Epair Anual: HP 500 / HP 590 / HP 600 "Long" Version Stage 3
Epair Anual: HP 500 / HP 590 / HP 600 "Long" Version Stage 3
Epair Anual: HP 500 / HP 590 / HP 600 "Long" Version Stage 3
004273
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
1-1
Table of contents HP 500 / 590 / 600 “long” version
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
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
1-2
HP 500 / 590 / 600 “long” version Table of contents
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
1-4
HP 500 / 590 / 600 “Long” version General comments
RE WO RK I NG
TRANSMISSION ASSEMBLY
1-5
General comments HP 500 / 590 / 600 “Long” version
1-6
HP 500 / 590 / 600 “Long” version Important information
Companies repairing ZF units are responsible for their Read this manual carefully before starting any tests or
own work safety. repair work.
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
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
1-8
HP 500 / 590 / 600 “long” version Transmission cross section
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
1-9
Transmission overview HP 500 / 590 / 600 “long” version
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
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.
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
1-11
Adjustment data HP 500 / 590 / 600
“long” version
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
1-12
HP 500 / 590 / 600 Adjustment data
“long” version
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)
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
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
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
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
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
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
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)
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
1-16
HP 500 / 590 / 600 Adjustment data
“long” version
Miscellaneous
transmission data
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
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
0732 041 934 Control element, stator ring 13.50 1.40 16.35 56.20
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
1-19
Notes HP 500 / 590 / 600 “long” version
1-20
HP 500 / 590 / 600
Special tools
“long” version
Assembly hooks
1 for lifting planetary carrier out of
housing
Internal extractor
3 for needle bearing (18x24x16) in
planetary carrier II and in input shaft
(use with 1X56 122 227)
Internal extractor
4 for needle bearing (45x52x16)
(use with 1X56 122 227)
Internal extractor
5 for needle bearing (55x63x20)
(use with 1X56 122 227)
1-21
HP 500 / 590 / 600
Special tools
“long” version
Counter bracket
6 use with internal extractors
1X56 122 205 and 1X56 122 208
Base tool
7 use with grip 1X56 136 706
Extractor
8 for grooved ball bearing
(0635 331 232) in control insert
Extractor plate
9 for bearing inner race on stator quill
shaft
Extractor
10 for speedo worm
1-22
HP 500 / 590 / 600
Special tools
“long” version
Lifting device
11 for complete output
Punch
12 for tab washer on output flange
13 Hot-air blower
for heating various components
Adapter (LH)
14 for supporting the transmission (use
with assembly stand 1X56 137 450)
Adapter (RH)
15 for supporting the transmission (use
with assembly stand 1X56 137 450)
1-23
HP 500 / 590 / 600
Special tools
“long” version
M8 Hook
17 for lifting control insert off clutch
carrier
Grip
18 for tapered roller bearing
(0635 370 006) on output
Extractor
19 for cover plate behind torque
converter
Adjustment device
20 for tapered roller bearing on output
1-24
HP 500 / 590 / 600
Special tools
“long” version
Support
21 for oil feed flange when fitting
control insert
Punch
22 for removal of bush in stator quill
shaft
M8 guide bolts
23 for installation of control insert and
primary pump
Inserter
24 for shaft sealing ring (90 x 125 x 10)
on output and bearing outer race in
output cover
Thread coupling
25 for axle in PTO
(only version with PTO)
1-25
HP 500 / 590 / 600
Special tools
“long” version
Lifting device
26 for converter
Rod
27 for needle bearing (18 x 24 x 16) in
planetary carrier III and input shaft
Rod
28 for needle bearing (45 x 52 x 16) in
clutch body hub
Pressure piece
29 for pulling off grooved ball bearing
in control insert
(use with 1X56 122 322)
Pressure piece
30 for inserting securing rings in front
of “A” piston cup springs
1-26
HP 500 / 590 / 600
Special tools
“long” version
Device
31 for inserting spacer rings
7
7 10
1X5
6 13
4139 310 018 in control insert
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
Rod
33 for separating clutch carrier from
control insert
Lifting device
34 for Ecomat transmissions
Clamping device
35 for inductive sensor ring
1-27
HP 500 / 590 / 600
Special tools
“long” version
Insertion bush
36 for leakage check of clutches in
clutch carrier
Forcing device
37 for converter leak test
Punch
39 for knocking in and peening the
pressure control unit orifices
Support
40 for stator bearing
1-28
HP 500 / 590 / 600
Special tools
“long” version
Insert
41 for cleaning oil cooler
Punch
42 for knocking out orifices
Holding device
43 for loosening and tightening M16
cap screw in converter
Plug gauge
44 range 0.03 to 0.12” (0.7 to 3.0 mm),
for measuring orifices
Lifting device
45 for turbine shaft
1-29
HP 500 / 590 / 600
Special tools
“long” version
Extractor
47 for output flange
Puller
49 for planet carrier II HP 600
Puller
50 HP 600
for planet carrier II
(in combination with1X56 137 387)
1-30
HP 500 / 590 / 600
Special tools
“long” version
Extractor
51 for pressing off piston ring carrier
from stator quill shaft
Assembly stand
52 can be swivelled/pivoted
Support
53 for securing planetary gear pins
Punch
54 for closing in the planetary gear pins
of planetary carrier I
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
Brace bracket
56 for loosening and tightening screw
plugs in converter
Tool
57 for needle bearing (55x63x20)
in planet carrier III and IV
Measurement rod
58 for measuring inductive sensor
clearance
M6 threaded pin
59 for control unit
1-32
HP 500 / 590 / 600
Special tools
“long” version
ø1
L1 80 80
L2 8 8
L2
ø2
1-33
HP 500 / 590 / 600 “long” version Assembly jig
NOTE
Preceding work: removing transmission
7
2 3
7
4 6
004264
2-1
Assembly jig HP 500 / 590 / 600 “long” version
000786
004265
! DANGER
Take care when inserting shackle. Refer to instructions
on lifting device.
