ZF Manual Reparação ECOMATICl

REPAIR MANUAL
005380
005380
HP 500 / HP 590 / HP 600

EST 18
Stages 1-2
4139 751 626e
Subject to alterations in design
Copyright by ZF
Reproduction in whole or in part, is only allowed with our written approval and authorization.
Printed in Germany
Edition: 11.95
4139 751 626e

HP 500 / HP 590 / HP 600 Contents
Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjustment data and tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Special notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Arrangement of peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cutaway views of Ecomat transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Clutch combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1 Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.2 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Oil grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.5 Operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6 Adding oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7 Checking oil level at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.8 Checking oil level when cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.9 Checking oil level with engine off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.10 Checking oil level on versions with heat exchanger higher than centre line of transmission . . . . . . . . . 19
1.11 Changing oil at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.12 Adjusting load sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1 Renewing filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.2 Renewing retarder solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3 Renewing accumulator solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4 Renewing accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.5 Renewing temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.6 Renewing output sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.7 Removing and fitting oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.8 Renewing turbine sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9 Renewing complete hydraulic control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.10 Renewing speedometer drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.11 Renewing output flange and/or radial seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.12 Pressure tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Contents HP 500 / HP 590 / HP 600
Page
3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Troubleshooting chart for Ecomat with EST 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
A Test instructions for test cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1P01 137 002

B MOBiDIG 200 diagnostic system with "Plug-In" card . . . . . . . . . . . . . . . . . . 6038 756 108
C Test instructions for PR 87 tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4139 756 109
D Testing with terminal tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4139 756 110
E Circuit diagrams
Hydraulic circuit diagram for “short” version of Ecomat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1

Hydraulic circuit diagram for “long” version of Ecomat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2
Ecomat pneumatic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3
Connection diagram for commercial vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4
Connection diagram for buses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E5
Ecomat hydraulic circuit diagram 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E6
Ecomat hydraulic circuit diagram 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E7
For wiring diagram, see “Testing with terminal tester”

HP 500 / HP 590 / HP 600 Preface
This manual is intended for skilled personnel who have been trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products.
This manual deals with the standard ZF product in accordance with the state of development at issue date.
However, due to continuing development of the product, repair work might require work practises and test or
adjustment data which are not contained in this manual. We therefore recommend that work done on your ZF
product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on
a regular basis at our after-sales service training courses.
Service points equipped by ZF Friedrichshafen all over the world offer you:
1. Well-trained personnel
2. Specified equipment, e.g. specialized tools
3. Genuine ZF spares, to our latest specifications
All work performed in these service points is carried out conscientiously and with care.
Repair work carried out at ZF service points is guaranteed in accordance with the prevailing contractual
conditions.
Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner, together
with follow-on costs caused by such work, is excluded from the contractual guarantee agreement. This also applies
where ZF spares have not been used.
ZF FRIEDRICHSHAFEN AG
Friedrichshafen Division
After-Sales Service
3
General HP 500 / HP 590 / HP 600
Important work safety notice:
Companies who repair ZF units are responsible for their own work safety.
To avoid injury to personnel and damage to products, all safety regulations and legal requirements which
apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize
themselves with these regulations.
Personnel required to carry out repairs on these ZF products must receive appropriate training in advance. It is the
responsibility of each company to ensure that their repair staff is properly trained.
The following safety instructions appear in this manual:
NOTE: Refers to special processes, techniques, data, use

of auxiliary equipment, etc.
CAUTION This is used when incorrect, unprofessional

working practices could damage the product.
This is used when lack of care could lead to

! DANGER
personal injury or death.
NOTE: Read this manual carefully before starting any tests or repair work.
CAUTION
Pictures, drawings and components do not always represent the original object, but are used to illustrate working
procedures.
Pictures, drawings and components are not to scale and no information about size and weight should be inferred
(even within a complete illustration).
Always follow the working steps as described in the text.
NOTE: After completion of repair work and testing, skilled staff must satisfy themselves that the product is
functioning correctly.
4
HP 500 / HP 590 / HP 600 Tightening torques
Tightening torques for bolts and nuts, excerpt from ZF Standard ZFN 148
This Standard applies for bolts to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and for nuts to DIN 934.
This Standard contains data on tightening torques (MA) for bolts in strength categories 8.8, 10.9 and 12.9 and nuts
in strength categories 8, 10 and 12.
Surface condition of bolts: heat-treated blackened finish and oiled or galvanized and oiled or galvanized, chrome-
plated and oiled.
Tighten screws using a calibrated signal or pointer-type torque wrench.
Metric coarse pitch thread Metric fine pitch thread
Size Tightening torque Size Tightening torque

MA (Nm) for MA (Nm) for
Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12
M 4 2,8 4,1 4,8 M 8x1 24 36 43

M 5 5,5 8,1 9,5 M 9x1 36 53 62
M 6 9,5 14 16,5 M 10 x 1 52 76 89
M 7 15 23 28 M 10 x 1,25 49 72 84
M 8 23 34 40 M 12 x 1,25 87 125 150
M 10 46 68 79 M 12 x 1,5 83 122 145
M 12 79 115 135 M 14 x 1,5 135 200 235

M 14 125 185 215 M 16 x 1,5 205 300 360
M 16 195 280 330 M 18 x 1,5 310 440 520
M 18 280 390 460 M 18 x 2 290 420 490

M 20 390 560 650 M 20 x 1,5 430 620 720
M 22 530 750 880 M 22 x 1,5 580 820 960
M 24 670 960 1100 M 24 x 1,5 760 1100 1250

M 27 1000 1400 1650 M 24 x 2 730 1050 1200
M 30 1350 1900 2250 M 27 x 1,5 1100 1600 1850
M 27 x 2 1050 1500 1800

M 30 x 1,5 1550 2200 2550
M 30 x 2 1500 2100 2500
Edition: August 1991
5
Adjustment Data HP 500 / HP 590 / HP 600
Description Dimension Measurement device Remarks
01. Kickdown adjustment at PR 87 tester Control lever on injection

accelerator pedal 6008 004 001 or pump must be at full-load
Ohmmeter stop before kickdown switch
is depressed (circuit open).
02. Internal resistance of R = approx. Ohmmeter and test Resistance rises with
solenoid valves for clutches 67 ohm at 68°F (20°C) cable 1P01 137 002 temperature to approx. 74
and brakes in transmission or terminal tester Ohm when transmission at
6008 199 001 operating temperature.
03. Internal resistance of R = 1080 ± 40 ohm at Ohmmeter Resistance rises with

inductive sensors (speed 68°F (20°C) temperature to approx. 1350
sensors) nT and nOut Ohm when transmission at
operating temperature.
04. Tightening torque for 310 in-lbs Torque wrench Renew copper sealing ring.
M14x1.5 temperature sensor 26 ft-lbs
(35 Nm)
05. Tightening torque for 440 in-lbs Torque wrench Renew copper sealing ring.
M22x1.5 oil drain plug in oil 37 ft-lbs
pan 50 Nm
06. Clearance between 0.02 - 0.027" Depth gauge Adjust clearance with
inductive sensor - output (0.5 - 0.7 mm) Depth finder shims.
and induction ring 1P01 137 833
07. Clearance between 0.024 - 0.03" Depth gauge Adjust clearance with
inductive sensor - turbine (0.6 - 0.8 mm) Depth finder shims.
and induction ring 1P01 137 833
08. Tightening torque for 440 in-lbs Torque wrench Do not overtighten.
inductive sensors (speed 37 ft-lbs
sensors) (50 Nm)
09. Endfloat of speedo shaft 0.004 - 0.012" Depth gauge May also be checked by
(0.1 - 0.3 mm) hand (play can be felt).
10. Backlash of speedo pinion 0.004 - 0.008" Check by hand May also be checked by
(0.1 - 0.2 mm) hand (play can be felt).
11. Tightening torque for 88 ft-lbs Torque wrench Renew copper sealing ring
speedo drive (approx. 120 Nm)
6
HP 500 / HP 590 / HP 600 Adjustment Data
Description Dimension Measurement device Remarks
12. Insertion depth of shaft 0.55 - 0.59" Depth gauge Use tool 1X56 136 824.
seal in output cover (14 - 15 mm) This gives correct insertion
depth.
13. Tightening torque for M6 55 in-lbs Torque wrench

hex nuts on output cover 5 ft-lbs
(6 Nm)
14. Tightening torque for 530 in-lbs Torque wrench Secure with lock plate
M12 hex bolts at output 44 ft-lbs Use tool 1X56 136 471
flange (60 Nm)
15. Tightening torque for 60 - 74 ft-lbs Torque wrench

M42x2 screw plug in duct 80 - 100 Nm
plate
16. Tightening torque for 110 in-lbs Torque wrench Do not overtighten
M10x1 screw plugs on the 9 ft-lbs
pressure measuring points (12 Nm)
7
Special Tools HP 500 / HP 590 / HP 600
Fig. Special tools Order no. Application Qty. Remarks

no.
1X56 136 471 1
Tool
1 for lock plate on output flange
1P01 136 670 1
Pressure test gauge

0 - 362 psi (0 - 25 bar) with
2
M10x1 connectors
1X56 136 824 1
Tool
for fitting radial seal in
3
output flange
1P01 137 002 1
Test cable
for testing solenoid valves
4
1X56 137 126 1
Lifting attachment
for transmission
5
8
HP 500 / HP 590 / HP 600 Special Tools
Fig. Special tools Order no. Application Qty. Remarks

no.
1P01 137 833 1
Depth finder
for inductive sensors (speed
6
sensors), for measuring clearance
1P01 137 833
1P01 137 834 old version 1

