4149 751 604

REPAIR MANUAL
009396
HP 502 / HP 552 / HP 592 / HP 602

Stage 3
4149 751 604

Subject to alterations in design
Copyright by ZF
This repair manual is protected by copyright. Any reproduction and dissemination in whatever
form – also in adapted, paraphrased or extracted form, in particular as a reprint, photomechanical or
electronic reproduction or as a storage in data-processing equipment or data networks – without approval
by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law.
Printed in Germany
Edition:: 2000-09
4149 751 604

HP 502 / HP 552 / HP 592 / HP 602 Table of Contents
Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Work Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Expendable Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cross-section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjustment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Spring Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1 Assembly Stand - Insert and Remove Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Assembly Stand - Insert Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Assembly Stand - Remove Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2 Retarder Accumulator - Remove and Install, Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 Retarder Accumulator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Retarder Accumulator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Retarder Accumulator - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 Retarder Accumulator - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3 Heat Exchanger - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Heat Exchanger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Heat Exchanger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
4 Converter - Remove and Install, Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Converter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Converter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.1 Converter End Play - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.2 Converter Installation Dimension - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.3 Converter - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.3.1 ZFW 380-30 Converter - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.3.2 ZFW 360-10 Converter - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.3.3 Stator - Dismantle (ZFW 380-30 and ZFW 360-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.3.4 Stator - Assemble (ZFW 380-30 and ZFW 360-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.3.5 Turbine Wheel and Circuit Cover on ZFW 380-30 Converter - Dismantle . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.3.6 Circuit Cover and Turbine Wheel on ZFW 380-30 Converter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.3.7 Turbine Wheel and Circuit Cover on ZFW 360-10 Converter - Dismantle . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.3.8 Circuit Cover and Turbine Wheel on ZFW 360-10 Converter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . 4-31
4.4 Converter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4.4.1 ZFW 380-30 Converter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4.4.2 Axial Bearing End Play on ZFW 380-30 Converter - Measure and Adjust . . . . . . . . . . . . . . . . . . . . . . . 4-39
4.4.3 ZFW 360-10 Converter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
4.4.4 Axial Bearing End Play on ZFW 360-10 Converter - Measure and Adjust . . . . . . . . . . . . . . . . . . . . . . . 4-45
4.5 Converter Leak-Tightness - Check (ZFW 380-30 and ZFW 360-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Table of Contents HP 502 / HP 552 / HP 592 / HP 602
Page
5 Cover Plate - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Cover Plate - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Cover Plate - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
6 Oil Pan - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 Oil Pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Oil Pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
7 Inductive Pickup - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 Inductive Pickup - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Inductive Pickup - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
8 Hydraulic Control Unit - Remove and Install, Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Hydraulic Control Unit - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Hydraulic Control Unit - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 Oil Level Indicator - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.3.1 Oil Level Indicator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.3.2 Oil Level Indicator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.4 Hydraulic Control Unit - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8.4.1 Throttle Pressure Valve - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.4.2 Throttle Pressure Valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.4.3 Valve Block F2 - Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.4.4 Valve Block for Brake "F" and Clutch "WK", "C" and "A" - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.4.5 Valve Block for Clutch "B", Brake "E" and "D" - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.5 Hydraulic Control Unit - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.5.1 Valve Block for Brake "F" and Clutch "WK", "C" and "A" - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
8.5.2 Valve Block for Clutch "B", Brake "E" and "D" - Assemble
Hydraulic Control Unit - Assemble (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
9 Retarder Valve - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1 Retarder Valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Retarder Valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
10 Output Cover - Remove and Install, Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.1 Output Cover/Inductive Pickup - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.1.1 Inductive Pickup - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Output Cover - Remove (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.2 Output Cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.2.1 Sun Gear End Play - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.3 Output Cover - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
10.4 Output Cover - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
10.4.1 Tapered Roller Bearing - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
10.4.2 Brake "F" Disc Play - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
HP 502 / HP 552 / HP 592 / HP 602 Table of Contents
Page
11 Mechanical Transmission Section - Remove and Install ................................................................... 11-1

11.1 Mechanical Transmission Section - Remove ......................................................................................... 11-1
11.1.1 Planetary Carrier II - Dismantle; Version HP 502 / 552 / 592................................................................. 11-5
11.1.2 Planetary Carrier II - Assemble; Version HP 502 / 552 / 592 ................................................................. 11-9
11.1.3 Planetary Carrier I - Dismantle; Version HP 502 / 552 / 592 ................................................................. 11-13
11.1.4 Planetary Carrier I - Assemble; Version HP 502 / 552 / 592 .................................................................. 11-15
11.2 Mechanical Transmission Section - Dismantle; Version HP 592 / 602 .................................................. 11-19
11.2.1 Planetary Carrier II - Dismantle; Version HP 592 / 602.......................................................................... 11-25
11.2.2 Planetary Carrier II - Assemble; Version HP 592 / 602 .......................................................................... 11-26
11.2.3 Planetary Carrier I - Dismantle; Version HP 592 / 602 .......................................................................... 11-29
11.2.4 Planetary Carrier I - Assemble; Version HP 592 / 602 ........................................................................... 11-30
11.2.5 Planetary Carrier II and I - Assemble; Version HP 592 / 602 ................................................................. 11-33
11.2.6 E Piston and Disc Carrier - Remove ....................................................................................................... 11-37
11.2.7 Sun Gear - Remove from Disc Carrier; Version HP 502 / 552 / 592 ...................................................... 11-39
11.2.8 Sun Gear - Install in Disc Carrier; Version HP 502 / 552 / 592 .............................................................. 11-39
11.2.9 Sun Gear - Remove from Disc Carrier; Version HP 592 / 602 ............................................................... 11-40
11.2.10Sun Gear - Install in Disc Carrier; Version HP 592 / 602 ....................................................................... 11-40
11.2.11Hollow Shaft/Input Shaft - Remove ....................................................................................................... 11-41
11.3 Mechanical Transmission Section - Install ............................................................................................ 11-43
12 Control Unit - Remove and Install, Dismantle and Assemble ........................................................... 12-1
12.1 Control Unit - Remove ........................................................................................................................... 12-1
12.2 Control Unit - Install .............................................................................................................................. 12-3
12.3 Control Unit - Dismantle ........................................................................................................................ 12-7
12.3.1 Control Insert - Dismantle ...................................................................................................................... 12-9
12.3.2 Control Insert - Assemble ...................................................................................................................... 12-21
12.3.3 Clutch Carrier - Dismantle ..................................................................................................................... 12-35
12.3.4 Clutch Carrier - Assemble ...................................................................................................................... 12-43
12.3.5 Clutch Carrier Leak-tightness and Function - Check ............................................................................. 12-57
12.4 Control Unit - Assemble ......................................................................................................................... 12-59
13 D Brake - Remove and Install ............................................................................................................. 13-1