004266
2-2
HP 500 / 590 / 600 “long” version Assembly jig
004267
! 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
004270
! DANGER
Assembly block must not be raised with ring.
004271
! DANGER
Secure right-hand adapter to prevent it swinging.
! DANGER
The transmission may lower somewhat, there is a
danger of crushing.
004272
2-4
HP 500 / 590 / 600 “long” version Pressure reservoir
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
7
9
003481
003 483
003483
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
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
003 484
003484
003485
2-8
HP 500 / 590 / 600 “long” version Retarder accumulator
NOTE
Coat O-ring with Vaseline.
003486
003485
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
001558
001565
001565
2-10
HP 500 / 590 / 600 “long” version 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
003 487
003487
NOTE
If the threaded pins are damaged, unscrew them from
the rear cover.
003 488
003488
003 490
003489
2-12
HP 500 / 590 / 600 “long” version Pressure reservoir
NOTE
All parts must be cleaned thoroughly prior to assembly.
Groove rings, O-rings, piston guide rings, flange
packings etc. should always be replaced.
CAUTION
Groove rings must be installed with the open side facing
outwards. 003 490
003490
CAUTION
Ensure that the groove rings are not damaged when
installing the piston.
003 491
003491
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
NOTE
The shoulder of the connecting plate (arrow) must point
towards the bracket (arrow) on the rear cover.
003493
NOTE
Use new retaining nuts.
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
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
003314
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
003317
NOTE
Transmission version may be one which does not have
screw plugs.
003 318
003318
003 31
003319
2-17
Oil cooler HP 500 / 590 / 600 “long” version
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
003 315
003315
003321
2-18
HP 500 / 590 / 600 “long” version Oil cooler
9 003 003320
320
003 31
003319
! DANGER
Refer to the special safety specifications for cleaning
agents.
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
003317
CAUTION
Take great care when lifting off and transporting the oil 2
cooler. 1
001561
001561
2-20
HP 500 / 590 / 600 “long” version Oil cooler
004311
2-21
Oil cooler HP 500 / 590 / 600 “long” version
003 322
003322
003 323
003323
003 324
003324
2-22
HP 500 / 590 / 600 “long” version Oil cooler
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
003 326
003326
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.
003 328
003328
NOTE
When fitting the cover, ensure that the gaskets are not
displaced.
003 324
003324
003 323
003323
2-24
HP 500 / 590 / 600 “long” version Oil cooler
003 322
003322
3
5
1 001563
001563
3
5
001564
001564
2-25
Torque converter HP 500 / 590 / 600 “long” version
NOTE
Preceding work: clamping transmission in assembly jig
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
2-27
Torque converter HP 500 / 590 / 600 “long” version
NOTE
Depending on the version used, there may be an
assembly cover (22) or a screw plug.
22
003 329
003329
003331
CAUTION
The Allen screws around the circumference of the
HP 590 / HP 600 converter must not be unscrewed.
003 330
003330
2-28
HP 500 / 590 / 600 “long” version Torque converter
003332
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
003334
2-29
Torque converter HP 500 / 590 / 600 “long” version
003335
003 335
003 336
003336
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
! 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.
003 339
003339
2-31
Torque converter HP 500 / 590 / 600 “long” version
! 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
003341
003346
2-32
HP 500 / 590 / 600 “long” version Torque converter
C-B=D
Note down distance “D”.
D B
C
001580 001580
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
2-33
Torque converter HP 500 / 590 / 600 “long” version
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.
NOTE
Thicker washers result in more play.
003349
2-34
HP 500 / 590 / 600 “long” version Torque converter
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.
003340
11 Measure installation depth of converter
NOTE
The converter must be installed with no end float.
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
Außen Ø
If installation depth “F” is between X + 0.05 mm and X
- 0.05 mm, the setting is correct.
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.
003330
2-36
HP 500 / 590 / 600 “long” version Torque converter
NOTE
Ensure that the rubber washer is in place on the thread
of the holder.
003333
003342
003335
2-37
Torque converter HP 500 / 590 / 600 “long” version
003332
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
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
2-40
HP 500 / 590 / 600 “long” version Torque converter
CAUTION
Do not strike the circuit cover or pump gear.
003499
003500
NOTE
Only remove spur gear (43) if necessary.
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
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
003796
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
003354
003 355
003355
! 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
CAUTION
The diameter of the pressure piece must match the
external diameter of the bearing.
