towards


the recesses in the clutch carrier.

26 Remove end disc from clutch carrier.

003656

27 Remove entire disc assembly (20/21/26) for


clutch B with pin (22) from clutch carrier.
20/21/26
28 Remove pin (22) from the last disc.

003657

29 Disengage retaining pins (11) by pushing inwards.

30 Remove split rings (44).

31 Remove end disc (43).

003658

2-275
Clutch carrier HP 500 / 590 / 600 “long” version

32 Remove entire disc assembly (41/42) for clutch A


from clutch carrier.

33 Remove retaining plate (40) and plate spring (39).

003833

NOTE
Steps 34 to 36 only apply to version with clutch C

34 Turn clutch carrier over and remove piston C (14).

35 Remove inner lip-type seal ring (13) of piston C.

CAUTION
Check item number of piston C.
New item number 4139 270 016.
Whenever carrying out repairs to stage 3, a changeover
must be made to the new piston.;
refer to Service Information No.: 27/94 from 25.11.94

003659

36 Remove lip-type seal ring (15) from clutch carrier.

003660

2-276
HP 500 / 590 / 600 “long” version Clutch carrier

37 Place clutch carrier in bottom section of clamping


device 1X56 137 127.

38 Place thrust piece 1X56 137 105 on remaining


plate spring (36).

39 Screw on hand wheel.

40 Press plate spring (36) down by screwing in hand


wheel until the circlip can be snapped out.

41 Snap out circlip and slide over annular groove with


retaining plate.

003661

42 Remove thrust piece.

43 Remove circlip (38) and retaining plate (37).

44 Remove plate spring (36) from clutch carrier.

004951

45 Grip piston A (35) with suitable pliers. Loosen by


gently tapping on the hub using plastic mallet and
remove piston A from clutch carrier.

003662

2-277
Clutch carrier HP 500 / 590 / 600 “long” version

46 Remove outer lip-type seal ring (34) and inner lip-


type seal ring (33) from piston A.

003663

47 Loosen and remove piston B (18) by striking end


face of clutch carrier with plastic mallet.

003664

48 Remove inner rectangular ring (17) and outer plate


compression ring (19) from piston B.

003665

2-278
HP 500 / 590 / 600 “long” version Clutch carrier

HINWEIS
Only remove needle bearing, if necessary.

49 Grip needle bearing (6) with internal extractor


1X56 122 208. Screw on steady 1X56 122 227 and
pull needle bearing out of bearing bore.

003666

50 eat clutch carrier in furnace to approx. 150 °C.

51 Drive hub (8) out of clutch carrier using a plastic


mallet.

! DANGER
Only handle hot clutch carrier when wearing protec-
tive gloves.

003667

2-279
Clutch carrier HP 500 / 590 / 600 “long” version

13.4.2 Assembling clutch carrier

1 Screw two guide pins 1X56 136 821 into opposite


sides of clutch carrier.

2 Heat clutch carrier in furnace to approx. 150 °C.

3 Push hub (8) over guide bolts and press on until it


makes axial contact.

! DANGER
Only handle hot clutch carrier when wearing
protective gloves.

4 Unscrew guide bolts.


003668

5 Coat circumference of needle bearing (6)


with Vaseline, insert in hub and use attachment
1X56 137 103 to drive fully home.

NOTE
Fit attachment in the bearing side with reinforced
casing. The lettered side of the needle bearing is the
driving side.

003669

6 Insert piston A (35) without lip-type seal rings into


clutch carrier.

003670

2-280
HP 500 / 590 / 600 “long” version Clutch carrier

7 Check outer and inner discs for wear.

8 Use a straight-edge to check that all the discs are


flat. Use a surface plate for this.

9 Uneven, dished and damaged discs must be


replaced.

005402

10 Place plate spring (39) on piston A so that the edge


of the bore rests on the piston.

11 Push retaining plate (40) over plate spring with clo-


sed side pointing upwards.

12 Insert entire disc assembly (41/42) for clutch A in


clutch carrier and starting with an inner disc.

NOTE
The last disc is an outer disc. Refer to associated parts
list for the parts of the disc assembly.

003834

13 Fit end disc (43).

14 Insert split ring (44).

003672

2-281
Clutch carrier HP 500 / 590 / 600 “long” version

15 Measure distance “A” from end face of hub to end


face of end disc (43).

16 Note down distance “A”.

003673

17 Push end disc (43) up against split ring until it rea-


ches stop.

18 Measure distance “B” from end face of hub to end


face of end disc.

19 Note down distance “B”.

20 Distance “A” - distance “B” = disc play of clutch A

NOTE
The disc play of clutch ”A” must be between 3.2 and
3.7 mm. The disc play can be adjusted using different
gauges of steel disc (2 and 2.5 mm).