13.1 D Brake - Remove .................................................................................................................................. 13-1
13.2 D-Brake - Install ..................................................................................................................................... 13-3
Preface HP 502 / HP 552 / HP 592 / HP 602
This manual is intended for skilled personnel who have

been trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products.
This manual deals with the standard ZF product in

accordance with the state of development on the date
of issue.
However, due to continuing development of the product,

repair work might require work practices and test or
adjustment data which are not contained in this manual.
We therefore recommend that work done on your ZF
product is carried out only by skilled mechanics who
have had their practical and theoretical knowledge upda-
ted on a regular basis at our After-Sales Service training
courses.
Service points equipped by ZF Friedrichshafen AG all

over the world offer you:
1. Well-trained personnel
2. Specified equipment, e.g. special tools
3. Genuine ZF spares, to our latest specifications
All work performed at 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

ZF FRIEDRICHSHAFEN AG personnel in an improper and unprofessional manner,
Division Comm. Vehicle/Special Transmissions together with follow-on costs caused by such work, is
Service Werk 2 excluded from the contractual guarantee agreement.
Tel.: (0 75 41) 77-0 This also applies where genuine ZF spares have not
Fax: (0 75 41) 77-5726 been used.
6
HP 502 / HP 552 / HP 592 / HP 602 Important Information
SAFETY NOTI CE G ENER AL I NFO RMATI O N
Companies who repair ZF units are responsible for their Read this manual carefully before starting any tests or
own work safety. repair work.
To avoid injury to personnel and damage to pro-

ducts, all safety regulations and legal requirements CAUTION
which apply to repair and maintenance work must Pictures, drawings and components do not always
be adhered to. represent the original object, but are used to illustrate
Before starting work, mechanics must familiarize working procedures.
themselves with these regulations. Pictures, drawings and components are not to scale
and no information about size and weight should be
Personnel required to carry out repairs on ZF products inferred (even within a complete illustration).
must receive appropriate training in advance. It is the Always follow the working steps as described in the
responsibility of each company to ensure that their text.
repair staff is properly trained.
After completion of repair work and testing, skilled staff

must satisfy themselves that the product is functioning
The following safety instructions appear in this correctly.
manual:
! THREATS TO THE ENVIRONMENT !

NOTE Lubricants and cleaning agents must not be allowed
Refers to special processes, techniques, data, use to enter the soil, ground water or sewage system.
of auxiliary equipment, etc. • Ask your local environment agency for
safety information on the relevant products
and adhere to their requirements.
CAUTION • Collect used oil in a suitably large container.
This is used when incorrect, unprofessional • Dispose of used oil, dirty filters, lubricants
working practices could damage the product. and cleaning agents in accordance with
environmental protection guidelines.
• When working with lubricants and cleaning
! DANGER agents, always refer to the manufacturer’s
This is used when lack of care could lead to instructions.
personal injury or death.
CAUTION
The transmission must NOT be hung on the
input shaft NOR on the output flange.
7
Repair Instructions HP 502 / HP 552 / HP 592 / HP 602
In any cases of doubt always turn to the the relevant G AS K ETS , LO CK I NG P LATES
department within ZF After-Sales Services for
advice. Parts which cannot be removed without being damaged
must always be replaced with new parts (e.g. gaskets
and locking plates).
After removing the transmission from the vehicle, clean
thoroughly before opening.
Pay particular attention to the corners and angles of
housings and covers when cleaning. S H AFT S EALS
Parts held on with Loctite can be slightly loosened if
warmed with a hot air blower. Always renew shaft seals with rough, ripped or
hardened packing washers. Seal contact surfaces must
be totally clean and in perfect condition.
C L E A N I N G PA RT S
Remove the old remains of gaskets from mating faces. RE WO RK I NG

Carefully remove burrs or other similar patches of
roughness using an oil-stone Rework may only be carried out on the seal contact
surfaces using plunge-cut grinding, never use an emery
Lube bores and grooves must be free of anti-corrosion cloth. Ensure that there are no grinding traces or rifling
agents and foreign matter, check that they can move from grinding.
without encountering any problems.
If rework is needed on spacer washers, shims etc. becau-
Carefully cover opened transmissions to prevent the se of clearance settings, ensure that the reworked areas
entry of foreign matter. contain no face runout and have the same surface quali-
ty.
R E U S I N G PA RT S
T R A N S M I S S I O N A S S E M B LY
Parts such as ball or roller bearings, multi-discs, thrust
washers etc., must be inspected by a competent person, Find a clean site to assemble the transmission. Gaskets
who should decide whether or not they can be re-used. are installed without the use of sealing compound or
Replace parts which are damaged or have suffered from grease. When measuring silicon-coated gaskets, take
excessive wear. care not to include the silicon layer in the measure-
ment.
During assembly, comply with all adjustment data,
checking data and tightening torques in the Repair
Manual.
8
HP 502 / HP 552 / HP 592 / HP 602 Repair Instructions
BEARINGS d) Duo shaft seals have two packing

washers. The dust-proof packing
If the bearings are fitted while hot, these should be washer (X) must face outwards.
warmed up accordingly (e.g. in a heating cabinet). X
The temperature should be approx. 85 °C and may not e) Fill the gap between the packing
exceed 120 °C. All bearings must be coated with trans- washers so it is 60% filled with grease (use a grease
mission oil after assembly. e.g. produced by Aral such as Aralub HL2 or by
DEA such as Spectron FO 20).
f) If possible, heat shaft seal bores to between 40 and