003358
003357
003 359
003359
2-44
HP 500 / 590 / 600 “long” version Torque converter
! 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
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
003363
003797
003364
003 3
2-46
HP 500 / 590 / 600 “long” version Torque converter
NOTE
There are springs (44) on the last outer disc (10).
Remove the springs with the last outer disc.
003 365
003365
! DANGER
Edge of groove on plate piston may have sharp edges.
Wear protective gloves.
2-47
Torque converter HP 500 / 590 / 600 “long” version
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.
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.
NOTE
The rectangular rings must lie snugly in the base of the
annular groove around their entire circumference.
003364
003 36
2-48
HP 500 / 590 / 600 “long” version Torque converter
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
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.
2-49
Torque converter HP 500 / 590 / 600 “long” version
1.18 Align end disc so that the bores in the circuit cover
are in alignment with the bores in the end disc.
NOTE
Before tightening the hexagon bolts, drive the plate
piston fully home with a plastic mallet.
003363
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
Converter
with 475 mm external diameter 001570
2-50
HP 500 / 590 / 600 “long” version Torque converter
NOTE
Install the spacer washer with the bores (arrow) at the
top.
CAUTION
Do not damage the annular groove.
003 373
003373
003374
! 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.
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.
003 377
003377
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
NOTE
After inserting, lubricate rollers with transmission oil
and turn the stator several times.
003 379
003379
2.10 Place support 1X56 137 152 in press and lay stator
assembly on support with inserted ball bearing.
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
CAUTION
The beveled edge of the housing washer must face
towards the spur gear.
003381
2-53
Torque converter HP 500 / 590 / 600 “long” version
NOTE
The shaft disc (31) is marked ‘WS’ the housing
disc (33) is marked ‘GS’.
003 382
003382
NOTE
In transmissions with PTOs, the spur gear and pump
gear are each located with two dowel pins. Drive in
dowel pins, if necessary.
CAUTION
Always use new Torx powerlock bolts. The recesses of
the bolt head bores must be level. Countersink, if 003 351
003351
necessary.
003 385
003385
2-54
HP 500 / 590 / 600 “long” version Torque converter
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
003 387
003387
003 388
003388
2-55
Torque converter HP 500 / 590 / 600 “long” version
NOTE
Step 21.1 only applies to torque converter version
HP 500/590 (external diameter 430 mm)
003389
NOTE
The measuring bar must not rest on the stator.
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.
003391
2-56
HP 500 / 590 / 600 “long” version Torque converter
NOTE
Do not put a gasket on the sealing surface of the circuit
cover for this measurement.
CAUTION
003393
The distances in the example calculation are only
theoretical.
2-57
Torque converter HP 500 / 590 / 600 “long” version
003394
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.
003 395
003395
003501
2-58
HP 500 / 590 / 600 “long” version Torque converter
003 396
003396
003397
40
003499
2-59
Torque converter HP 500 / 590 / 600 “long” version
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).
004288
CAUTION
Allen screws (3) are coated.
Always use new Allen screws (3).
004289
2-60
HP 500 / 590 / 600 “long” version Torque converter
003 398
003398
2-61
Torque converter HP 500 / 590 / 600 “long” version
NOTE
Preceding work; removing torque converter
8 17 2
6 1 3
5
4
9 003126
2-62
HP 500 / 590 / 600 “long” version Torque converter
! 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
003344
CAUTION
The water in the tank must be at a temperature of 20 °C
and be mixed with antifreeze in the ration 1:120.
003 127
003127
2-63
Torque converter HP 500 / 590 / 600 “long” version
NOTE
The torque converter must be absolutely airtight.
003126
! DANGER
The converter weighs approx. 60 kg. Two people are
required to turn it over and it must be secured to
prevent it falling.
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
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
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
2-66
HP 500 / 590 / 600 “long” version Cover plate
NOTE
Before removing the cover plate, swivel up transmission
and drain oil. Only remove oil pipe (21) if necessary.
003502
003799
2-67
Cover plate HP 500 / 590 / 600 “long” version
003504
003505
003506
2-68
HP 500 / 590 / 600 “long” version Cover plate
003507
003512
003800
2-69
Cover plate HP 500 / 590 / 600 “long” version
003508
003509
003510
2-70
HP 500 / 590 / 600 “long” version Torque converter
003511
003511
003510
2-71
Cover plate HP 500 / 590 / 600 “long” version
003509
NOTE
The circlips and disc must face towards the control
element.
003512
2-72
HP 500 / 590 / 600 “long” version Torque converter
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
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.
003502
2-73
Cover plate HP 500 / 590 / 600 “long” version
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
NOTE
The lubricant used should be a water-soluble detergent
concentrate.
003513
2-74
HP 500 / 590 / 600 “long” version 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
2-75
Oil pan HP 500 / 590 / 600 “long” version
004304
004302
004295
2-76
HP 500 / 590 / 600 “long” version Oil pan
NOTE
Only remove oil pipe, if necessary.
10
12
004305
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.
004307
2-77
Oil pan HP 500 / 590 / 600 “long” version
004294
NOTE
The gasket must remain in the same position when the 1
oil pan is attached.
CAUTION
Attach new Cu seal rings (2) to the two hexagon bolts
(arrow) to assist the sealing.