Terminal tester 55-pole
7 6008 199 001 new version

Terminal tester 68-pole with
adapter 68 ☛ 55-pole
for electrical troubleshooting
1P01 137 856 1
Pressure test gauge

0 - 145 psi (0 - 10 bar) with
8
M10x1 connectors
6008 070 002 1
Diagnostics system MOBiDIG 200
the diagnostics system includes:

00
2 TER
IG TES
BiD ONIC
MO ECTR
EL
RE
S
F4
F3 F
B
MOBiDIG 200 Diagnostics unit with
F2 E
7
connecting cable 3 .3ft (1 m)

A
F1 D
6 3
C 9 T
2 EN
8
4
5
1 .
0 +/-
9 CLR
Order no.: 6008 003 003
“Plug-In” card with test instructions

Order no.: 6008 298 002
6008 003 003.2
Optional:
Connecting cable
36 ft (11 m) 6008 303 021
72 ft (22 m) 6008 303 022
9
Special Tools HP 500 / HP 590 / HP 600
Bild Abbildung Bestell-Nr. Anwendung Stück- Bemerkung

Nr. zahl
6008 004 005 6.5 ft (2 m) 1 Optional

6008 004 014 16 ft (5 m)
6008 004 021 36 ft (11 m)
10 6008 004 022 65 ft (20 m)
Connecting cable
for use with 6008 004 001
6008 004 004 6.5 ft (2 m) 1 Optional

6008 004 009 36 ft (11 m)
11
Adapter cable
6008 004 001 1
PR 87 tester
for testing Ecomat transmissions
12
6008 304 024 1

037
304
MAT
6008
NR.
IEN.
FOL
ECO
H1
BRL
EST 18 mask
MVS
13 2
4
5
3 fenschalt
sstu
er
6
for PR 87 tester
1 Brem 001
8 004
: 600
24V
PR 87
SBM
002
004
6008
12V:
BC MVP
SDL
ABS z
/2kH
z AU
/5kH
z VP1
n Ab /2kH
z
/5kH
6008 3004 018
10
HP 500 / HP 590 / HP 600 Special Notice
Please read the following instructions and comply with them when using this manual.
CAUTION
Always comply with tightening torques and adjustment data indicated in this manual.
When no other torque is stated, tighten all nuts and bolts to the torques shown on page 5.
NOTE: All bolts and screw threads in this transmission are metric. Only use metric wrenches and sockets.
The correct sizes and reference numbers of the bolts can be found in the spare parts lists.
LAYOUT OF THIS REPAIR MANUAL:
Dismantling and reassembly should be performed in the order described in this manual.
NOTE: Only use an oil-soluble grease, e.g. vaseline. Wheel bearing greases or gun greases containing lithium
or graphite compounds must not be used.
! ENVIRONMENTAL HAZARD !
Lubricants and cleaning agents must not be allowed to enter the ground, the water table or the sewage system.
• Request safety information for the products concerned from your local environmental protection
authority, and follow any instructions herein at all times.
• Always collect used oil in a suitably large container.
• Always dispose of used oil, clogged filters, lubricants and cleaning agents in accordance with
environmental protection laws.
• Always observe manufacturer instructions when dealing with lubricants and cleaning agents.
11
Arrangement of HP 500 / HP 590 / HP 600
peripheral equipment
Arrangement of peripheral equipment
8 35
N R
3 D
1 2
29
O C
25
26 14 2
31 7
32 9
12 15
11 5 3 18
7
1
6 10 16
27
13 34 19
28
20
22
33
30
4 17
21 23 24
002729
1 Transmission electrical power plug 19 Changeover valve

2 EST 18 plug 20 Retarder control relay
3 Load sensor plug connection 21 Retarder control solenoid valve
4 Retarder, memory and temperature sensor plug 22 Pressure reduction valve 1.2 bar
5 Kickdown switch 23 Pressure reduction valve 2.0 bar
6 Dipstick (check with engine stopped / oil condition) 24 Pressure reduction valve 3.0 bar
7 MOBiDIG and PR 87 connection plug 25 Retarder switch OFF/ON
8 Push button speed range selector 26 Interface to vehicle electrical power system
9 Load sensor 27 Pressure switch NBS
10 Dipstick (check with oil cold / oil condition) 28 Pressure reduction valve 1.2 bar
11 Foot pedal brake valve 29 EST 18 electronic control unit
12 Accelerator pedal (full load) 30 Air supply for auxiliaries
13 Retarder modulation valve 31 Retarder braking range selector
14 Temperature gauge 32 Injection pump linkage
15 Accelerator pedal (idling speed) 33 Retarder torque reduction solenoid valve
16 Dipstick (check with oil warm / oil condition) 34 Retarder pressure switch
17 Check for leaks 35 Electronic control unit for injection pump EDC
18 MOBiDIG test device
12
HP 500 / HP 590 / HP 600 Cutaway view
ZF Ecomat transmission, 4-speed version
1 2 4 5 6 7 9 10 11 12 13
004 250
25 24 23 22 21 20 19 18 17 16 15 14
004250
1 Input 15 Brake “F”

2 Cover plate 16 Brake “E”
4 Control element 17 Brake “D”
5 Oil feed flange 18 Control unit
6 Clutch “A” 19 Inductive sensor “turbine”
7 Clutch “B” 20 Oil pan
9 Housing 21 Retarder
10 Planet gear set I 22 Primary pump
11 Planet gear set II 23 Torque converter
12 Planet gear set III 24 Lock-up clutch “WK”
13 Output 25 Turbine shaft
14 Inductive sensor “output”
13
Cutaway view HP 500 / HP 590 / HP 600
ZF Ecomat transmission, 5 & 6-speed “short” version
1 2 3 4 5 6 7 8 9 10 11 12 13
004 251
25 24 23 22 21 20 19 18 17 16 15 14
004251
1 Input 14 Inductive sensor “output”

2 Cover plate 15 Brake “F”
3 Drive gears for PTO 16 Brake “E”
4 Control element 17 Brake “D”
5 Oil feed flange 18 Control unit
6 Clutch “A” 19 Inductive sensor “turbine”
7 Clutch “B” 20 Oil pan
8 Clutch “C” 21 Retarder
9 Housing 22 Primary pump
10 Planet gear set I 23 Torque converter
11 Planet gear set II 24 Lock-up clutch “WK”
12 Planet gear set III 25 Turbine shaft
13 Output
14
HP 500 / HP 590 / HP 600 Cutaway view
ZF Ecomat transmission, 5 & 6-speed “long” version
1 2 3 4 5 26 6 7 8 9 10 11 12 27 13
004 249
25 24 23 22 21 20 19 18 17 16 29 15 28 14
004249
1 Input 15 Brake “F”

2 Cover plate 16 Brake “E”
3 Drive gears for PTO 17 Brake “D”
4 Control element 18 Control unit
5 Oil feed flange 19 Inductive sensor “turbine”
6 Clutch “A” 20 Oil pan
7 Clutch “B” 21 Retarder
8 Clutch “C” 22 Primary pump
9 Housing 23 Torque converter
10 Planet gear set I 24 Lock-up clutch “WK”
11 Planet gear set II 25 Turbine shaft
12 Planet gear set III 26 Power take-off
13 Output 27 Planet gear set IV
14 Inductive sensor “output” 28 Brake “G”
29 Pressure gauging port
15
Clutch combination HP 500 / HP 590 / HP 600
Clutch and brake combinations

Transmission model and Parts List No.
No. of speeds HP 500 HP 590 HP 600 Ratio range Version
4-speed 4139 002 … 4139 052 … 4139 062 … 2.81 - 1.0 short
4-speed 4139 006 … 4139 056 … 4139 066 … 3.43 - 1.0 short
5-speed 4139 001 … 4139 051 … 4139 061 … 2.81 - 0.8 short
5-speed 4139 003 … 4139 053 … 4139 063 … 3.43 - 0.83 short
6-speed 4139 004 … 4139 054 … 4139 064 … 3.43 - 0.59 short
5-speed 4139 008 … 4139 058 … 4139 068 … 5.6 - 1.0 long
6-speed 4139 005 … 4139 055 … 4139 065 … 5.6 - 0.83 long
Short version A B1 B2 D E F1 F2 Long version A B1 B2 D E F1 F2 G

4-speed i = 2.81 to 1.0 5-speed i = 5.6 to 1.0
3.43 to 1.0
Reverse
Neutral
• •• Reverse
Neutral
• ••
Neutral NBS
• •* 1st gear
• •
1st gear
• • 2nd gear
• •
2nd gear
• • 3th gear
• •
3th gear
• • 4th gear
• •
4th gear
•• 5th gear
••
Short version A B C D E F1 F2 Long version A B C D E F1 F2 G
5-speed i = 2.81 to 0.8 6-speed i = 5.6 to 0.83
and 3.43 to 0.83
6-speed 3.43 to 0.59 Reverse
• ••
Reverse
• •• Neutral
Neutral 1st gear
• •
Neutral NBS
• •* 2nd gear
• •
1st gear
• • 3th gear
• •
2nd gear
• • 4th gear
• •
3th gear
• • 5th gear
••
4th gear
•• 6th gear
• •
5th gear
• •
6th gear
• •
B1= inner piston face, clutch B
B2= outer piston face, clutch B
F1= outer piston face, brake F
F2= inner piston face, brake F
* = reduced pressure
16
HP 500 / HP 590 / HP 600 Maintenance
1. Maintenance
1.1 Oil change intervals
NOTE: The suction filter must be renewed at every oil change. Before changing the filter, drain off the oil
(while still hot).
The complete filter kit (filter and sealing rings) is available with order No. 4139 298 936.
Transmission oil change Mileage Operating hours
Oil change following transmission repair. 600 miles ( 1 000 km) 50
Oil change in normal service