50°C (this makes fitting easier). Press in the shaft
SEALING seal to the correct depth using a punch or suitable
plate and make sure the seal remains flat.
If a sealing agent* is to be used for carrying out sealing,
comply with the manufacturer’s directions for use.
Apply a thin layer of sealing agent to the surfaces and
spread evenly. Do not allow sealing agent to enter oil LO CK I NG AGE NTS
ducts and bores. On oil-carrying ducts and bores, wipe
off the sealing agent on the surfaces to be sealed near Locking agents* may only be used in places as
apertures to ensure that no sealing agent penetrates the specified in the parts list.
oil feeds when the surfaces are sealed. Always comply with manufacturer’s directions for use
when using locking agents (e.g. Loctite).
During assembly, comply with all adjustment data,
checking data and tightening torques.
SHAF T SEALS
a) Apply a light coat of sealing agent on outer edge of TRANSMISSION OIL

shaft seals with “steel surround”.
After completing repairs, fill the transmission with
b) Never apply sealing agent to shaft seals with transmission oil. For the procedure and approved oils,
“rubber surround” but apply a thin coat of Vaseline refer to the transmission operating manual and List of
8420 to the outer edge or wet with a lubricant, e.g. a Lubricants TE-ML (refer to identification plate) which
water-soluble, concentrated washing-up liquid (e.g. are available from any ZF After-Sales Service center.
Pril, Coin, Palmolive). After filling the transmission with oil, tighten the screw
plugs at the oil filling point and the oil overflow to the
c) Shaft seals with steel and rubber surrounds should be specified torques.
treated on the outer edge of the rubber surround as
described above in section b).
* refer to expendable material
9
Tightening Torques HP 502 / HP 552 / HP 592 / HP 602
Tightening torques for nuts and bolts, extract from

ZFN 148
This Standard applies to bolts to DIN 912, DIN 931, Surface condition of bolts: heat-treated blackened
DIN 933, DIN 960, DIN 961 and nuts to DIN 934. finish and oiled or galvanized and oiled or galvanized,
This Standard contains data on tightening torques (MA) chrome-plated and oiled.
for bolts in strength categories 8.8, 10.9 and 12.9 and
nuts in strength categories 8, 10 and 12. Bolts must be tightened using a calibrated ratchet or tor-
que wrench.
NOTE
Divergent tightening torques are listed separately in the
Repair Manual.
Metric coarse pitch thread Metric coarse 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
10
HP 502 / HP 552 / HP 592 / HP 602 Tightening Torques
Screw plugs DIN 908, 910 and 7604

Union screws DIN 7643
The screw plug tightening torques MA were determined
according to DIN 7604, for screwing into steel, grey The tightening torques MA were determined for
cast, and aluminium alloys. screwing into steel, grey cast and aluminium alloys.
The values are based on experience, and are The values are based on experience and are inten-
intended as reference values for the mechanic. ded as reference values for the mechanic.
The values for the tightening torque MA shall also be
used for screw plugs according to DIN 908 and General rule: screw/bolt class 5, ZFN 148-1
DIN 910, as the thread geometries are almost identical. Material 9SMnPb28K acc. to DIN 1651
General rule: Screw/bolt class 5, ZFN 148-1 Surface conditions: as manufactured
Screw/bolt material: steel acc. to (without surface protection) and lightly
DIN 7604. Surface condition: as manu- oiled or galvanized, chromated and
factured (without surface protection) and lightly oiled
lightly oiled or galvanized, chromated
and lightly oiled
Screw plugs (DIN 908, 910, 7604) Union screws (DIN7643)
Dimensions Tightening torque Pipe Thread Tightening-

screwed into outer torque MA
steel/grey cast Al alloy diameter in Nm
M 8x1 20 10 4-5 M8x1 30
M 10 x 1 25 / 30* 15 / 20*
M 12 x 1.5 35 25 6 M 10 x 1 35
M 14 x 1.5 35 25
M 16 x 1.5 40 30 8 M 12 x 1.5 40
M 18 x 1.5 50 35
M 20 x 1.5 55 45 10 M 14 x 1.5 40
M 22 x 1.5 60 / 80* 50 / 65*
M 24 x 1.5 70 60 12 M 16 x 1.5 45
M 26 x 1.5 80 / 105* 70 / 90*
M 27 x 2 80 70 15 M 18 x 1.5 50
M 30 x 1.5 100 / 130* 90 / 130*
M 30 x 2 95 85 18 M 22 x 1.5 60
M 33 x 2 120 110
M 36 x 1.5 130 115 22 M 26 x 1.5 90
M 38 x 1.5 140 120
M 42 x 1.5 150 130 28 M 30 x 1.5 130
M 42 x 2 145 125
M 45 x 1.5 160 140 35 M 38 x 1.5 140
M 45 x 2 150 130
M 48 x 1.5 170 145
M 48 x 2 160 135
M 52 x 1.5 180 150
M 60 x 2 195 165
M 64 x 2 205 175
* DIN 7604 Form C
11
Expendable Material HP 502 / HP 552 / HP 592 / HP 602
Description Name Approx. Application Remarks

ZF reference no. quantity
Grease For example:

0750 199 001 Spectron FO 20 Gen. assembly aid
Sealing compound WEVO-L100

0666 790 017 Output flange screw connection
Jointing compound Loctite no.: 648 1g Threaded bush on