004295
004296
2-78
HP 500 / 590 / 600 “long” version Oil pan
004302
004303
004304
2-79
Inductive sensor HP 500 / 590 / 600 “long” version
NOTE
Preceding work; removing oil pan
1
2
3
4
004291
2-80
HP 500 / 590 / 600 “long” version Inductive sensor
004298
2
4
004297
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
003306
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.
001571
2-82
HP 500 / 590 / 600 “long” version Inductive sensor
CAUTION
Circlip (7) must remain in the same position when the
measuring rod is pulled.
003303
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
A 001572
2-83
Inductive sensor HP 500 / 590 / 600 “long” version
CAUTION
Do not exceed torque.
004297
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
2-85
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
003 462
003462
NOTE
If necessary, unfasten lug (5) and unscrew plug
connection until it disconnects from lug.
003 463
003463
CAUTION 1
Do not loosen M6 hexagon bolts.
! 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
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
NOTE
Tighten hexagon bolts starting from inside and working
outwards
2
003515
003 463
003463
2-87
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
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
* 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
CAUTION
Observe the markings and assignment of the individual
cables to the solenoid valves. If necessary, mark the cable.
003 400
003400
003 401
003401
003516
2-91
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
003802
003 402
003402
003803
2-92
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit
003403
NOTE
18
22
Fitted as standard as of transmission no. 078844.
20
003 461
003461
2-93
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
003404
NOTE
22
22
Fitted as standard as of transmission no. 078844.
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.
003405
NOTE
Check duct plate for damage and replace if necessary.
003406
003505
2-95
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
003 407
003407
003 408
003408
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
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
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.
003404
003803
003 402
003402
2-98
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit
003802
003 401
003401
003516
2-99
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
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
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
2-101
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
003807
003 413
003413
003 411
003411
2-102
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit
003 412
003412
003 410
003410
003411
2-103
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
003 412
003412
003 413
003413
003807
2-104
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit
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
003 414
003414
NOTE
Leave one hexagon bolt (arrow) in the valve block.
! DANGER
The cover plate is spring-loaded. Remove the cover
plate carefully.
003 416
003416
2-107
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
34 003809
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
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
! DANGER
The cover plate is spring-loaded. Remove the cover
plate carefully.
003 419
003419
003 443
003443
003 428
003428
2-109
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
003853
16
003420
28
003 421
003421
2-110
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit
003422
003 422
CAUTION
The peening tool must be ground off before removing
the orifices.
003 423
003423
NOTE
Peen orifices twice at right angles.
2-111
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
003 425
003425
16
003420
003853
2-112
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit
7
8 003 428
003428
003 429
003429
! DANGER
The cover plate is spring-loaded. The cover plate must
be secured until the hexagon bolts are screwed in.
003 430
003430
2-113
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
003 431
003431
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
34 003809
003 416
003416
! DANGER
Cover plate is spring-loaded. The cover plate must be
secured until the hexagon bolt is screwed in.
30 003 415
003415
2-115
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
003 414
003414
2-116
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit
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
2-118
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit
003432
NOTE
Leave one hexagon bolt (arrow) in valve block.
! DANGER
Cover plate is spring-loaded. Remove the cover plate
carefully.
003433
003 434
003434
2-119
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
9 003809
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
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
! DANGER
The cover plate is spring-loaded. Remove the cover
plate carefully.
003 437
003437
003 442
003442
003 438
003438
2-121
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
003853
22
003 439
003439
10
003440
003 440
2-122
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit
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.
003 441
003441
CAUTION
The peening tool must be ground off before removing
the orifices.
003423
NOTE
Peen orifices twice at right angles.
2-123
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
10
003440
003 440
003 439
003439
003853
2-124
HP 500 / 590 / 600 “long” version Hydraulic transmission control unit
003 438
003438
003 446
003446
! DANGER
The cover plate is spring-loaded. The cover plate must
be secured until the hexagon bolts are screwed in.
003 447
003447
2-125
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
003 448
003448
NOTE
The pistons may fall out when the valve block is turned
over.
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
9 003809
4 003 416
003416
! DANGER
Cover plate is spring-loaded. The cover plates must
be secured until the hexagon bolt is screwed in.
003 433
003433
2-127
Hydraulic transmission control unit HP 500 / 590 / 600 “long” version
003432
2-128
HP 500 / 590 / 600 “long” version 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
2-129
Retarder valve HP 500 / 590 / 600 “long” version
003449
003 449
2 Remove cover (6), take out O-ring (7) and shims (8).
003450
003 451
003451
2-130
HP 500 / 590 / 600 “long” version Retarder valve
7 Pull out stop (16) and bush (10) using threaded bolt
or screw.
003 452
003452
003 454
003454
2-131
Retarder valve HP 500 / 590 / 600 “long” version
003 454
003454
003455
003456
003 45
2-132
HP 500 / 590 / 600 “long” version Retarder valve
NOTE
The bores (arrow) in the bush must point vertically
upwards.
003 457
003457
003458
2-133
Retarder valve HP 500 / 590 / 600 “long” version
NOTE
Push on the seal ring with open side pointing towards
the piston crown.
003451
7
8
003464
003 465
003465
2-134
HP 500 / 590 / 600 “long” version Retarder valve
003 466
003466
003449
003 449
Output HP 500 / 590 / 600 “long” version
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
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
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
18
16
004352
CAUTION
Ensure that all remaining shims are removed from the
output end cover.