(max. 230°F/110°C). 18 000 miles (30 000 km)
Oil change in service involving high-

thermal loading (230-300°F/110-150°C). 12 000 miles (20 000 km)
Construction machinery or special vehicles

mobile cranes, garbage trucks, etc. 1 000
CAUTION
Only use synthetic ATF in the
“short” model ECOMAT version.
If using synthetic ATF. 56 000 miles (90 000 km)

[If conversion to synthetic ATF took place
before the specified oil change at 12 000 miles
(20 000 km) or 18 000 miles (30 000 km)].
If the conversion to synthetic ATF took place later,

change the synthetic oil next after 28 000 miles (45 000 km).
Following this, the oil change intervals can be increased to 56 000 miles (90 000 km).
But at least once every year.
1.2 Oil capacities
First fill of dry transmission (with oil cooler) approx. 8 gal. (30 liters)
1 1
At oil changes approx. 3 /2 - 4 /2 gal. (14-17 liters)
1
Refilling after installing transmission in vehicle approx. 5 /2 gal. (20 liters)
The above quantities are guide quantities; the exact amount must always be found by measuring with the dipstick.
1.3 Oil grade
See ZF List of Lubricants TE-ML 14. This list can be requested from any ZF After-Sales Service point.
17
Maintenance HP 500 / HP 590 / HP 600
1.4 Checking oil level
– The oil level must be checked at least once every

week.
– Vehicle must be standing level.
– Engine at idling speed.
– Before checking oil level, shift into Neutral.
CAUTION
Always ensure that the correct oil level is maintained.
Too little oil may cause malfunction or failure of the
transmission. Too much oil may cause the transmission
to overheat.
1.5 Operating temperature
The correct operating temperature at which to check

the oil level can be seen on the gauge in the vehicle.
150
NOTE: Before the oil level is checked, the 130 °c
transmission oil must have reached an operating
temperature of 176 - 194°F (80 - 90°C).
110
80
1.6 Adding oil 50
VDO
Pour in transmission oil through the same hole

as is used for measuring with the dipstick.
1 quart (1 liter) changes the oil level by approx.
001683
0.4" (10 mm).
1.7 Checking oil level at operating temperature
Conditions:
• Vehicle standing level

• Speed range selector at “N” (Neutral)
hot range {
• Engine idling (approx. 2 minutes) 80 - 90°C /
180 - 195°F
The oil level must be between the upper and lower
marks of the hot zone. If the oil level is not between
these marks, repeat check, ensuring that the cap of
the dipstick is firmly located in the bayonet socket
when the dipstick is inserted.
000817
18
1.8 Checking oil level when cold
Conditions:

• Speed range selector at "N" (Neutral)
• Engine idling
After 3 to 5 minutes running at idling speed, the oil

level in the transmission must be between the upper
and lower marks for the cold zone. If the oil is below
the lower mark, add oil immediately. Adjust the final
oil level after checking again at operating temperature. cold range {
30°C / 86°F
000 819
1.9 Checking oil level with engine off
Conditions:
• Vehicle on level ground

• Ensure oil level is inside stationary range or stationary range {
higher (engine stopped)
• Do not drain oil even if level is higher
This method can only be used for transmissions with a

direct-mounted heat exchanger, and for transmissions
where the heat exchanger is lowernthan the
transmission.
000 818
1.10 Checking oil level on versions with heat
exchanger higher than centre line of
transmission
Conditions:

• Speed range selector in Neutral setting
• Run engine at 1200 to 1500 rpm for 15 to 20
seconds
Then within 3 minutes, with engine idling, check oil

level as described in "Checking oil level when cold"
and recheck as described in "Checking oil level at
operating temperature".
19
1.11Changing oil at operating temperature
– Switch off engine. oil drain plug 37 ft-lbs (50 Nm)
– Drain out oil through drain hole in oil pan.
– Unscrew filter cover and renew suction filter (see

Section 2.2).
– Screw in drain plug (37 ft-lbs/50 Nm) and fit

filter cover (17 ft-lbs/23 Nm), see Sections 2.1
and 2.2.
001 651
– Pull out dipstick and pour in max. 2.65 gal. (10 filter cover bolts oil cooler
liters) transmission oil.
001651
– Start engine and immediately, with engine
idling, slowly pour in 1 gal. (4 liters)
transmission oil.
– Insert dipstick and check oil level as described in

“Checking oil level when cold” (see Section 1.8).
Adjust oil level if necessary.
– Run vehicle until transmission oil reaches

operating temperature (176 - 194°F / 80 - 90°C).
Check oil level at operating temperature (see
Section 1.7) and adjust if necessary.
NOTE: Further details of maintenance are given

in the Operating Manual for the ZF Ecomat range.
20
1.12 Adjustment of load sensor
Check:
• after maintenance work on transmission or engine
• if gearshifts are rough
• at least every 3 months
If the sensor is incorrectly adjusted, the transmission may

be damaged due to excessive clutch/brake slip times!
! DANGER
Do not adjust with engine running.
Engine and ignition must be switched off.
accelerator pedal
injection pump control lever idling pos.
kickdown full load pos.
overtravel pluger kickdown pos.
full load idling
full load idling
kickdown switch
engine
injection pump load
sensor
001 652
001652
Check adjustment using marks on end or top of load

sensor housing.
– Switch off engine.

load sensor lever
– Apply parking brake.
– Depress accelerator pedal to full-load stop.
– Hold in position. idling mark full load mark
– Mark on load sensor lever must align with full-load

mark on housing.
– Release accelerator pedal to idling position. full load mark idling mark
– Mark on load sensor lever must align with idling

mark on housing.
001415
21
1.12.1 Adjustment of load sensor for electronic

accelerator equipment
NOTE: You cannot always adjust the load sensor

by operating the accelerator pedal.
! DANGER
Engage parking brake.
Ensure selector lever is in neutral.
Basic requirements:
-- Idling
Idling speed
speed position
position on injectoronpump
injector
= idling pump = idling
speed position on loadspeed
sensor position on load sensor
- Full-load
Full - load position
position on injectoronpump
injector pump
= full-load = full
position - load
on load sensorposition on load sensor
Adjustment of idling speed position:
1. With idling speed stop on injector pump:
Requirements: - Engine stopped

- Ignition off
- Pump filling control lever of engine
injector pump must be at the idling injection pump
speed stop control lever
Set load sensor to the idling speed mark. full-load idling
full-load idling
full-load idling
2. Without idling speed stop on injector pump:
Requirements: - Ignition on engine injector

- Engine running at idling speed and at pump
operating temperature
- Electronic accelerator adjusted to LOAD SENSOR setting device001
for416
idling speed position electronic accelerator
Set load sensor to the idling speed mark.
Setting full-load position:
Requirements: - Engine stopped 001 416

- Ignition off
Press the pump-filling control lever of the engine

injector pump to the full-load stop by hand (disconnect
electronic accelerator if required). Hold this position load sensor lever
and set the load sensor to the full-load mark.
NOTE: Do not use the end stop on the load sensor for
adjustment purposes.
idling mark full load mark
Electrical check:
Only use MOBiDIG 200 with plug-in card or PR 87
test device.
Restrictions:
In some vehicles, the electronic accelerator system has full load mark idling mark
a safety feature which prevents the full-load position
being reached when the vehicle is stationary or a brake
signal is present.
In such cases, this test can only be performed when driving.

001 415
22
HP 500 / HP 590 / HP 600 Overhaul
2. Overhaul
2.1 Renewing filter
1 Remove filter cover
2 Pull out old filter element. Check filter for

contamination.
NOTE: Filter must always be renewed. It must not be

cleaned and reused.
004128
3 Insert new filter element (No. 0750 131 003).
4 Check that O-ring of filter is still correctly seated

and is undamaged.
5 Smear O-ring with transmission oil.
004129
6 If suction pipe was pulled out with old filter,

remove O-ring from suction pipe.
7 Insert new O-ring into transmission housing and

push in suction pipe.
8 Insert new filter element.
NOTE: The O-ring for the oil pipe is not included in the
oil change parts kit.
004130
23
Overhaul HP 500 / HP 590 / HP 600
9 Renew O-ring in filter cover and place cover in

position.
10 Tighten hex bolts to 17 ft-lbs (23 Nm).
NOTE: Fill transmission with oil (see Section 1.6).
004131
2.2 Renewing retarder solenoid valve
1 Disconnect 2-core cable connector from solenoid

valve.
2 Disconnect air line.
3 Unscrew both M8 hex bolts.
004132
4 Smear new O-ring with grease and insert into

groove in solenoid valve.
5 Fit valve.
6 Tighten both M8x55 hex bolts to 17 ft-lbs (23 Nm).
7 Reconnect air line and cable connector.
004133
24
2.3 Renewing accumulator solenoid valve
1 Disconnect 2-core cable connector from solenoid

valve.
2 Disconnect air line.
3 Unscrew both M8 hex bolts.
004134
4 Smear new O-ring with grease and insert into

groove in solenoid valve.
5 Fit valve.
6 Tighten both M8x55 hex bolts to 17 ft-lbs (23 Nm).
7 Reconnect air line and cable connector.
004135
25
2.4 Renewing accumulator
1 Remove solenoid valve from accumulator as

described in Section 2.3.
2 Unscrew M8 hex bolts from end of accumulator

nearest transmission output.
004136
3 Remove the two M8 socket-head bolts from end of

accumulator nearest transmission input.
004137
4 Insert new O-ring into groove in accumulator.
5 Insert accumulator and screw two M8x25 socket-

head bolts with washers into each end.
Tightening torque 17 ft-lbs (23 Nm).
004138
26
2.5 Renewing temperature sensor
1 Release 2-core cable connector from temperature

sensor.
2 Unscrew temperature sensor.
004139
3 Slide new copper sealing ring onto temperature

sensor.
4 Reconnect 2-core cable connector with marking

“TG”.
004140
27
2.6 Renewing output sensor
1 Remove cover from inductive sensor.
004141
2 Disconnect cable connectors from inductive sensor.