0666 690 048 transmission housing
Sealing band Elring Pife / 300 mm

0634 307 728 sold by the meter Oil fill pipe Ecomat 2 transm.
Surface sealer Loctite no.: 574 80 mm3 Slotted nut on

0666 790 033 oil fill pipe
Grease Vaseline 8420

0671 190 016 Gen. assembly aid
Operating oil See TE-ML14

List of lubricants Gen. assembly aid
NOTE: Inquire about the size of bundles that can be delivered before placing any orders!
12
HP 502 / HP 552 / HP 592 / HP 602 Cross-section
ZF Ecomat 2 transmission,
4-speed version
1 2 4 5 6 7 9 10 11 12 13
013468
26 25 24 23 22 21 20 19 18 17 16 15 14
013468
Key to drawing
1 Input 15 Inductive pickup “output”

2 Cover plate 16 Brake “F”
4 Control insert 17 Brake “E”
5 Oil feed flange 18 Brake “D”
6 Clutch “A” 19 Shift control
7 Clutch “B” 20 Inductive pickup “turbine”
9 Housing 21 Oil pan
10 Planet gear set I 22 Retarder
11 Planet gear set II 23 Primary pump
12 Planet gear set III 24 Converter
13 Speedo sensor 25 Torque converter and clutch “WK”
14 Output 26 Turbine shaft
13
Cross-section HP 502 / HP 552 / HP 592 / HP 602
ZF Ecomat 2 transmission,
5 & 6-speed version
1 2 4 5 6 7 8 9 10 11 12 13
013467
26 25 24 23 22 21 20 19 18 17 16 15 14
013467
Key to drawing
1 Input
2 Cover plate 15 Inductive pickup “output”
4 Control insert 16 Brake “F”
5 Oil feed flange 17 Brake “E”
6 Clutch “A” 18 Brake “D”
7 Clutch “B” 19 Shift control
8 Clutch “C” 20 Inductive pickup “turbine”
9 Housing 21 Oil pan
10 Planet gear set I 22 Retarder
11 Planet gear set II 23 Primary pump
12 Planet gear set III 24 Converter
13 Speedo sensor 25 Torque converter and clutch “WK”
14 Output 26 Turbine shaft
14
HP 502 / HP 552 / HP 592 / HP 602 Adjustment Data
Designation Dimension Measuring device Comments
Converter
01. Converter installation 2.81 ± 0.02" Depth gauge Installation dimensions

dimension (71.25 ± 0.5 mm) measured between flange
(depending on version) 3.01 ± 0.02" surface on converter and
(77.00 ± 0.5 mm) flange surface on transmis-
3.20 ± 0.02" sion housing. Installation
(81.25 ± 0.5 mm) dimensions can be adjusted
3.40 ± 0.02" using one or more spacer
(86.25 ± 0.5 mm) rings on stator hollow shaft.
02. Converter end play bet- Between Depth gauge End play can be adjusted
ween end face of conver- 0.01 and 0.016" using shim on end face of
ter internal sprag race and (0.3 and 0.4 mm) turbine shaft.
spacer ring on stator hol-
low shaft
03. Disc play of converter Between Feeler gauge Disc play is measured bet-
lock-up clutch 0.02 and 0.043" ween end disc and inner
(0.5 and 1.1 mm) disc.
04. End play on axial bearing Between Measuring bars and Adjusted using shims bet-
in converter 0.004 and 0.01" depth gauge ween housing and turbine
(0.1 and 0.3 mm) wheel flange.
05. Maximum pressure for 36 + 7 psi Forcing device 1X56 Converter test is performed
testing converter for leaks (2.5 + 0.5 bar) 137 129, compressed using air under water.
air unit 1X56 137 130
and water container
06. Tightening torque of Torque wrench

socket head screws on
converter
HP 502 / 552 / 592 (M8) = 26 ft-lbs (35 Nm)
HP 592 / HP 602 (M10) = 48 ft-lbs (65 Nm)
07. Tightening torque of M16 Between Torque wrench Use counter-support

socket head screw in 133 and 140 ft-lbs and locking device 1X56 137 658 to hold
turbine shaft (180and 190 Nm) 1X56 137 158 converter.
08. Tightening torque of Between Torque wrench Fit copper sealing ring. Use
M33x2 screw plug in 140 and 155 ft-lbs counter-support
converter (190 and 210 Nm) 1X56 137 658 to hold
converter.
09. Tightening torque of 50 ft-lbs (68 Nm) Torque wrench Only ZFW 380-30 converter.
M10x35 hex bolts
15
Adjustment Data HP 502 / HP 552 / HP 592 / HP 602
Output
10. Distance between output Between Depth gauge, measu- Distance can be adjusted
inductive pickup and end 0.02 and 0.027" ring rod 1X56 138 149/ using shims.
face gearing on planetary (0.5 and 0.7 mm) 1X56 138 150
carrier
11. Tightening torque of M6 7 ft-lbs (9.5 Nm) Torque wrench Do not exceed value.
mounting bolt for induc-
tive pickup
12. Distance between speed- Between Depth gauge Clearance is set, do not
ometer pulse generator 0.027 and 0.054" exceed value.
and toothed ring on output (0.7 and 1.4 mm)
13. Tightening torque of 26 ft-lbs (35 Nm) Torque wrench Do not exceed value.
speedo pulse generator
14. Installation dimensions of 0.60 -0.04" Depth gauge Installation dimensions bet-
shaft seal in output cover (15 -1 mm) ween end face of taper roller
bearing inner race and front
face of sealing ring can be
adjusted using special tool
1X56 136 824. Check again
as part of monitoring operat.
15. Preload of taper roller Between Adjuster Set to 1.8 - 6.4 Nm roll tor-
bearing in output cover 0.002 and 0.006" 1P01 136 816, dial que of taper roller bearing.
when cold (approx. 20 ºC) (0.05 and 0.15 mm) gauge and spring Adjusted using spacer was-
preload balance hers. Difference between
speedometer worm and set-
1.3 ft-lbs to 4.7 ft-lbs ting ring = dimension “C”.
(1.8 - 6.4 Nm) Thickness "S" of spacer was-
Roll torque her = C + 0.05 mm.
16. Total end play between Between Measuring bars and Adjusted using shims on
sun gear and output 0.02 and 0.03" depth gauge output.
(0.6 and 0,8 mm)
17. Installation dimensions of 0.10 + 0.04" Depth gauge Measured between thrust
needle bearing in planet (2.5 +1 mm) surface of shim and end face
carrier III of needle bearing. Correct
installation assured if special
tool 1X56 137 101 is used.
16
18. End play on planet Between Feeler gauge Clearance is set, check
gears in planetary carrier 0.02 and 0.05" again as part of monitoring
III (0.5 and 1.2 mm) operation.
19. Tightening torque of M6 Between Torque wrench