004353
004354
2-138
HP 500 / 590 / 600 “long” version Output
20
21
a
001566
005273
m
5m
NOTE
Measuring rod must be at right angles to gear.
NOTE
The circlip must not move.
004355
2-139
Output HP 500 / 590 / 600 ”long” version
003303
003304
003 304
NOTE
The distances used in the example calculation are Shims are available for installation in the following
theoretical. gauges:
2-140
HP 500 / 590 / 600 “long” version Output
20
004356
NOTE
The flat connectors can be attached in any way.
004357
NOTE
Lightly lubricate O-ring.
18
16
004352
2-141
Output HP 500 / 590 / 600 “long” version
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.
6 Use attachment 1X56 100 632 (c) to push seal ring 001578
2-142
HP 500 / 590 / 600 “long” version Output
! DANGER
Wear protective glasses: risk from flying metal
splinters. 12
NOTE 13
Counter output flange using flange retainer.
11
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
NOTE
Beveled side of thrust washer must be facing outwards.
13 11
003312
2-143
Output HP 500 / 590 / 600 “long” version
! 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
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
! DANGER
Wear protective glasses: risk from flying metal
splinters.
NOTE
To unscrew the two hexagon bolts, counter output flange
with flange retainer.
NOTE
004361
If necessary gently tap thrust washer with plastic mallet
to remove it.
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
CAUTION
When lifting off the output end cover, carefully guide
the cable for the inductive sensor through the housing
bore.
004358
CAUTION
Place washers underneath. The sealing surface must not
be damaged.
003517
003518
2-146
HP 500 / 590 / 600 “long” version Output
M
B
003519
005218
10 Calculate 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.
003568
2-148
HP 500 / 590 / 600 “long” version Output
CAUTION
Use washers. The sealing surface must not be damaged.
003517
NOTE
The end disc must be an outer disc.
004994
4 Calculate “C”:
Distance “A” - distance “B” = distance “C”.
003519
2-149
Output HP 500 / 590 / 600 “long” version
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
NOTE
Before attaching the output end cover, ensure that brake 1
“G” has been installed correctly.
004359
004358
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
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
NOTE
Beveled side of thrust washer must be facing outwards.
003817
! 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
11
16 17
15
14 19
12
23
13 25
24
22
18 20 21
1
2
3
4
5
6
7
9
10
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
2-154
HP 500 / 590 / 600 “long” version Output
! DANGER
Do not put fingers under planet carrier to lift it.
CAUTION
Place soft material under planet carrier.
003527
005401
005401
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
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.
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.
003531
2-156
HP 500 / 590 / 600 “long” version Output
CAUTION
Do not damage the thread of the speedo worm when
fitting the puller.
CAUTION
Attach pressure piece to face end of output shaft.
003532
003533
NOTE
Only remove tapered roller bearing if necessary.
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
11
003535
CAUTION
Only remove needle bearing if necessary. The bearing
should be destroyed once removed.
003536
CAUTION
Never drive the dowel pins in as far as their stops.
003540
2-158
HP 500 / 590 / 600 “long” version Output
13
18
003819
25
24
22
20 21
003820
2-159
HP 500 / 590 / 600 “long” version Output
NOTE
005401
Piston G must make axial contact and must slide in 005401
easily.
19
003819
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.
003540
13
18
003819
2-161
Output HP 500 / 590 / 600 “long” version
NOTE
The end float must be between 0.5 and 1.2 mm.
Take measurement on all planet gears.
003548
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
CAUTION
The output end cover must not be allowed to cool
below 85 °C.
2a
003552
2
003553
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
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
CAUTION
Do not displace the dowel pins when unscrewing the
hexagon bolt.
003554
NOTE
Repeat measurement at several points and determine
average value.
003556
2-164
HP 500 / 590 / 600 “long” version Output
003557
003558
CAUTION
Do not strike the rollers. Drive tapered roller barring 66
fully home after it has cooled.
003559
2-165
Output HP 500 / 590 / 600 “long” version
003560
7 5
6
003 560
003561
003531
2-166
HP 500 / 590 / 600 “long” version Output
11
003562
003563
22 Coat circumference of shaft seal ring (1) with
detergent.
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.
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
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
2-170
HP 500 / 590 / 600 “long” version Intermediate housing
003568
003569
003570
2-171
Intermediate housing HP 500 / 590 / 600 “long” version
NOTE
Mark the order of the discs and tie together.
003571
22
005399
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
CAUTION 15
Carefully guide cable for inductive sensor through
housing bore.
13
003576
2-173
Intermediate housing HP 500 / 590 / 600 “long” version
003577
12
10 11
003578
2-174
HP 500 / 590 / 600 “long” version Intermediate housing
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
2-175
Intermediate housing HP 500 / 590 / 600 “long” version
NOTE
The end disc must be an outer disc.
003815
003816
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
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
003577
NOTE
Install dowel pin (14) in transmission housing, if 15
removed.
CAUTION
Carefully guide cable for inductive sensor through
housing bore (arrow).
2-177
Intermediate housing HP 500 / 590 / 600 “long” version
003580
18
003573
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.
005399
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.