These are blade connectors which should be pulled
straight outwards.
3 Unscrew inductive sensor.
004142
CAUTION
Take care not to let shim washer(s) fall into
transmission. Remove all shim washers.
004143
28
4 Push circlip approx. 0,24 in. (6 mm) onto depth

finder 1P01 137 833.
004144
5 Insert depth finder 1P01 137 833 straight into bore

for inductive sensor. Push depth finder in (circlip
will slide back) until the end touches the tip of a
tooth.
6 Carefully pull out depth finder, without displacing

circlip.
004145
7 Measure distance from end of depth finder to

circlip and note down as dimension “b”.
004146
29
8 Measure distance from end face of inductive sensor

to contact face for shim washers, and note down as
dimension “c”.
004147
Sensor clearance (dimension “a”) must be

0.02 – 0.027" (0.5 – 0.7 mm).
Adjust with shim washers (4).
c–b=d 1
2
d + a = thickness “S”
of shim washer 3
4
1 Teeth on planet carrier

2 Output cover
3 Inductive sensor
4 Shim washers a
001566
001566
The shim washers for fitting are available in the

following thicknesses:
0730 003 049 = 0.024" (0.6 mm)

0730 003 050 = 0.031" (0.8 mm)
0730 002 069 = 0.040" (1.0 mm)
0730 002 068 = 0.047" (1.2 mm)
0730 002 067 = 0.055" (1.4 mm)
0730 002 066 = 0.062" (1.6 mm)
0730 002 065 = 0.070" (1.8 mm)
0730 002 064 = 0.078" (2.0 mm)
0730 002 063 = 0.086" (2.2 mm)
0730 002 062 = 0.094" (2.4 mm)
0730 002 061 = 0.102" (2.6 mm)
0730 003 299 = 0.110" (2.8 mm)
0730 003 300 = 0.118" (3.0 mm)
004148
30
9 Select shim washers of the correct thickness, grease

lightly and slide onto inductive sensor. Screw in
inductive sensor.
004143
10 Tighten inductive sensor to max. 37 ft-lbs (50 Nm).

Do not overtighten.
004149
11 Push cable connectors onto inductive sensor.

Cables may be connected either way round.
12 Renew O-ring on cover and secure cover with two

M6 hex bolts and washers.
Only tighten to 5 ft-lbs (6 Nm).
004150
31
2.7 Removing and fitting oil pan
1 Drain out oil and remove oil filter as described in

Section 2.1.
004151
2 Remove hex bolts from oil pan.
3 Release oil pan from sealing face by tapping lightly

with plastic mallet.
! DANGER
Ensure oil pan is well supported so that it cannot fall.
004152
4 Remove oil pan.
5 Before refitting oil pan, place new gasket onto oil

pan.
6 Place oil pan onto transmission housing, insert 2
hex bolts (with steel washers) at opposite points
and tighten.
004153
32
7 The two hex bolts at the middle of the front end of

the oil pan require copper washers. Use steel
washers for the rest of the oil pan bolts.
004154
8 Tighten M8x60 hex bolts on oil pan to
17 ft-lbs (23 Nm).
004155
9 Insert and tighten oil drain plug as described in

Section 1.1.
10 Renew oil filter and fill transmission with oil as

described in Sections 1.1 and 2.1.
004156
33
2.8 Renewing turbine sensor
1 Remove oil pan as described in Section 2.7.
004152
2 Remove M42x2 screw plug.
004157
3 Disconnect cable connectors from sensor. These are

blade connectors which should be pulled off
straight.
4 Unscrew inductive sensor.
004158
34
5 Ensure that all shim washers under sensor are

removed.
NOTE: The bottom washer tends to stick to the

mounting plate.
004159
6 Using a large screwdriver or similar, turn the torque

converter and at the same time use a small
screwdriver to find the raised points on the sensor
induction ring.
004160
7 When one of these raised points is in line with the

bore for the sensor, measure gap “a” between the
sensor (3) and a raised point on the induction ring
(1).
1
CAUTION 2
It is important to measure onto a raised point on the
induction ring, otherwise the sensor will be damaged by
the raised points on the ring when the engine is started. 3
4
a
001572
35
8 Push circlip approx. 0,24 in. (6 mm) onto depth

finder 1P01 137 833.
004161
9 Insert depth finder 1P01 137 833 straight into bore

for inductive sensor. Insert depth finder until end
touches induction ring.
004162
10 Circlip (4) on depth finder (3) is pushed back by

mounting plate (2) as depth finder is inserted.
1 Sensor induction ring

4
2 Mounting plate
3 Depth finder 1P01 137 833
4 Circlip
1 2 3
001571
001571
36
11 Carefully draw out depth finder without displacing

circlip.
004162
12 Measure distance from end of depth finder to

circlip and note down as dimension “b”.
004146
13 Measure distance from end face of sensor to

contact face for shim washers, and note down as
dimension “c”.
004147
37
Sensor clearance (dimension “a”) must be 0.024 – 0.03"

(0.6 – 0.8 mm).
Adjust clearance with shim washers (4).
1
c–b=d 2
d + a = thickness “S”
of shim washer
3
1 Sensor induction ring
2 Mounting plate 4
3 Inductive sensor
4 Shim washers
a
001572
The shim washers for fitting are available in the

following thicknesses:
0730 003 049 = 0.024" (0.6 mm)

0730 003 050 = 0.031" (0.8 mm)
0730 002 069 = 0.040" (1.0 mm)
0730 002 068 = 0.047" (1.2 mm)
0730 002 067 = 0.055" (1.4 mm)
0730 002 066 = 0.062" (1.6 mm)
0730 002 065 = 0.070" (1.8 mm)
0730 002 064 = 0.078" (2.0 mm)
0730 002 063 = 0.086" (2.2 mm)
0730 002 062 = 0.094" (2.4 mm)
0730 002 061 = 0.102" (2.6 mm)
0730 003 299 = 0.110" (2.8 mm)
0730 003 300 = 0.118" (3.0 mm)
004148
14 Select shim washers of correct thickness, slide onto

sensor and screw sensor in.
004159
38
15 Tighten sensor to max. 37 ft-lbs (50 Nm).

Do not overtighten.
16 Push cable connectors onto sensor. Cables may be

connected either way round.
004163
17 Screw M42x2 screw plug into duct plate and

tighten to 60 – 74 ft-lbs (80 – 100 Nm).
004164
18 Fit oil pan as described in Section 2.7.
19 Screw in oil drain plugs as described in Section 1.9.
20 Renew oil filter and fill transmission with oil as

described in Sections 1.1 and 2.1.
004130 004151
39
2.9 Renewing complete hydraulic control module
CAUTION
Before unscrewing cable harness from transmission,
remove any dirt and dust from the area around the cable
harness connector.
1 Release cable harness connector by turning locking

ring anti-clockwise.
004165
2 Unscrew the two M8 hex bolts with washers from

the CANNON socket.
004166
3 Remove oil pan as described in Section 2.7.
004152
40
4 Release 2-pole connector (see arrow) from valve

block, using screwdriver.
001 653
001653
5 Pull flat-pin plug out of socket.
004167
6 Loosen, but do not remove, the 39 M8 hex bolts

which hold the shift control module in the
transmission housing.
CAUTION
Do not loosen or remove the M6 hex bolts.
! DANGER
The shift control module weighs approx.
40 lbs. (18 kg). Ensure it is well supported so that it
cannot fall and injure you or other persons under the
vehicle.
004168
41
! DANGER
When the control module is released, oil will spurt
out. Protect yourself and especially your eyes from
the oil.
7 Unscrew M8 hex bolts and remove shift control

module.
CAUTION
Take care that cable connectors on shift control module
do not snag in transmission, or they may be torn off.
004169
8 When re-installing shift control module, follow the

above instructions in reverse order, paying attention
to the following points:
a. The sensor clearance only needs to be reset if the

shift control module is renewed. Remove inductive
sensor before installing shift control module. See
Section 2.8.
004159
b. The 39 M8 hex bolts which hold the shift control

module are of two different lengths: 1.77 and 1.38"
(45 mm and 35 mm).
The 9 shorter bolts are for the recessed areas.