studs on output cover 3.7 and 5.6 ft-lbs
(5 and 7.5 Nm)
20. Tightening torque of M6 5 ft-lbs Torque wrench Do not exceed specified

hex bolts on output cover (6 Nm) value.
21. Tightening torque of M12 44 ft-lbs Torque wrench Secure with locking plate.
hex bolts on output flange (60 Nm) Use special tool
1X56 136 471.
Control unit
22. Displacement quantities approx. 18.5 gal/min Graduated vessel and Measured at pump speed n =
of primary pump tested (60 l/min) stopwatch 1500 rpm. Use SAE 10 W
separately (theoretical oil at 80 ºC. The primary
value) pump is a single-piece part.
23. Distance between spring 0.06 + 0.02" Sliding gauge Adjusted by removing or fit-
guide and stator ring guide (1.6 + 0.5 mm) ting disc springs. Measure-
pin ments are taken without pre-
tensioning the disc springs.
Clutch carrier
24. Pressure test (PÜ) for 36 + 7 psi Feed bush Pressure test for leakage:
pistons of clutches “A”, (2.5 + 0.5 bar) 1X56 137 128, Pressure drop of 36 + 7 psi
“B” and “C” compressed air unit to 20 psi (2.5 + 0.5 bar to 1.4
1X56 137 130 bar) after cut-off = 10 sec.
25. Disc play on clutch “A” Between Depth gauge Rectify deviations by fitting
0.13 and 0.15" steel discs of appropriate
(3.2 and 3.7 mm) thickness.
(HP 502 / HP 552 /
HP 592 / HP 602)
17
26. Disc play on clutch “B” Between Feeler gauge Measured by placing
0.06 and 0.082" feeler gauge between end
(1.6 and 2.1 mm) disc and outer disc. Rectify
(HP 502); deviations by fitting steel
0.08 and 0.10" discs of appropriate thick-
(2.0 and 2.5 mm) ness.
(HP 552/592/602)
27. Disc play on clutch “C” Between Feeler gauge Measured by placing
0.05 and 0.06" feeler gauge between R gear
(1.2 and 1.7 mm) pot. and outer disc. Rectify
(HP 502); deviations by fitting steel
0.06 and 0.082" discs of appropriate thickn-
(1.6 and 2.1 mm) ess.
(HP 552/592/602)
28. Run-out of inductive + 0.008" Dial gauge Measure from the raised
pickup ring when installed (+ 0.2 mm) point on the inductive pickup
ring. Correct by tapping
with plastic-tip hammer
29. Tightening torque of M8 26 ft-lbs Torque wrench

hex bolts on rotor (retar- (35 Nm)
der)
Mechanical transm. section
30. End play of planetary Between 0.02 and 0.05" Feeler gauge End play is fixed, double-
gears in planetary carrier I (0.5 and 1.2 mm) check.
31. Disc play on brake “D” Between Feeler gauge Measure by inserting feeler
0.05 and 0.06" gauge between end disc and
(1.2 and 1.7 mm) outer disc. Correct deviati-
(HP 502); ons by fitting steel discs of
0.06 and 0.082" appropriate thickness.
(1.6 and 2.1 mm)
(HP 552/592/602)
32. Installation dimension of 0.16 + 0.04" Depth gauge Measured between thrust
needle bearing in input (4 +1 mm) face of thrust washer and
shaft end face of needle bearing.
If punch 1X56 137 101 is
used, correct installation is
assured
33. End play of planetary Between Feeler gauge End play is fixed, double-
gears in planetary 0.02 and 0.05" check.
carrier III (0.5 and 1.2 mm)
18
34. Disc play on brake “E” Between Feeler gauge Measure by inserting feeler
0.11 and 0.13" gauge betw. sealing ring and
(2.8 and 3.3 mm) outer disc. Correct deviati-
(HP 502 / HP 552 / ons by fitting steel discs of
HP 592 / HP 602) appropriate thickness.
35. Disc play on brake “F” Between Depth gauge Correct deviations by fitting
0.10 and 0.12" steel discs of appropriate
(2.6 and 3.1 mm) thickness.
(HP 502 / HP 552 /
HP 592 / HP 602)
Hydraulic control unit
36. Distance between in- Between Depth gauge, measur- Distance can be adjusted
ductive pickup - turbine 0.02 and 0.03" ing rod 1X56 138 149 using shims.
and pulse generator ring (0.6 and 0.8 mm) und 1X56 138 150
37 Tightening torque of M6 7 ft-lbs (9.5 Nm) Torque wrench