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
003570
003568
2-180
HP 500 / 590 / 600 “long” version Mechanical transmission part
NOTE
Preceding work; removing output end cover and intermediate housing
Diagram: transmission version - HP 500 / HP 590
2
4
003839
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
003698
2 Pull sun gear (32) with thrust washer (33) off drive
shaft.
003699
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
! DANGER
Secure planet carrier so that it cannot tilt.
Planet carrier is unstable when suspended by hooks.
003700
NOTE
Mark disc assemblies for identification. The discs of the
various assemblies must not be confused.
003844
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
NOTE
The pins (27) are removed together with the last discs
(refer to step 13).
003848
! DANGER
Secure planet carrier so that it cannot tilt.
Planet carrier is unstable when suspended by hooks.
003702
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
003704
NOTE
The disc assembly must be marked for identification.
The discs of the various assemblies must not be
confused.
004924
NOTE
The centering pin must not be dropped into the trans-
mission.
003705
2-188
HP 500 / 590 / 600 “long” version Mechanical transmission part
NOTE
Wire the disc assembly together and mark for identifica-
tion. The discs of the various assemblies must not be
confused.
004989
003707
003788
2-189
Mechanical transmission part HP 500 / 590 / 600 “long” version
003709
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
NOTE
Ensure that the circlip does not slip back into the annu-
lar groove.
003711
NOTE
If necessary, separate the ring gear from the planet car-
rier by tapping gently with a plastic mallet.
003712
003713
2-191
Mechanical transmission part HP 500 / 590 / 600 “long” version
003714
003715
003716
2-192
HP 500 / 590 / 600 “long” version Mechanical transmission part
003717
003718
2-193
Mechanical transmission part HP 500 / 590 / 600 “long” version
003745
NOTE
Ensure that the circlip does not slip back into the annu-
lar groove once disengaged.
003744
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
003719
003720
! DANGER
Wear goggles when peening the planet gear shafts.
003721
2-195
Mechanical transmission part HP 500 / 590 / 600 “long” version
003722
003 722
003723
2-196
HP 500 / 590 / 600 “long” version Mechanical transmission part
003719
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
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
003723
NOTE
Two thrust plates (2) are fitted in transmission
version HP 600.
003725
2-198
HP 500 / 590 / 600 “long” version Mechanical transmission part
NOTE
Do not push in mandrel with force or knock in.
NOTE
Use new planet gear shafts.
Always replace entire sets of planet gears.
All the planet gears are installed in the same way.
003726
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
003727
2-199
Mechanical transmission part HP 500 / 590 / 600 “long” version
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
14 Align gearing.
003730
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
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
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
NOTE
First fit the thrust plate with three apertures.
003734
NOTE
Do not push in the mandrel with force or knock it in.
NOTE
Use new planet gear shafts. All the planet gears are
installed in the same way. Always replace entire sets of
planet gears.
003735
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
003736
NOTE
End float is between 0.5 and 1.2 mm
Take measurement of all planet gears.
003737
14 Align gearing.
003738
2-203
Mechanical transmission part HP 500 / 590 / 600 “long” version
NOTE
Install circlip with the gap at the bore (arrow).
The circlip must be fully engaged in the annular groove.
003739
18 Fit circlip.
003740
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
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.
003742
003743
NOTE
The circlip must be fully engaged in the annular groove.
003744
2-205
Mechanical transmission part HP 500 / 590 / 600 “long” version
003745
003746
2-206
HP 500 / 590 / 600 “long” version Mechanical transmission part
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
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
003778
2-208
HP 500 / 590 / 600 “long” version Mechanical transmission part
003777
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
003750
NOTE
Step 6 only applies to version HP 500 / HP 590
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
003751
2-210
HP 500 / 590 / 600 “long” version Mechanical transmission part
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
Special tools: 1X56 122 227, 1X56 122 205, 1X56 137 101
2-211
Mechanical transmission part HP 500 / 590 / 600 “long” version
NOTE
Steps 1 and 2 only apply to version with clutch C
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
4 5
003854
003772
2-212
HP 500 / 590 / 600 “long” version Mechanical transmission part
NOTE
The thrust washer may stick on the drive shaft.
003754
NOTE
Only remove needle bearing (2) if required.
003755
NOTE
Removing and installing brake D;
refer to Chapter 14, page 300
2-213
Mechanical transmission part HP 500 / 590 / 600 “long” version
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
003770
003771
2-214
HP 500 / 590 / 600 “long” version Mechanical transmission part
CAUTION
The drive shaft must make axial contact.
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
003752
2-215
Mechanical transmission part HP 500 / 590 / 600 “long” version
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
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.
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.
003773
2 10
003774
003774
2-217
Mechanical transmission part HP 500 / 590 / 600 “long” version
003775
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
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
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
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
2-221
Mechanical transmission part HP 500 / 590 / 600 “long” version
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
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).
003782
B) Second version
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
003704
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.
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
! DANGER
Counter the planet carrier I when lifting to prevent it
from slipping off the assembly hooks.
003702
CAUTION
The first outer disc must be 3 mm thick.
CAUTION
Install the thrust ring so that the round recesses
(arrow A) are over the housing bores.
NOTE
The guide tunes are conical. Always install the guide
tubes with the longer bevels pointing upwards.
003843
003785
2-225
Mechanical transmission part HP 500 / 590 / 600 “long” version
! 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
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).