Be sure to fit washers under all hex bolts.
Tighten all M8 bolts to 17 ft-lbs (23 Nm).
004190
42
c. Insert connector socket into recess in housing and

screw in both M8x20 hex bolts with washers.
NOTE: Fit the connector into the recess with the guide
tab on the CANNON socket pointing towards the input
end of the transmission.
004166
d. Insert flat-pin plug for output sensor cables into

socket on side of shift control module. Ensure guide
tab engages correctly.
004167
e. Measure sensor clearance as described in Section

2.8, screw in sensor with new shim washers and
reconnect cables.
Fit oil pan and new filter as described in Section

2.7.
004163
43
2.10 Renewing speedometer drive
1 Unscrew speedometer drive.
004170
2 Slide new copper sealing ring onto speedo drive.
3 Smear transmission oil on screw thread and screw

in speedo drive.
Tightening torque approx. 88 ft-lbs (120 Nm).
4 Check backlash of speedo pinion

0.004 – 0.008" (0.1 to 0.2 mm). Play must be felt
when turned back and forth by hand.
004171
44
2.11 Renewing output flange and/or radial seal
1 Disconnect propshaft from output flange. Remove

lock plate from output flange.
! DANGER
Wear eye protection, metal chips may fly out.
004172
2 Unscrew both M12 hex bolts from output shaft.
NOTE: When unscrewing bolts, use a suitable lever to

prevent output flange from turning.
3 Remove clamping plate. If necessary, release by

tapping with plastic mallet.
004173
4 Pull off output flange using a standard 2-arm puller.
NOTE: Protect end of output shaft with a washer or

similar.
004174
45
5 Pull radial seal off input shaft using a suitable tool.
CAUTION
Take care not to damage seal bore while pulling out
seal.
004175
6 Place radial seal onto tool 1X56 136 824 with

sealing lip facing towards output cover.
CAUTION
Do not fit seal the wrong way round. The spring load on
the sealing lip must be visible when the seal is on the
tool.
004176
7 Wet outer edge of radial seal with lubricant (e.g.

liquid detergent concentrate/washing-up liquid).
CAUTION
Do not use grease or transmission oil on outside of seal
or leaks may result.
8 Drive in radial seal until tool abuts against bearing.
004177
46
NOTE: Correct seal insertion depth of 0.59–0.04 in.

(15–1 mm), measured from the face of the bearing inner 15-1
ring to the face of the seal, is given by using tool 1X56
136 824.
9 Pack the space between the sealing lip and the dust
lip with grease.
001 654
001654
10 Heat output flange to 210° to 230°F

(100 – 110°C).
CAUTION
Do not heat output flange over 230°F (110°C) or seal
will be damaged.
! DANGER
Always wear protective gloves when handling hot
output flange.
11 Push or drive flange fully home onto shaft.
NOTE: Insert hex bolts before fitting flange.

004178
47
12 Coat sealing face of clamping plate (flat face

without chamfer) with sealing compound and place
plate onto flange.
004179
13 Screw in M12x30 hex bolts. Tighten to

44 ft-lbs (60 Nm).
NOTE: Always use new hex bolts here.
004180
14 Drive lock plate over M12 hex bolts using tool

1X56 136 471 until lock plate is in firm contact
with clamping plate.
15 Reconnect propeller shaft. Tighten hex bolts in

accordance with vehicle manufacturer’s
instructions.
004181
48
2.12 Pressure tests
Pressure tests with transmission installed in vehicle:
1 Remove screw plugs (1 for each test). Screw in

pressure gauge and check in accordance with table
below.
Pressure gauges 1P01 136 670 and
1P01 137 856.
004182
2 After finishing pressure tests, remove pressure

gauges.
3 Screw in screw plugs with new sealing rings and

tighten to 9 ft-lbs (12 Nm).
004183
49
Pressure measurement:
1 = Main pressure PH 5 = Retarder pressure PRet.
2 = Throttle pressure PD1 6 = Oil temperature toil
3 = Pressure of torque converter inlet Pv.W. neng = Engine speed
4 = Lube oil pressure Pschm. WK = Lock-up clutch
Pressure table A: Normal main pressure

B: Higher main pressure for engines more powerful than 1036 ft-lbs (1400 Nm)
ZF - ECOMAT NORMAL MAIN PRESSURE [ PSI ]
6 1 2 3 4 5*
Pressure table A M 10 x 1 M 10 x 1 M 10 x 1 M 10 x 1 M 10 x 1
neng toil PH PD1 Pv.W. Pschm. PRet.
Load Gear WK
(rpm) (°F) (psi) (psi) (psi) (psi) (psi)
Idling N Open 700 68 - 104 101 - 217 87 - 101 58 - 80 11.5 - 26
7 - 14.5
cold
Idling N D Open 550 68 - 104 101 - 217 58 - 80 11.5 - 26
for 1 sec.
Full-load N Open 2000-2500 68 - 104 261 - 304 87 - 101 87 - 123 26 - 36
Full-load Engaged Closed 2000-2500 68 - 104 145 - 174 87 - 101 87 - 123 26 - 40
Idling N Open 700 176 - 194 101 - 217 87 - 101 43 - 65 1.5 - 11.5
7 - 14.5
warm
Idling N D Open 550 176 - 194 101 - 217 43 - 65 1.5 - 11.5
for 1 sec.
Full-load N Open 2000-2500 176 - 194 ◆232-290 87 - 101 87 - 123 26 - 36
* Values are shown in the relevant parts list or may be obtained from ZF.
◆ If the pressure falls below this value: Please contact the relevant ZF service agency before removing the transmission.
ZF - ECOMAT HIGHER MAIN PRESSURE [ PSI ]
6 1 2 3 4 5*
Pressure table B M 10 x 1 M 10 x 1 M 10 x 1 M 10 x 1 M 10 x 1
Load Gear WK
(rpm) (°F) (psi) (psi) (psi) (psi) (psi)
Idling N Open 700 68 - 104 188 - 319 116 - 131 58 - 80 11.5 - 26
cold
Idling N D Open 550 68 - 104 188 - 319 7 - 22 58 - 80 11.5 - 26

for 1 sec.
Full-load N Open 2000-2500 68 - 104 304 - 362 116 - 131 87 - 123 26 - 36
Idling N Open 700 176 - 194 145 - 246 116 - 131 43 - 65 1.5 - 11.5
warm
7 - 22
Idling N D Open 550 176 - 194 145 - 246 43 - 65 1.5 - 11.5
for 1 sec.
Full-load N Open 2000-2500 176 - 194 304 - 348 116 - 131 87 - 123 26 - 36
*Values are shown in the relevant parts list or may be obtained from ZF.
50
Pressure measurement:
1 = Main pressure PH 5 = Retarder pressure PRet.
2 = Throttle pressure PD1 6 = Oil temperature toil
3 = Pressure of torque converter inlet Pv.W. neng = Engine speed
4 = Lube oil pressure Pschm. WK = Lock-up clutch
Pressure table A: Normal main pressure

B: Higher main pressure for engines more powerful than 1036 ft-lbs (1400 Nm)
ZF - ECOMAT NORMAL MAIN PRESSURE [ BAR ]
6 1 2 3 4 5*
Pressure table A M 10 x 1 M 10 x 1 M 10 x 1 M 10 x 1 M 10 x 1
Load Gear WK
(min-1) (°C) (bar) (bar) (bar) (bar) (bar)
Idling N Open 700 20 - 40 7 - 15 6,0 - 7,0 4,0 - 5,5 0,8 - 1,8
0,5 - 1,0
cold
Idling N D Open 550 20 - 40 7 - 15 4,0 - 5,5 0,8 - 1,8
for 1 sec.
Full-load N Open 2000-2500 20 - 40 18 - 21 6,0 - 7,0 6,0 - 8,5 1,8 - 2,5
Full-load Engaged Closed 2000-2500 20 - 40 10 - 12 6,0 - 7,0 6,0 - 8,5 1,8 - 2,8
Idling N Open 700 80 - 90 7 - 15 6,0 - 7,0 3,0 - 4,5 0,1 - 0,8
0,5 - 1,0
warm
Idling N D Open 550 80 - 90 7 - 15 3,0 - 4,5 0,1 - 0,8
for 1 sec.
Full-load N Open 2000-2500 80 - 90 ◆16 - 20 6,0 - 7,0 6,0 - 8,5 1,8 - 2,5
◆ If the pressure falls below this value: Please contact the relevant ZF service agency before removing the transmission.
ZF - ECOMAT HIGHER MAIN PRESSURE [ BAR ]
6 1 2 3 4 5*
Pressure table B M 10 x 1 M 10 x 1 M 10 x 1 M 10 x 1 M 10 x 1
Load Gear WK
(min-1) (°C) (bar) (bar) (bar) (bar) (bar)
Idling N Open 700 20 - 40 13 -22 8,0 - 9,0 4,0 - 5,5 0,8 - 1,8
cold
Idling N D Open 550 20 - 40 13 - 22 0,5 - 1,5 0,8 - 1,8