mounting bolt for induc-
tive pickup
Retarder accumulator
38. Tightening torque of M8 Between Torque wrench Only replace stud bolts with
stud bolts on rear cover of 5.6 and 7.4 ft-lbs new ones if damaged.
retarder accumulator (7.5 and 10 Nm)
39. Tightening torque of M8 11 ft-lbs (15 Nm) Torque wrench Fit washers.
lock nuts on retarder accu-
mulator cover
40. Tightening torque of 18 ft-lbs (25 Nm) Torque wrench Fit new copper sealing was-
M12x1.5 screw plug in her.
solenoid valve
19
Other transmission data
41. Installation dimension of 1.57 + 0.04" Depth gauge Measured betw. mating face
oil filler pipe (40 +1.0 mm) of transmission housing (oil
pan flanging face) and end
face of filler pipe.
(Use sealing band on pipe)
42. Tightening torque of approx. 60 ft-lbs Experience Secure slotted nut with Loc-
M30x1.5 slotted nut on oil (80 Nm) tite no. 574.
filler pipe
43. Tightening torque of 37 ft-lbs Torque wrench Fit new copper sealing was-
M22x1.5 oil drain plug in (50 Nm) her
oil pan
44. Tightening torque of 9 ft-lbs Torque wrench Fit new copper sealing was-
M10x1 screw plug on (12 Nm) her
pressure measuring ports
45. Tightening torque of approx. 15 ft-lbs Torque wrench Fit new copper sealing was-
M10x1 union (hollow) (20 Nm) her
screws in cover plate
20
HP 502 / HP 552 / HP 592 / HP 602 Spring Table
Order no. Installation position Number Wire dia- Outer spring Untensioned
of coils meter diameter length
0732 042 113 Control element - 17.50 0.110" 0.61" 2.93"
main pressure valve 2.80 mm 15.66 mm 74.56 mm
0732 042 114 Control element - 11.50 0.118" 0.90" 2.79"

main pressure valve 3.00 mm 22.90 mm 71.14 mm
0732 041 125 Control element - 4.50 0.098" 0.91" 0.89"

lubrication pressure valve 2.50 mm 22.94 mm 22.70 mm
0732 041 102 Control element - 10.50 0.11" 0.736" 2.07"

torque converter press. valve 2.80 mm 18.70 mm 52.60 mm
0732 040 786 Control element - 14.50 0.098" 0.69" 2.65"

cooler changeover valve 2.50 mm 17.54 mm 67.40 mm
0732 041 373 Shift control - 27.50 0.035" 0.21" 1.51"

valve blocks 0.90 mm 5.40 mm 38.40 mm
0732 041 374 Shift control - 13.50 0.051" 0.41" 1.48"

0732 041 148 Shift control - 14.50 0.082" 0.75" 2.49"

0732 041 720 Shift control - 13.75 0.086" 0.76" 2.38"

0732 042 683 Shift control - 12.50 0.062" 0.75" 2.71"

0732 041 095 Shift control - 12.50 0.070" 0.73" 2.63"

0732 041 216 Shift control - 14.00 0.082" 0.75" 2.36"

valve blocks 2.10 mm 19.19 mm 60.10±0,5 mm
0732 041 199 Shift control - 13.50 0.070" 0.74" 2.87"

0732 041 381 Shift control - 6.00 0.088" 0.77" 1.138"

torque converter valve 2.25 mm 19.65 mm 28.90 mm
0732 042 613 Shift control - 25.50 0.049" 0.281" 2.061"

valve block F2 1.25 mm 7.16 mm 52.36 mm
0732 042 274 ZF torque converter 380-30 6.50 0.063" 0.546" 0.939"
1.60 mm 13.87 mm 25.13 mm
21
Spring Table HP 502 / HP 552 / HP 592 / HP 602
Order no. Installation position Number Wire dia- Outer spring Untensioned
of coils meter diameter length
0732 041 934 Retarder - stator ring 13.50 0.055" 0.643" 2.212"
1.40 mm 16.35 mm 56.20 mm
1204 318 011 Retarder - control valve 5.00 0.082" 1.20" 1.496"
2.10 mm 30.50 mm 38.00 mm
0732 042 471 Disc brake “D” 11.50 0.062" 0.417" 1.284"
1.60 mm 10.59 mm 32.62 mm
0732 042 334 Disc brake “E” 22.50 0.062" 0.33" 4.84"
1.50 mm 8.96 mm 62.36 mm
0732 042 259 Disc brake “F” 11.50 0.075" 0.387" 1.421"
1.90 mm 9.8 mm4 36.10 mm
0732 041 421 Clutch carrier, 24.50 0.078" 0.456" 3.114"

Reverse gear pot 2.00 mm 11.60 mm 79.10 mm
22
HP 502 / HP 552 / HP 592 / HP 602 Special Tools
Fig. Diagram Order no. Application Quan- Comments

no. tity
1X56 097 775 2
Assembly hook
1 for lifting planet carrier
out of housing
1X56 122 205 1
Internal extractor / puller

2 for needle bearing (18 x 24 x 16) in
planet carrier II and in input shaft
(in conjunction with 1X56 122 227)
1X56 122 208 1
Internal extractor / puller

conjunction with 1X56 122 227
1X56 122 227 1
Bridge yoke / counter-support

4 in conjunction with internal extractor
1X56 122 205 and 1X56 122 208
1X56 122 306 1
Basic tool
5 in conjunction with gripper
1X56 136 706
23
Special Tools HP 502 / HP 552 / HP 592 / HP 602

no. tity
1X56 122 322 1
Extractor
6 for grooved ball bearing
(0635 331 232) in control element
1X56 124 659 1
Extracting plate
7 for bearing inner race
of stator hollow shaft
1X56 136 260 1
Lifting device
8 for lifting complete output
1X56 136 471 1
Punch
9 for locking plate on output flange
1X56 136 513 1 Available either

Hot air blower 220 Volt as a 220 volt
or version or
10 1X56 137 575 110 volt version
Hot air blower 110 Volt
for heating up various parts
24

no. tity
1X56 136 594 1
Adapter (LH)
11 for securing transmission
(in conjunction with assembly stand
1X56 137 450)
1X56 136 595 1
Adapter (RH)
12 for securing transmission
(in conjunction with assembly stand
1X56 137 450)
1X56 136 605 1 only for