003674

21 Remove entire disc assembly, retaining plate and


plate spring from clutch carrier.

22 Remove piston A from clutch carrier.

23 Check rectangular rings (17/19) of piston B for


damage and replace if necessary.

24 Insert rectangular rings in annular groove of


piston B.

NOTE
Both sealing rings must lie snugly in the base of the
groove without play

003675

2-282
HP 500 / 590 / 600 “long” version Clutch carrier

25 Coat seal rings and contact surface of piston ”B”


with Vaseline.

26 Insert piston B (18) into clutch carrier centrally and


without tilting.

27 Drive piston B fully home by tapping gently with a


plastic mallet.

CAUTION
Do not damage the seal rings. The piston must slide in
tightly.

003676

28 Install outer lip-type seal ring (34) and inner lip-


type seal ring (33) in annular groove in piston A
with the groove pointing towards the pressure side.

NOTE
Stretch the inner lip-type seal ring before installing so
that it lies snugly in the base of the groove. Ensure that
the two lip seal rings rest in the base of the groove
without play.

003663

29 Insert piston A (35) in clutch carrier and move into


axial contact by tapping gently with a plastic mallet.

CAUTION
Coat lip-type seal ring and contact surface of piston A
prior to installation. Do not damage the lip-type seal
ring when installing.

30 Fit plate spring (36) on piston A so that the reces-


ses in the plate spring mesh with the teeth of the
piston.

003677

2-283
Clutch carrier HP 500 / 590 / 600 “long” version

31 Push retaining plate (37) over hub with the recess


pointing upwards.

32 Push circlip (38) over hub.

003678

33 Attach thrust piece 1X56 137 105 onto plate spring


(36).

NOTE
Turn the thrust piece by 90 ° to attach end of circlip.
Use two screwdrivers to press circlip onto recess of
thrust piece and simultaneously press down until the
circlip is snapped into place.

34 Push plate spring downwards using clamping


device 1X56 137 127.

35 Push retaining plate (37) over annular groove and


snap in circlip (38).

003661

CAUTION
Ensure that the circlip is engaged around its entire
circumference.

36 Check outer and inner discs of clutch B for wear.

37 Use a straight edge to check that the all discs are


flat.

38 Uneven, dished and damaged discs must be


replaced.

003671

2-284
HP 500 / 590 / 600 “long” version Clutch carrier

39 Insert outer disc (20) of clutch B into clutch carrier.

NOTE
The first disc is an outer disc and is 3 mm thick. This
outer disc has no gaps.

003679

40 Insert one inner disc (21) and one outer disc (26)
into clutch carrier.

NOTE
Insert the second outer disc and all the other outer discs
of clutch B with the recesses (arrow) over the bores.
Note the arrangement of the teeth on the discs in groups
of three and four.

41 Install disc assembly in clutch carrier by inserting


alternately one outer then one inner disc.

NOTE
Refer to the associated parts list for the size of the disc
assembly required.
003680

42 Insert end disc (27) and turn.

NOTE
Insert the end disc so that the machined smaller bores
in the end disc point exactly to the bores with square
recesses in the clutch carrier.

003681

2-285
Clutch carrier HP 500 / 590 / 600 “long” version

43 Insert two retaining pins (24) into bores with


square grooves.

24

003655

44 Use a feeler gauge to measure disc play of clutch B


between end disc (27) and last outer disc.

45 Repeat measurement at several points around the


circumference and note down average.

NOTE
Nominal disc play of clutch B: for transmission
HP 500, between 1.6 and 2.1 mm; for transmission
HP 590 / HP 600, between 2 and 2.5 mm.
The disc play can be adjusted using different gauges of
outer disc (2 and 2.5 mm).

003682

46 Fit unslotted plate spring (39) on piston A so that


the edge of the bore rests on the piston.

47 Push retaining plate (40) over plate spring with the


closed side pointing upwards.

003683

2-286
HP 500 / 590 / 600 “long” version Clutch carrier

48 Insert entire disc assembly for clutch A into clutch


carrier and follow the specified sequence.

CAUTION
The first disc is an inner disc, the last disc must be an
outer disc.

003835

49 Insert end disc (43) into clutch carrier.

50 Insert split ring (44).

003672

51 Lift end disc and insert the three pins (11).

003684

2-287
Clutch carrier HP 500 / 590 / 600 “long” version

NOTE
Steps 52 to 60 only apply to version without clutch C 23
52 Insert pins (22) into compression springs (23).

53 Install compression springs (23) with pins (22) in


bores around the circumference of the clutch carri-
er.

NOTE
The pins (22) must lie on the first outer disc (20) of
clutch B.