4,0 - 5,5
for 1 sec.
Full-load N Open 2000-2500 20 - 40 21 - 25 8,0 - 9,0 6,0 - 8,5 1,8 - 2,5
Idling N Open 700 80 - 90 10 - 17 8,0 - 9,0 3,0 - 4,5 0,1 - 0,8
warm
0,5 - 1,5
Idling N D Open 550 80 - 90 10 - 17 3,0 - 4,5 0,1 - 0,8
for 1 sec.
Full-load N Open 2000-2500 80 - 90 21 - 24 8,0 - 9,0 6,0 - 8,5 1,8 - 2,5
51
52
Troubleshooting Chart for Ecomat with EST 18
3.
Troubleshooting
(Test instructions - Order number 6038 756 106)
Troubleshooting with Diagnostic System MOBiDIG 200
Fault, or flashing
warning on speed
range selector
MOBiDIG 200
Diagnostic tester
Errors 12-18 Errors 25-66, 75, 77 Errors 73, 79

Errors 23, 71 Speed range selector, No error message
Slip time outside Inductive sensor,
Load sensor short/open circuit supply voltage to load FF
tolerance sensor
Vehicle circuit
Mechanical
Oil level OK? voltage – Resistance PR 87
adjustment?
of solenoid D1
PR 87
PR 87 Terminal tester
Gearshifts? Load
Load sensor voltage? Resistances?
sensor voltages?
HP 500 / HP 590 / HP 600

Test drive with
Test cable
subjective
Resistances?
assessment
Troubleshooting
table,
Stage 1/2
Repair Manual
Remedy
HP 500 / HP 590 / HP 600 Troubleshooting
Troubleshooting Table for Ecomat with EST 18
Code Fault Possible cause Check Remedy

FF Hard engagement ECU defective Measure D1 current Exchange ECU
jolts in all gears using PR 87
FF Hard engagement Throttle pressure valve Measure D1 pressure If >> 7 psi (0.5 bar),
jolts in all gears defective during N-D exchange throttle pressure
valve
FF Retarder effect too Oil level too low Check oil level Adjust oil level
small according to service
plan
FF Retarder effect too Oil foaming Check oil Check retarder control
small valve and accumulator for
leaks, and repair if
necessary
FF No retarder effect Solenoid valve MV 1 Check whether no R3 Exchange MV1

mechanically defective pressure
(sticking)
FF Retarder level 1 Pneumatic actuation Check air pressure for Check and repair
(and perhaps 2) not functioning actuation of retarder pneumatic actuation
does not function control valve system (solenoid valve,
reducing valves, air lines)
FF Transmission does Load sensor not in Adjust load sensor

not engage any idling position
gears Engine idling speed Adjust engine idling speed
> 900 rpm
FF Loud noises Cavitation noise in oil 1. Check oil 1. Change oil if required
pump (viscosity)
2. Check oil level 2. Adjust oil level if
required
FF Engine cannot be Starter interlock relay Check relay Exchange relay

started defective.
ECU connector loose Check plug connection Reconnect plug
Speed range selector Switch speed range
ECU defective not in Neutral selector into Neutral
FF Vehicle does not ECU in fault mode Switch ignition off/on

move
Transmission defective Check condition of Request ZF service
Oil level too low filter Top up oil
53
Troubleshooting HP 500 / HP 590 / HP 600

FF Oil temperature too Oil level too high Check oil level Adjust oil level
high Retarder engaged Check hand lever Switch off retarder
Internal damage setting Request ZF service
11 Transmission Lack of oil Check oil level Adjust oil level

slipping according to service
plan
11 Transmission Damage caused by Read error memory As described under Error

slipping failure of speed sensor using MOBiDIG 200 27 or 25
at turbine or output (Error No. 27 = turbine
sensor failure/No. 25 =
output sensor failure)
11 Transmission ECU hardware Perform function test Exchange ECU

slipping defective using PR 87
12- Slip time too long Lack of oil Check oil level Adjust oil level
18 according to service
plan
12- Slip time too long Valve D1 defective Read error memory As described under
18 using MOBiDIG 200 Error 77
(Error No. 77 =
incorrect resistance in
solenoid D1)
12- Slip time too long Valve D1 dirty Measure D1 pressure If pressure does not rise to
18 during N-D 87 - 101 psi (6 - 7 bar)
within 1.5 seconds after
sinking < 14.5 psi (1.0
bar), exchange valve D1
12- Slip time too long ECU defective PR 87 Exchange ECU

18
12- Slip time too long Damage caused by load Read error memory As described under
18 sensor misadjustment using MOBiDIG 200 Error 71
(Error No. 71 =
incorrect load sensor
adjustment)
54

12- Slip time too long Fault caused by failed Read error memory As described under
18 or defective load sensor using MOBiDIG 200 Error 23
(Error No. 23 = load
sensor failure)
23 Load sensor failure Faulty plug connection Read error memory Check and adjust load
(output voltage between load sensor using MOBiDIG 200 sensor/ECU plug
< 0.24 V and ECU (Error No. 23 = load connection
or > 4.75 V) sensor failure)
23 Load sensor failure Cable break, output Move accelerator pedal Renew load sensor/cable
(output voltage (pin 24) on 55-pole and measure voltage on harness
< 0.24 V or connector PR 87.
> 4.75 V) Voltage reading =
0 volt
23 Load sensor failure Cable break, load Measure supply voltage Ensure correct supply
(output voltage sensor power supply to ECU voltage to ECU.
< 0.24 V (pin 25 on 55-pole Renew load sensor/cable
or > 4.75 V) connector) harness
23 Load sensor failure Cable break, load Load sensor voltage Renew load sensor/cable
(output voltage sensor ground (pin 18 reading on PR 87 harness
< 0.24 V on 55-pole connector) =5V
or > 4.75 V)
25 Output sensor Cable break/loose joint ECU connector /output Remake plug connection,
failure in output sensor lead pin 14. Check wire 492 renew cable harness
(pin 14 on 55-pole for interruption
connector)
25 Output sensor Cable break in ground Not registered in error Remake plug connection,
failure line (pin 36 on 55-pole memory. ECU conn. renew cable harness
connector) /output pin 36. Check
wire 464 for interruption
25 Output sensor Output sensor defective Measure resistance Renew output sensor
failure using test cable and
multimeter (should be
1080 Ohms)
25 Output sensor Sensor clearance not Check clearance Adjust clearance

failure correctly adjusted (should be 0.02 -
0.027" / 0.5 - 0.7 mm)
55

27 Turbine sensor Cable break/loose ECU connector /turbine Remake plug connection,
failure contact at turbine pin 43. Check wire 484 renew cable harness
sensor lead (pin 43 on for interruption
55-pole connector)
27 Turbine sensor Cable break on ground Not registered in error Remake plug connection,
failure line (pin 36 on 55-pole memory. ECU conn. renew cable harness
connector) /output pin 36. Check
wire 464 for interruption
27 Turbine sensor Sensor induction ring Check circular runout Realign sensor ring and
failure out of round (4-speed of sensor ring readjust sensor
transmissions only)
27 Turbine sensor Turbine sensor Measure resistance Renew turbine sensor

failure defective using test cable and
multimeter (should be
1080 Ohms)
27 Turbine sensor Sensor clearance not Check clearance Adjust clearance

failure correctly adjusted (should be 0.024 -
0.03"/0.6 - 0.8 mm)
31 Short circuit, ECU AD1 - pin 45. PR 87, terminal tester, Renew cable harness,
brake G Moisture in plug test cable, ohmmeter. attach cables correctly,
connecton. Wire abraded. Inspect visually for eliminate moisture
Cables incorrectly fitted abrasion
brake F Moisture in plug test cable, ohmmeter. attach cables correctly,
brake E Moisture in plug test cable, ohmmeter. attach cables correctly,
brake D Moisture in plug test cable, ohmmeter. attach cables correctly,
56

clutch C Moisture in plug test cable, ohmmeter. attach cables correctly,
clutch B Moisture in plug test cable, ohmmeter. attach cables correctly,
clutch A Moisture in plug test cable, ohmmeter. attach cables correctly,
38 Short circuit, torque ECU AD8 - pin 1. PR 87, terminal tester, Renew cable harness,
converter lock-up Moisture in plug test cable, ohmmeter. attach cables correctly,
clutch WK connecton. Wire abraded. Inspect visually for eliminate moisture
retarder output Moisture in plug test cable, ohmmeter. attach cables correctly,
exhaust brake Moisture in plug test cable, ohmmeter. attach cables correctly,
output connecton. Wire abraded. Inspect visually for eliminate moisture
exhaust brake Moisture in plug test cable, ohmmeter. attach cables correctly,
output connecton. Wire abraded. Inspect visually for eliminate moisture
V signal 1 Moisture in plug test cable, ohmmeter. attach cables correctly,
43 Short circuit, PTO ECU AD13 - pin 11. PR 87, terminal tester, Renew cable harness,
output Moisture in plug test cable, ohmmeter. attach cables correctly,
57

antigas signal Moisture in plug test cable, ohmmeter. attach cables correctly,
45 Short circuit, load ECU AD15 - pin 12. PR 87, terminal tester, Renew cable harness,
reduction/gear Moisture in plug test cable, ohmmeter. attach cables correctly,
signal 1 connecton. Wire abraded. Inspect visually for eliminate moisture
interlock solenoid / Moisture in plug test cable, ohmmeter. attach cables correctly,
fault indicator lamp connecton. Wire abraded. Inspect visually for eliminate moisture
(H1) Cables incorrectly fitted abrasion
51 Interruption/reverse Interruption in cable Check wire G (444) for Repair or renew cable
current, brake G betw. transm.connector interruption. Measure connection
pin G and ECU pin 45 resist. using term. tester
52 Interruption/reverse Interruption in cable Check wire F (440) for Repair or renew cable
current, brake F betw. transm.connector interruption. Measure connection
pin F and ECU pin 44 resist. using term. tester
53 Interruption/reverse Interruption in cable Check wire E (436) for Repair or renew cable
current, brake E betw. transm.connector interruption. Measure connection
pin E and ECU pin 42 resist. using term. tester
54 Interruption/reverse Interruption in cable Check wire D (432) for Repair or renew cable
current, clutch D betw. transm.connector interruption. Measure connection
pin D and ECU pin 39 resist. using term. tester
55 Interruption/reverse Interruption in cable Check wire C (428) for Repair or renew cable
current, clutch C betw. transm.connector interruption. Measure connection
pin C and ECU pin 4 resist. using term. tester
56 Interruption/reverse Interruption in cable Check wire B (424) for Repair or renew cable
current, clutch B betw. transm.connector interruption. Measure connection
pin B and ECU pin 22 resist. using term. tester
57 Interruption/reverse Interruption in cable Check wire A (420) for Repair or renew cable
current, clutch A betw. transm.connector interruption. Measure connection
pin A and ECU pin 3 resist. using term. tester
58