HP 502 / 592
Punch transmission
13 for shaft seal with
(125 x 150 x 10) behind ZFW 360-10
torque converter converter
1X56 136 612 2
M8 hook
14 for lifting control element off the
clutch carrier
1X56 136 706 1
Gripper
15 for taper roller bearing
(0635 370 006) on output
25

no. tity
1X56 136 815 3
Puller
16 for cover plate behind torque
converter
1P01 136 816 1
Adjuster
17 for taper roller bearing on output
1X56 136 818 1
Fixture
18 for oil feed flange to assemble
control element
1X56 136 820 1
Punch
19 for removing bush from stator
hollow shaft
1X56 136 821 2
M8 guide screw
20 for installing control element
and primary pump
26

no. tity
1X56 136 824 1
Punch
21 for radial sealing ring (90 x 125 x 10)
and bearing outer race
on output
1X56 136 862 1
Lifting device
22 for torque converter
1X56 137 101 1
Punch
planet carrier II and in input shaft
1X56 137 103 1
Punch
hub, clutch hub
1X56 137 104 1
Thrust piece / pad

25 for extracting grooved ball bearing
in control element (in conjunction
with 1X56 122 322)
27

no. tity
1X56 137 105 1
Thrust piece / pad

26 for inserting the snap rings
in front of the disc springs of the
A piston
1X56 137 107 1
Device
27 6 13
7 10
7 for inserting spacer ring
1X5
4139 310 018 in control element
1X56 137 108 1
Clamping device
28 for removing and installing the main
and lubrication pressure valve and
converter backpressure valve in con-
trol insert
1X56 137 109 1
Punch
29 for separating clutch carrier
from control insert
1X56 137 126 1
Lifting device
30 for Ecomat transmissions
28

no. tity
1X56 137 127 1
Clamping device
31 for reverse gear pot
1X56 137 128 1
Feed bush
32 for leakage test of clutches in clutch
carrier
1X56 137 129 1
Forcing device
33 for converter leakage test
1X56 137 130 1
Compressed air unit

34 for converter and clutch carrier
leakage test in conjunction with feed
bush 1X56 137 128 and 1X56 137
129
1X56 137 151 1
Caulking tool
35 for punch-marking and caulking the
orifices of the pressure control unit
29

no. tity
1X56 137 152 2
Support
36 for stator bearing
1X56 137 156 1
Caulking tool
37 for knocking out the orifices
1X56 137 158 1
Holding device
38 for loosening and tightening the M16
socket head screw in the converter
1P01 137 173 1
Plug gauge
39 of between 0.7 and 3 mm for
measuring the orifices
1X56 137 213 1
Lifting device
40 for turbine shaft
30

no. tity
1X56 137 273 1
Hexagon socket head insert

41 for socket head screw
on control insert
1X56 137 382 1 only for

HP 592 / 602
Punch transmission
42 for radial sealing ring with
(142 x 162 x 10) behind torque ZFW 380-30
converter converter
1X56 137 388 1 only for HP 602

transmission
Puller
43 for planet carrier II
(in conjunction with 1X56 137 387)
1X56 137 432 1
Puller
44 for forcing the piston ring carrier
off the stator quill shaft
1X56 137 450 1
Assembly stand
45 can be swivelled
31

no. tity
1X56 137 464 1
Support
46 for securing planet gear pins
1X56 137 465 1
Caulking tool
47 for caulking the planet gear pins in
planetary carrier I
1X56 137 466 1
Caulking tool
48 for caulking the planet gear pins in
planetary carrier II and III
1X56 137 658 1
Counter support / bracket brace

49 for loosening and tightening the
screw plug in the converter
1P01 137 906 1
Adjuster
50 for setting NBS (Neutral at bus stop)
32

no. tity
1X56 138 149 1
Measuring rod
51 for measuring distance on inductive
pickup - output. (In conjunction with
test device 1X56 138 150)
1X56 138 150 1
Test device
52 for measuring distance on inductive
pickup - output. (In conjunction with
test device 1X56 138 150)
1X56 150 111 2
M6 threaded pin
53 for control
33
Auxiliary tools for in-house production
Auxiliary drifts for centering the planet gears
ø1
4139 333 041 4139 233 049 / 4139 333 667
ø1 0.9834 - 0.002” 1.1803 - 0.002”

24.98 - 0.05 mm 29.98 - 0.05 mm
ø2 0.5897 - 0.002” 0.7866 - 0.002”
L1
14.98 - 0.05 mm 19.98 - 0.05 mm
L1 3.15” 3.15”
80 mm 80 mm
L2
L2 0.315” 0.315”
ø2 8 mm 8 mm
34
HP 502 / HP 552 / HP 592 / HP 602 Assembly Stand
1 Assembly Stand - Insert and Remove

Transmission
1 2
1.1 Assembly Stand - Insert Transmission
1 Attach adapters 1X56 136 594 and 1X56 136 595

(1/2) to the transmission assembly stand (3).
2 Tighten the M10 hexagon nuts and bolts; 3

4
tightening torque: 46 Nm
3 Undo the hexagon socket head screws (4).

5
4
4 Adjust the center crossbeam (5) so that the
distance “A” is approx. 550 mm.
5 Tighten the hexagon socket head screws (4). 000786
6 Fit lifting device 1X56 137 126 on the output

cover (1).
7 Screw in the four M16x1.5 hexagon bolts;

008385
8 Undo the shackle (1) and insert it into the correct

bore with the ring (2). Fasten the shackle.
2
! DANGER
Insert the shackle carefully. See the instruction plate
on the lifting device.
1
9 Attach the ring (2) to the crane hook. Move the
transmission over the assembly stand, center it bet-
ween the adapters and lower it into the assembly
stand.
008381
1-1
Assembly Stand HP 502 / HP 552 / HP 592 / HP 602
10 Fasten the RH adapter to the transmission.