003699
003 698
NOTE
Uneven, dished and damaged discs must be replaced.
003781
2-226
HP 500 / 590 / 600 “long” version Mechanical transmission part
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
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
CAUTION
The last outer disc must not be used for compensating
play.
003851
2-227
Mechanical transmission part HP 500 / 590 / 600 “long” version
003787
003704
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
CAUTION
The first outer disc must be 3 mm thick.
003789
CAUTION
Insert cable for inductive sensor in the correct housing
duct.
2-229
Mechanical transmission part HP 500 / 590 / 600 “long” version
NOTE
The inductive sensor ring only needs to be measured in
version “without clutch C”.
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.
Induktivgeberring
001572
2-230
HP 500 / 590 / 600 “long” version 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
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
NOTE
Step 1 only applies to transmissions with new housing
(as of vol. prod. no.: 96173)
003581
003582
003597
2-233
Control unit HP 500 / 590 / 600 “long” version
! DANGER
Only handle transmission housing when wearing
protective gloves.
003583
! 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
CAUTION
Whilst the lifting device is being unscrewed, the turbine
shaft must be held (by hand) to prevent it falling out.
003584
003585
! 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
CAUTION
The lug (arrow) on the intermediate plate must engage
in the recess (arrow) in the sealing washer.
003587
003588
! DANGER 17
Grooved ball bearing is hot. Wear protective gloves.
003589
2-236
HP 500 / 590 / 600 “long” version Control unit
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
003585
2-237
Control unit HP 500 / 590 / 600 “long” version
003592
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
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
003594
003595
4 Use hot air blower 1X56 136 513 to heat seat for
control unit in transmission housing
to approx. 140 °C.
! 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
13 11
003598
003597
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
CAUTION
When screwing in and tightening the Allen screws,
ensure that the sealing surface is not damaged.
13 11
003598
003597
003599
NOTE
If the intake pipe is difficult to install, drive it in
carefully using a plastic mallet.
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
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
Special tools
107
137
1X56
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
CAUTION
The pistons and other individual parts of the control
element must be handled with great care and kept clean.
1.1 Counter spacer ring (24) and pull out cylinder pin
(23).
! DANGER
Spacer ring is spring loaded.
003601
003602
003603
2-244
HP 500 / 590 / 600 “long” version Control unit
! DANGER
The washers are spring-loaded. When relieving the
spindles, ensure that the sealing washers do not jump
out.
003604
003832
! 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
! DANGER
Do not touch the housing with bare hands. The hou-
sing has sharp edges.
003606
003607
2-246
HP 500 / 590 / 600 “long” version Control unit
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.
NOTE
When installing spacer element, turn it so that it does
003608
not protrude over the coat side of the control element.
003609
003610
2-247
Control unit HP 500 / 590 / 600 “long” version
003604
! DANGER
Before unscrewing the spindles, ensure that the circlip
is correctly engaged.
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.
003605
2-248
HP 500 / 590 / 600 “long” version Control unit
003612
! DANGER
Before unscrewing the spindles, ensure that the circlip
is correctly engaged.
003613
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
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
Special tools
1X56 122 322 1X56 124 659 1X56 136 818 1X56 136 820 1X56 136 821
2-252
HP 500 / 590 / 600 “long” version Control unit
003614
NOTE
Use SW 46 open end wrench to counter puller on lock
nut.
003615
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:
C
001582
001582
003618
2-254
HP 500 / 590 / 600 “long” version Control unit
! 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
003620
NOTE
The spring seat (28) may stick to the compression
spring (29).
003621
2-255
Control unit HP 500 / 590 / 600 “long” version
003637
003636
003622
2-256
HP 500 / 590 / 600 “long” version Control unit
003623
003624
NOTE
The two dowel pins can remain in place.
003625
2-257
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.
003626
NOTE
Remove rectangular ring (2) with hooked gap as
follows:
C
001582
001582
003627
2-258
HP 500 / 590 / 600 “long” version Control unit
003628
CAUTION
The stamped numbers must match on the two halves of
the pulling device.
003629
003630
2-259
Control unit HP 500 / 590 / 600 “long” version
NOTE
The bush (9) and rectangular rings form a single part.
003631
NOTE
Only remove primary pump, if necessary.
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
19
003633
2-260
HP 500 / 590 / 600 “long” version Control unit
003634
NOTE
The recess in the thrust ring must point towards the sta-
tor ring.
003634
003633
2-261
Control unit HP 500 / 590 / 600 “long” version
003635
003636
003637
2-262
HP 500 / 590 / 600 “long” version Control unit
! 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
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.
003639
NOTE
Only tighten the Allen screw (17) after the control ele-
ment has cooled to room temperature;
torque: 23 Nm
NOTE
Align the lubrication bore (arrow) in the bore with the
bore in the stator shaft.
003640
2-263
Control unit HP 500 / 590 / 600 “long” version
! DANGER
Only handle hot inner bearing race when wearing
protective gloves.
003641
! DANGER
Only handle hot piston ring carrier when wearing pro-
tective gloves.
CAUTION
Never strike the piston ring carrier.
003642
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.