58 Interruption/reverse Interruption in cable Check wire H (448) for Repair or renew cable
current, lock-up betw. transm.connector interruption. Measure connection
clutch WK pin H and ECU pin 1 resistance using
terminal tester
59 Interruption/reverse Interruption in cable Check wire 690 for Repair or renew cable
current, retarder betw. BN2 pin 1 breaks. Measure
output. Indicator and ECU pin 49 resistance
lamp does not light
current, engine betw. BN2 pin 12 breaks. Measure
brake output. and ECU pin 50 resistance
Engine brake not
operative
current, retarder betw. BN1 pin 4 breaks. Measure
reduction output. and ECU pin 53 resistance
No retarder reduction
Interruption/reverse Interruption in cable Check wire 636 for Repair or renew cable
62 current, V signal 1 betw. BN1 pin 5 breaks. Measure
and ECU pin 55 resistance
63 current, PTO output betw. BN2 pin 6 breaks. Measure
and ECU pin 11 resistance
64 current, antigas betw. BN2 pin 4 breaks. Measure
signal and ECU pin 30 resistance
65 current, load reduc- betw. BN2 pin 9 breaks. Measure
tion (optionally gear and ECU pin 12 resistance
signal 2)
Interruption/reverse Interruption in cable Check wire 746 / 604 Repair or renew cable
66 current, interlock betw. BN2 pin 15 for breaks. Measure
solenoid/fault and shift selector resistance
indicator (speed pin 12
range selector lamp)
59

71 Load sensor Load sensor not Check mechanical Adjust load sensor
misadjustment correctly adjusted adjustment in idling correctly according to
and full-load positions service plan
71 Load sensor Linkage loose or bent ——— Repair linkage

misadjustment
71 Load sensor Kickdown switch PR 87, terminal tester Adjust kickdown switch
misadjustment incorrectly adjusted correctly
71 Load sensor End stops on injection If kickdown switch Readjust load sensor
misadjustment pump out of adjustment responds too early,
compare idling and
full-load settings on
injection pump with
marks on load sensor
73 Speed range Speed range selector SRS coding OK? Renew speed range
selector fault defective PR 87, terminal tester selector
73 Speed range Connection between SRS coding OK? Repair connection or

selector fault ECU and speed range PR 87, terminal tester renew speed range selector
selector defective
75 Vehicle circuit Loose contact in + or – Frequent occurrence of Check ECU and vehicle
voltage error supply line error suggests loose circuit connectors
contact
75 Vehicle circuit Short to ground in Check and repair vehicle

voltage error vehicle circuit electrical system
75 Vehicle circuit Battery defective Voltage drop when Recharge/renew battery.

voltage error starting engine < 12 V? Repair alternator regulator
77 Incorrect resistance, Broken circuit in No current during Renew valve D1

solenoid D1 solenoid D1 gearshift (PR 87).
Resistance > 8.6 Ohm
77 Incorrect resistance, Interruption in cable No current during Repair or renew cable

solenoid D1 connection to solenoid gearshift (PR 87). connection
D1 Resistance > 8.6 Ohm
60

79 Incorrect supply ECU defective Voltage < 4.5 V or Renew ECU
voltage to load > 5.5 V (terminal tester
sensor or PR 87)
79 Incorrect supply Large voltage drop in Measure current using If connection is good,
voltage to load line, caused by short to terminal tester between check cable harness and
sensor ground ECU pin 18 and pin 25. repair or renew as
Rated voltage = 5V appropriate
61
62
HP 500 / HP 590 / HP 600 Annex A
Test instructions for test cable 1P01 137 002
Solenoid valves, switches and inductive sensors

a) Insert Cannon plug of test cable into Cannon socket on transmission.
! DANGER
Only use test cable with vehicle stationary and engine OFF.
b) Measure resistances: measure resistance of solenoid valve coils and inductive sensors (see list below).
CAUTION
Do not apply voltage to emergency cut-off switch (yellow sockets) or to inductive sensor, or the switch or
sensor will be short-circuited and irreparably damaged. If the switch is damaged, the transmission must be
removed from the vehicle.
NOTE: resistance rises with temperature.
Brakes Ohmmeter
Cable
Component Clutches (nominal reading)
markings
Sensors
Solenoid valve M 7 Clutch A A approx. 67 Ω at 68°F
Solenoid valve M 6 Clutch B1 B approx. 67 Ω at 68°F
Solenoid valve M 5 Clutch B2 C approx. 67 Ω at 68°F
Solenoid valve M 4 Brake D D approx. 67 Ω at 68°F
Solenoid valve M 3 Brake E E approx. 67 Ω at 68°F
Solenoid valve M 2 Brake F F approx. 67 Ω at 68°F
Solenoid valve M 1 Brake G G approx. 67 Ω at 68°F
Solenoid valve M 8 Clutch WK H approx. 67 Ω at 68°F

Throttle pressure
valve (control D1 U approx. 8,6 Ω at 68°F
solenoid)
Inductive sensor nTurbine T approx. 1080 Ω at 68°F
Inductive sensor nOutput V approx. 1080 Ω at 68°F
Ground M
Ground N
63
Annex E
HP 500 / HP 590 / HP 600
Hydraulic circuit diagram for “short” version of Ecomat
001693
001693
E1
Annex E
HP 500 / HP 590 / HP 600
Hydraulic circuit diagram for “long” version of Ecomat
001695
001695
E2
Annex E
HP 500 / HP 590 / HP 600
Ecomat pneumatic circuit diagram
001698
001698
E3
Annex E
HP 500 / HP 590 / HP 600
Connection diagram for commercial vehicles
001700
001702
001700
001719
E4
Annex E
HP 500 / HP 590 / HP 600
Connection diagram for buses
X CAUTION
For numbers 672 and 680, line routing to chassis
must be divided into two lines.
LAENGEN INKL. STECKER
VON NACH LAENGE
X1 KN1 L1 1,0 m
KN1 KN2 L2 ......m
KN1 X2 L3 ......m
KN1 X3/X4 L4 ......m
X1 X25 L5 0,2 m
KN2 X6 L7 1,5 m
KN2 X5 L8 2,0 m
KN2 X7 L9 1,5 m
KN2 X8 L10 1,5 m
KN2 X9 L11 ..... m
S0033.TIF
ITEM DESCRIPTION ITEM DESCRIPTION
A1 ELECTR. CONTROL UNIT EST-18 K8 RELAY, REVERSING LAMP