003692

54 Insert attachment of clamping device 1X56 137


127 in clutch carrier. 45
45
55 Fit inductive sensor ring on compression springs.

56 Align bores (arrow) in inductive sensor ring with


bores in clutch carrier.

004952

57 Screw two threaded pins 1X56 150 111 into


threaded bores on clutch carrier.

58 Attach plate and hand wheel of clamping device


1X56 137 127.

003693

2-288
HP 500 / 590 / 600 “long” version Clutch carrier

59 Press inductive sensor ring against clutch carrier by


tightening hand wheel.

60 Unscrew threaded pins, insert hexagon bolts (46)


with washers and tighten:
torque: 9.5 Nm

003694

NOTE
Steps 61 to 76 only apply to version with clutch C.

61 Check outer and inner discs of clutch C for wear


and use straight edge to check that they are flat.

NOTE
Uneven, dished and damaged discs must be replaced.

003671

62 Insert disc assembly of clutch C into clutch carrier.

NOTE
The first disc to be inserted should be an outer disc.
Always alternately insert one outer disc and then one
inner disc. The last outer disc (30) with continuous
teeth should not be inserted yet.

003685

2-289
Clutch carrier HP 500 / 590 / 600 “long” version

63 Insert pins (22/25) in compression spring (23).

64 Install compression spring (23) with pins (22/25) 25


23
in bores around the circumference of the clutch
carrier.
22
NOTE
The pins (22) must lie on the first outer disc (20) of
clutch B.

003686

65 Install lip-type seal ring (15) on circumference of


clutch carrier.

NOTE
The groove must point towards the pressure side.

004950

66 Lastly, fit an outer disc with continuos teeth (30)


(wider teeth) on pins of compression springs and
align with gears.

003687

2-290
HP 500 / 590 / 600 “long” version Clutch carrier

67 Place clutch carrier on clamping device


1X56 137 127.

003688

68 Lubricate new O-ring and insert in reverse gear


housing. 32
NOTE 31
Stretch O-ring prior to installation. O-ring must rest in
the base of the groove without play.

003837

69 Place reverse gear housing on clutch carrier so that


the guide grooves engage on the guide rod.

NOTE
Ensure that the last outer disc does not slip off the com-
pression springs.

003652

2-291
Clutch carrier HP 500 / 590 / 600 “long” version

70 Press reverse gear housing and clutch carrier


together using clamping device.

NOTE
The reverse gear housing may tilt. Rectify position by
gently tapping reverse gear housing with a plastic mal-
let.

71 Turn clutch carrier over.

003689

CAUTION
Check the item number of piston C.
New item number 4139 270 016.
Whenever carrying out repairs to stage 3, a changeover
must be made to the new piston.;
refer to Service Information No.: 27/94 from 25.11.94

72 Install inner lip-type seal ring (13) in annular groo-


ve in piston C with groove facing towards pressure
side.

NOTE
Stretch inner lip-type seal ring before installing. The
lip-type seal ring must rest in the base of the groove
without play. 003690

73 Insert piston C (14) in reverse gear housing.

NOTE
Do not damage the lip-type seal ring.
The piston must slide in easily.

003659

2-292
HP 500 / 590 / 600 “long” version Clutch carrier

74 Snap circlip (12) into annular groove.

NOTE
The circlip must lie in the base of the groove around its
entire circumference.

003651

75 Use a feeler gauge to measure disc play of clutch C


between the last outer disc and the reverse gear
housing.

76 Repeat measurement at several points around cir-


cumference and note down average.

NOTE
Nominal disc play of clutch C: for transmission
HP 500, between 1.2 and 1.7 mm; for transmission
HP 590 / HP 600, between 1.6 and 2.1 mm.
Adjust disc play using different gauges of outer discs
(2 and 2.5 mm).

003691

77 Turn clutch carrier over.

78 Fit disc seal (5) on clutch carrier.

79 Engage rectangular ring (4) with lettering “TOP”


or “R” at the top.

003649

2-293
Clutch carrier HP 500 / 590 / 600 “long” version

80 Screw two guide bolts 1X56 136 821 into clutch


carrier.

81 Align rotor (2) with bores and install.

NOTE
The hole pattern ensures that the rotor can only be
installed in one position.

003695

82 Unscrew guide bolts.

83 Screw in eighteen M8x40 hexagon bolts (1) and


tighten to 32 Nm.

003648

2-294
HP 500 / 590 / 600 “long” version Clutch carrier

13.4.3 Checking clutch carrier for leaks and


checking function.

1 Push guide bush 1X56 137 128 into clutch carrier.

NOTE
Lightly lubricate the seal rings with transmission oil
before pushing in the guide bush.

003696

2 Screw knurled nut (45) onto guide bush until guide


bush makes axial contact.