003644
5
6 Dowel pin 4
6
7 Dowel pin
8 Stator shaft
15 Control element
8
6/7
7 15
003828
003645
2-265
Control unit HP 500 / 590 / 600 “long” version
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
! DANGER
Do not touch hot surface.
NOTE
Do not tilt the grooved ball bearing when driving it in.
003646
003621
2-266
HP 500 / 590 / 600 “long” version Control unit
NOTE
Push six plate springs in one direction onto the guide
pin. Install the next six the other way round etc.
NOTE
All threes spring guides are measured and adjusted in
the same way.
1,6 ± 0,5
003831
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
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
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
003648
2-270
HP 500 / 590 / 600 “long” version Clutch carrier
003649
NOTE
Steps 4 to 16 only apply to version with clutch C.
003650
NOTE
Tapping piston C gently helps to release the circlip.
003651
2-271
Clutch carrier HP 500 / 590 / 600 “long” version
003652
003837
003653
2-272
HP 500 / 590 / 600 “long” version Clutch carrier
003654
003685
NOTE
Steps 17 to 23 only apply to version without clutch C.
003694
2-273
Clutch carrier HP 500 / 590 / 600 “long” version
004952
NOTE 23
The version without clutch C has no bolts fitted on
the inductive sensor ring side of the compression
springs (23).
003692
24
003655
2-274
HP 500 / 590 / 600 “long” version Clutch carrier
003656
003657
003658
2-275
Clutch carrier HP 500 / 590 / 600 “long” version
003833
NOTE
Steps 34 to 36 only apply to version with clutch 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
003660
2-276
HP 500 / 590 / 600 “long” version Clutch carrier
003661
004951
003662
2-277
Clutch carrier HP 500 / 590 / 600 “long” version
003663
003664
003665
2-278
HP 500 / 590 / 600 “long” version Clutch carrier
HINWEIS
Only remove needle bearing, if necessary.
003666
! DANGER
Only handle hot clutch carrier when wearing protec-
tive gloves.
003667
2-279
Clutch carrier HP 500 / 590 / 600 “long” version
! DANGER
Only handle hot clutch carrier when wearing
protective gloves.
NOTE
Fit attachment in the bearing side with reinforced
casing. The lettered side of the needle bearing is the
driving side.
003669
003670
2-280
HP 500 / 590 / 600 “long” version Clutch carrier
005402
NOTE
The last disc is an outer disc. Refer to associated parts
list for the parts of the disc assembly.
003834
003672
2-281
Clutch carrier HP 500 / 590 / 600 “long” version
003673
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
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
CAUTION
Do not damage the seal rings. The piston must slide in
tightly.
003676
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
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.
003677
2-283
Clutch carrier HP 500 / 590 / 600 “long” version
003678
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.
003661
CAUTION
Ensure that the circlip is engaged around its entire
circumference.
003671
2-284
HP 500 / 590 / 600 “long” version 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.
NOTE
Refer to the associated parts list for the size of the disc
assembly required.
003680
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
24
003655
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
003683
2-286
HP 500 / 590 / 600 “long” version Clutch carrier
CAUTION
The first disc is an inner disc, the last disc must be an
outer disc.
003835
003672
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).
NOTE
The pins (22) must lie on the first outer disc (20) of
clutch B.
003692
004952
003693
2-288
HP 500 / 590 / 600 “long” version Clutch carrier
003694
NOTE
Steps 61 to 76 only apply to version with clutch C.
NOTE
Uneven, dished and damaged discs must be replaced.
003671
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
003686
NOTE
The groove must point towards the pressure side.
004950
003687
2-290
HP 500 / 590 / 600 “long” version Clutch carrier
003688
003837
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
NOTE
The reverse gear housing may tilt. Rectify position by
gently tapping reverse gear housing with a plastic mal-
let.
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
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
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
NOTE
The circlip must lie in the base of the groove around its
entire circumference.
003651
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
003649
2-293
Clutch carrier HP 500 / 590 / 600 “long” version
NOTE
The hole pattern ensures that the rotor can only be
installed in one position.
003695
003648
2-294
HP 500 / 590 / 600 “long” version Clutch carrier
NOTE
Lightly lubricate the seal rings with transmission oil
before pushing in the guide bush.
003696
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.
003836
2-295
Brake D HP 500 / 590 / 600 “long” version
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
! DANGER
Unscrew the clamps uniformly because the end disc is
spring-loaded.
003756
003757
2-297
Brake D HP 500 / 590 / 600 “long” version
003 758
003758
003759
004948
2-298
HP 500 / 590 / 600 “long” version Brake D
NOTE
Check lip-type seal rings for damage prior to
installation and replace if necessary. Thinly coat
lip-type seal rings with Vaseline.
004948
CAUTION
Do not damage the lip-type seal rings. The piston must
slide in easily.
003759
NOTE
Uneven, dished and damaged discs must be replaced.
003761
2-299
Brake D HP 500 / 590 / 600 “long” version
CAUTION
Install the outer disc so that the bores on the disc do not
lie above the deeper bores in the housing.
003763
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
NOTE
The last disc is an outer disc (3). Refer to the spare
parts catalogue for the number of discs required.
003850
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.
! 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
NOTE
Nominal disc play of brake D is between 1.6 and 2.1
mm. Compensate for variations using the appropriate 2
outer discs.
003768
2-302