LOCATE OPEN CONNECTOR SYSTEMS IN DRY COMPARTMENT A2 SPEED RANGE SELECTOR K9 RELAY, TEMPERATURE WARNING
A3 LOAD SENSOR K10 RELAY, RETARDER "ON"
ITEM NO. CONNECTOR DIAGAM SHOWN A4 TRANSMISSION HP 500/590/600
A1 VIEW ON INTERFACE SIDE OF THE UNIT A5 TEMPERATURE GAUGE S1 SWITCH, KICKDOWN
A6 TEMPERATURE SENSOR S2 SWITCH, RETARDER CONTROL
A7 DIAGNOSIS UNIT S3 SWITCH, ENGINE BRAKE
A8 PWM INTERFACE (OPTIONAL) S4 SWITCH, LOCK-UP CLUTCH OPEN/
ITEM NO. ITEM NO. ITEM NO. ITEM NO. ITEM NO. ITEM NO ITEM NO ITEM NO ITEM NO
UPSHIFT INTERLOCK
A4 A2 X3 X4 A6, Y1, Y2, A5 A3 X25 A7
F1 FUSE 8 AMPS S5 SWITCH, PROGRAM SELECTION
Y3, Y4, Y5
F2 FUSE 8 AMPS S6 SWITCH, EXTERNAL GEAR INTERLOCK
F3 FUSE 8 AMPS S7 SWITCH, NEUTRAL AT BUS STOP (NBS)
S8 SWITCH, EXTERNAL NEUTRAL
H1 LAMP, STATUS MONITORING
H2 LAMP, RETARDER OPERATION Y1 SOLENOID VALVE, RETARDER MV1
Y2 SOLENOID VALVE, RET. ACCUMULATOR MV2
K1 RELAY, ENGINE BRAKE Y3 SOLENOID VALVE, PTO
K2 RELAY, GEAR SIGNAL Y4 SOLENOID VALVE, ANTI-GAS
K3 RELAY, SPEED SIGNAL Y5 SOLENOID VALVE, RETARDER-REDUCTION
CANNON AMP MATE-N-LOK AMP MATE-N-LOK AMP MATE-N-LOK ROUND VDO CANNON Anschlussplan
AMP MATE-N-LOK INSTRUMENT
K4 RELAY, DETENT SOLENOID
K6 RELAY, STARTER INTERLOCK
19-PIN VG 12-PIN CONTACT 15-PIN CONTACT 15-PIN CONTACT CONNECTOR 3-PIN 4-PIN SS 3-PIN CONTACT SOCKET
004 916
2-PIN, K27 K7 RELAY, NEUTRAL (SPEED RANGE
CONNECTOR PART CAP PART CAP PART PLUG CONNECTOR CONNECTOR PART CAP 5-PIN, SOCKET
SELECTOR)
AMP 55-PIN
CONNECTOR 004916
E5
1 Wandler • Torque converter • Moment-
omvandlare • Koppelomvormer
2 Retarder • Retarder • Retarder • Retarder
3 Wandler-Sicherheitsventil • Torque converter
safety valve • Momentom-vandlarens
D2 A8
Säkerhetsventil • Koppel-omvormer-
2 Veiligheidsventiel
4 Druckspeicher • Accumulator • Ackumulator •
Drukreservoir
5 Kühler-Umschaltventil • Cooler changeover
valve • Omkopplingsventil kylare •
Koeleromschakelventiel
R2
6 Wärmetauscher • Heat exchanger •
WK R1 Värmeväxlare • Koeler
5
D7
R3 7 Schaltgetriebe • Planet gear train •
Automatväxellåda • Transmissie
8 WK-Ventileinheit • WK valve unit •
1 Ventilenhet WK • WK-ventielunit
12 D2 15 8.1 Magnetventil • Solenoid valve • Magnetventil •
R2 A8 D7 Magneetventiel
8.2 Drucksteuerventil • Pressure control valve •
P
Tryckregleringsventil • Drukregelventiel
8.3 Ausschaltventil • Shutoff valve •
16 Urkopplingsventil • Afschakelventiel
WK
9 Ventileinheit Kupplung/Bremse • valve unit
Clutches/Brakes • Ventilenhet Lamellkoppling •
R3 ventielunit Koppeling\Rem
D4
9.1 Magnetventil • Solenoid valve • Magnetventil •
PP R3
Magneetventiel
14 D8
18 Tryckregleringsventil • Drukregelventiel
Urkopplingsventil • Afschakelventiel
18 PVW PSCHM 10 Kupplung/Bremse A, B, C, D, E, F, G •
13
7 4 Clutches/Brakes • Lamellkoppling •
Koppeling\Rem
11 D2
10 11 Retarderregelventil • Retarder control valve •

Retarderstyrventil • Retarderregelventiel
3 D6 D5 12 Hauptdruckventil • Main pressure valve •
WK
8.1 9.1 Huvudtryckventil • Hoofddrukventiel
P
13 Filter • Filter • Filter • Filter
14 Pumpe • Pump • Pump • Pomp
8.2 9.2 15
6 Schmierdruck • Lubrication pressure •
Smörjoljetryck • Smeerdruk
D1 16 Wandlergegendruck • Converter counterpressure •

8.3 9.3
Momentomvandlarens mottrycksventil •
17 Koppelomvormertegendruk
P D1 D1 R2 P
17 Drosseldruckventil • Throttle pressure valve •
Tryckmoduleringsventil • Modulatiedrukventiel
Technische Änderungen vorbehalten • Subject to
technical change without notice • Rätt till tekniska 18 Luft • Air • Luft • Lucht
ändrigar förbehålles • Technische veranderingen
voorbehouden
WK
Ausschaltstellung
ECOMAT - HYDRAULIC 1 Position opened
Läge från
Uitschakelstand 4139 753 704 NK-A 02.92
1 Wandler • Torque converter • Moment-
omvandlare • Koppelomvormer
2 Retarder • Retarder • Retarder • Retarder
3 Wandler-Sicherheitsventil • Torque converter
safety valve • Momentom-vandlarens
D2 A8 Säkerhetsventil • Koppel-omvormer-
2 Veiligheidsventiel
4 Druckspeicher • Accumulator • Ackumulator •
Drukreservoir
5 Kühler-Umschaltventil • Cooler changeover
valve • Omkopplingsventil kylare •
Koeleromschakelventiel
R2
6 Wärmetauscher • Heat exchanger •
WK R1 Värmeväxlare • Koeler
5
D7
R3
7 Schaltgetriebe • Planet gear train •
Automatväxellåda • Transmissie
8 WK-Ventileinheit • WK valve unit •
1 Ventilenhet WK • WK-ventielunit
12 D2 15 8.1 Magnetventil • Solenoid valve • Magnetventil •
R2 A8 D7
Magneetventiel
P Tryckregleringsventil • Drukregelventiel
16 Urkopplingsventil • Afschakelventiel
WK 9 Ventileinheit Kupplung/Bremse • valve unit
Clutches/Brakes • Ventilenhet Lamellkoppling •
R3 ventielunit Koppeling\Rem
D4
9.1 Magnetventil • Solenoid valve • Magnetventil •
PP R3 Magneetventiel
14 D8 9.2 Drucksteuerventil • Pressure control valve •
18 Tryckregleringsventil • Drukregelventiel
Urkopplingsventil • Afschakelventiel
18 PVW PSCHM 10 Kupplung/Bremse A, B, C, D, E, F, G •
13 Clutches/Brakes • Lamellkoppling •
7 4 D5
Koppeling\Rem
11 D2
11 Retarderregelventil • Retarder control valve •
10 Retarderstyrventil • Retarderregelventiel
3 D6 D5 12 Hauptdruckventil • Main pressure valve •
WK Huvudtryckventil • Hoofddrukventiel
8.1 9.1
8 9 13 Filter • Filter • Filter • Filter
P
14 Pumpe • Pump • Pump • Pomp
8.2 9.2 6 15 Schmierdruck • Lubrication pressure •
Smörjoljetryck • Smeerdruk
D1 16 Wandlergegendruck • Converter counterpressure •

Momentomvandlarens mottrycksventil •
8.3 9.3 Koppelomvormertegendruk
17
P D1 D1 R2 P
17 Drosseldruckventil • Throttle pressure valve •
Tryckmoduleringsventil • Modulatiedrukventiel
Technische Änderungen vorbehalten • Subject to 18 Luft • Air • Luft • Lucht
technical change without notice • Rätt till tekniska
ändrigar förbehålles • Technische veranderingen
WK
voorbehouden
Einschaltstellung
ECOMAT - HYDRAULIC 2 Position locked
Läge till
Inschakelstand
4139 753 705 NK-A 02.92

ZF Manual Reparação ECOMATICl

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ZF Manual Reparação ECOMATICl

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REPAIR MANUAL

HP 500 / HP 590 / HP 600

4139 751 626e

1.1 Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.1 Renewing filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Troubleshooting chart for Ecomat with EST 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

A Test instructions for test cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1P01 137 002

Hydraulic circuit diagram for “short” version of Ecomat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1

For wiring diagram, see “Testing with terminal tester”

2. Specified equipment, e.g. specialized tools

3. Genuine ZF spares, to our latest specifications

Important work safety notice:

The following safety instructions appear in this manual:

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

CAUTION This is used when incorrect, unprofessional

This is used when lack of care could lead to

Always follow the working steps as described in the text.

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

Metric coarse pitch thread Metric fine pitch thread

Size Tightening torque Size Tightening torque

M 4 2,8 4,1 4,8 M 8x1 24 36 43

M 12 79 115 135 M 14 x 1,5 135 200 235

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

M 24 670 960 1100 M 24 x 1,5 760 1100 1250

M 27 x 2 1050 1500 1800

Edition: August 1991

Description Dimension Measurement device Remarks

01. Kickdown adjustment at PR 87 tester Control lever on injection

03. Internal resistance of R = 1080 ± 40 ohm at Ohmmeter Resistance rises with

Description Dimension Measurement device Remarks

13. Tightening torque for M6 55 in-lbs Torque wrench

15. Tightening torque for 60 - 74 ft-lbs Torque wrench

Fig. Special tools Order no. Application Qty. Remarks

1X56 136 471 1

1P01 136 670 1

Pressure test gauge

1X56 136 824 1

1P01 137 002 1

1X56 137 126 1

Fig. Special tools Order no. Application Qty. Remarks

1P01 137 833 1

1P01 137 833

1P01 137 834 old version 1

7 6008 199 001 new version

1P01 137 856 1

Pressure test gauge

6008 070 002 1

Diagnostics system MOBiDIG 200

the diagnostics system includes:

connecting cable 3 .3ft (1 m)

“Plug-In” card with test instructions

Bild Abbildung Bestell-Nr. Anwendung Stück- Bemerkung

6008 004 005 6.5 ft (2 m) 1 Optional

6008 004 004 6.5 ft (2 m) 1 Optional

6008 004 001 1

6008 304 024 1

6008 3004 018

LAYOUT OF THIS REPAIR MANUAL:

Arrangement of peripheral equipment

1 Transmission electrical power plug 19 Changeover valve

ZF Ecomat transmission, 4-speed version

1 Input 15 Brake “F”

ZF Ecomat transmission, 5 & 6-speed “short” version