3 Connect compressed air unit 1X56 137 130 to


connection for pistons A, B and C.

4 Turn adjusting wheel on regulator (46) a few


revolutions in the counter-clockwise direction.

5 Move lever (47) on shut-off cock to the horizontal


position. This opens the shut-off cock.

6 Set adjusting wheel on regulator (46) to max.


testing pressure of 3 bar.

003697
7 Move lever (47) on shut-off cock to the vertical
position. This closes the shut-off cock.

NOTE
Within 10 seconds, the pressure must drop from
2.5 + 0.5 bar to min. 1.4 bar. If the pressure at the
piston drops below 1.4 bar, the appropriate piston must
be removed again to eliminate the leak.

7 Remove compressed air unit.

003836

2-295
Brake D HP 500 / 590 / 600 “long” version

14. Mechanic transmission part, removing and installing brake D

NOTE
Preceding work; removing mechanical transmission part and control unit

Arrangement: brake D

003847

9
6 7
8
4 5
7
2 3
1

11 12
13
10 004946

2-296
HP 500 / 590 / 600 “long” version Brake D

1 Circlip
2 End disc
3 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
4 Pin
5 Compression spring
*6 Ring
7 Inner disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check coating, lubricate with transmission oil
8 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
9 Outer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check for discoloration
10 Piston D
11 Lip-type seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
12 Lip-type seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lubricate with transmission oil
13 Transmission housing

* this may be fitted or it may not depending on version, refer to spare parts catalogue

14.1 Removing brake D

1 Press end disc (2) parallel onto block using two


screw clamps.

2 Remove circlip (1) using a screwdriver.

3 Uniformly slacken screw clamps and remove.

! DANGER
Unscrew the clamps uniformly because the end disc is
spring-loaded.

4 Remove end disc (2) from transmission.

003756

5 Remove compression springs (5), thrust bolts (4)


and ring (*6).

6 Remove entire disc assembly (3/7/8/9) from


transmission housing, tie together and mark for
identification.

003757

2-297
Brake D HP 500 / 590 / 600 “long” version

7 Cover transmission housing with a suitable cloth.

8 Loosen piston D (10) by blowing compressed air


into one of the oil ducts (arrow).

003 758
003758

9 Lift piston (10) out of brake D in transmission


housing.

003759

10 Remove outer and inner lip-type seal rings (11/12)


from piston D.

004948

2-298
HP 500 / 590 / 600 “long” version Brake D

14.2 Installing brake D

1 Install inner lip-type seal ring (11) in piston D with


the annular groove facing the pressure side.

2 Install outer lip-type seal ring (12) in piston D with


annular groove facing the pressure side.

NOTE
Check lip-type seal rings for damage prior to
installation and replace if necessary. Thinly coat
lip-type seal rings with Vaseline.

004948

3 Insert piston D (10) in transmission housing.

4 Drive piston D fully home by gently tapping with a


plastic mallet.

CAUTION
Do not damage the lip-type seal rings. The piston must
slide in easily.

003759

5 Check outer and inner discs for war.

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

NOTE
Uneven, dished and damaged discs must be replaced.

003761

2-299
Brake D HP 500 / 590 / 600 “long” version

7 Install first outer disc (9).

CAUTION
Install the outer disc so that the bores on the disc do not
lie above the deeper bores in the housing.

003763

8 Insert thrust pins (4) into bores in outer disc.

9 Fit compression spring (5) on thrust pins and insert


rings (*6), depending on version.

10 Install one inner disc (7).

003 764
003764

11 Insert the next outer disc (8) so that the gap in the
teeth (arrow) is over the compression springs.

003765

2-300
HP 500 / 590 / 600 “long” version Brake D

12 Install entire disc assembly, alternately inserting


one inner disc (7) and one outer disc (8).

NOTE
The last disc is an outer disc (3). Refer to the spare
parts catalogue for the number of discs required.

003850

13 Install end disc (2).

CAUTION
The double stepped surface of the end disc must face
upwards.

003766

14 Insert two screw clamps and press the end discs (2)
parallel onto block.

15 Snap circlip (1) into annular groove.

16 Remove screw clamps.

! DANGER
Before removing the screw clamps, ensure that the
circlip is engaged in the annular groove around its
entire circumference.

003756

2-301
Brake D HP 500 / 590 / 600 “long” version

17 Use feeler gauge to measure disc play of brake D


between end disc (2) and last outer disc (3).

18 Repeat measurement at several points around cir-


cumference and note down average.

NOTE
Nominal disc play of brake D is between 1.6 and 2.1
mm. Compensate for variations using the appropriate 2
outer discs.

Outer discs are available in the following gauges:


2 mm, 2.5 mm, 3 mm

003768

2-302

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