Screw in the hexagon bolts (1);
1
008382
11 Pivot the LH adapter (1) upwards and fasten

it to the transmission with the M16x1.5
1
hexagon bolts;
12 Remove the crane hook and the lifting device.
13 Unlock the assembly stand and pivot the

transmission into the desired position.
! DANGER
Avoid knocking or hitting the transmission
outside of its axis of rotation.
008383
! DANGER
Stand clear when pivoting the transmission. Always
lock the assembly stand with the pin (1) after pivoting
the transmission. Secure the pin (1) with the tommy 1
nut (2). 2
008384
1-2
HP 502 / HP 552 / HP 592 / HP 602 Assembly Stand
1.2 Assembly Stand - Remove Transmission
1 Fit lifting device 1X56 137 126 on the output

cover. Screw in the four hexagon bolts;
008385
2 Attach the crane hook to the ring (1).
3 Using the lifting device, lift the transmission until

the ring (1) is under slight tension.
!DANGER
Do not lift the assembly stand off the ground.
008386
!DANGER
Secure the LH adapter to stop it swinging down.
4 Unscrew and remove the adapter hexagon bolts.
! DANGER
The transmission may drop slightly. Risk of crushing.
5 Remove the transmission from the assembly

stand.
008387
1-3
1-4
HP 502 / HP 552 / HP 592 / HP 602 Retarder Accumulator
2 Retarder Accumulator - Remove and Install,

Dismantle and Assemble
2.1 Retarder Accumulator - Remove
1 Unscrew and remove both the M8 hexagon bolts

(1).
011583
2 Unscrew and remove the two M8 hexagon bolts

with nuts (2) from the output end of the accumula-
tor.
011584
3 Unscrew and remove the two M8 socket head

screws (1) and remove the accumulator (2).
011587
2-1
Retarder Accumulator HP 502 / HP 552 / HP 592 / HP 602
2-2
2.2 Retarder Accumulator - Install
1 Coat a new O-ring (1) with Vaseline and place it

into the groove on the accumulator.
011588
2 Insert the accumulator. Insert the two M8x25

socket head screws with washers (1) on the input
end.
Tightening torque: 23 Nm.
011587
3 Insert and tighten two M8 hexagon bolts with

washers and M8 nuts (1) on the output end.
Tightening torque: 23 Nm.
011584
2-3
4 Coat a new O-ring (1) with Vaseline and

insert it into the solenoid valve.
008394
5 Insert and tighten the M8x55 hexagon bolts (1).

Tightening torque: 23 Nm
011585
2-4
2.3 Retarder Accumulator - Dismantle
1 Remove the M8 lock nuts (1) and washers.
2 Remove the connection plate (2).
008396
3 Remove the rear cover (1).
4 Slide the complete piston (2) out of the tube (3).
3
1
008398
5 Slide a suitable tool under the grooved rings (1)

and remove them from the piston. 2
6 Remove the piston guide ring (2) from the

1
piston.
008397
2-5
7 If one of the threaded pins (1) is damaged, use a

bolt drawer or bolt drift to remove it from the rear
cover.
8 Screw in a new threaded pin;

tightening torque: 7.5 to 10 Nm
008399
2-6
2.4 Retarder Accumulator - Assemble

2
NOTE
1
Clean all parts thoroughly before assembly.
Always renew grooved rings, O-rings, piston
guide rings, cap collars etc.
1 Insert the new grooved rings (1) into the piston

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

1
CAUTION
Insert the grooved rings with the open side facing
outwards.
008400
3 Coat the outside of the piston and the inside

of the tube with grease MIL-G-24 139.
Grease quantity: 2 cc to 4 cc
4 Insert the piston (1) into the tube (2).

2
CAUTION
Take care not to damage the grooved rings when
inserting the piston.
008401
5 Fit a new O-ring (1) onto the rear cover (2)

and coat with Vaseline.
6 Slide the tube (3) and piston onto the rear

cover. 2 3
CAUTION
Slide on the tube with the stamped number on the
piston facing the rear cover.
008402
2-7
7 Coat a new O-ring (1) with Vaseline and fit it on

the connection plate (2).
8 Slide the connection plate (2) onto the

2 1
threaded pins (3).
NOTE
Make sure the shoulder of the connection plate is
facing the bracket on the rear cover.
008403
9 Screw on the M8 lock nuts (1) with washers;

NOTE
Use new lock nuts.
008404
2-8
HP 502 / HP 552 / HP 592 / HP 602 Heat Exchanger
3 Heat Exchanger - Remove and Install
3.1 Heat exchanger - Remove
1 Unscrew and remove the four hexagon bolts (1)

from the heat exchanger bracket.
012364
2 Unscrew and remove the hexagon bolt (1) from

the oil pipe bracket.
NOTE
Hold the M8 lock nut on the rear of the bracket to
stop it from turning. Lay to one side together with
the washers, pipe and bracket.
2
3 Unscrew and remove the seven M8 socket head 1
screws from the fitting (2).
012365
4 Lift the heat exchanger off the transmission com-

plete with the pipes and the fitting.
012366
3-1
Heat Exchanger HP 502 / HP 552 / HP 592 / HP 602
5 Take out the two inserts (1).
012367
6 Take out the two O-rings (1).
012368
7 Remove the gasket from the fitting.
012369
3-2
8 Unscrew and remove the two hexagon bolts (1)

and lay them to one side together with the bracket 2
(2).
012370
9 Use a plastic-tip hammer to knock the fitting (1)

downwards so that it comes off the oil pipes.
2
CAUTION
Do not strike the pipes with the hammer as this could
damage the pipes.
10 Remove the two O-rings (2) from each of the oil

pipes.
1
012371
11 Unscrew and remove the two socket head screws

(1) and lay them to one side together with the
bracket (2).
012372
3-3
12 Lift off the oil pipe (1) and remove the O-rings (2)
from the heat exchanger. 1
13 Unscrew and remove the two hexagon bolts (3)

and lay them to one side together with the bracket.
3
012373
14 Pull out the oil pipe (1) and remove the O-rings
(2).
15 Unscrew and remove the three hexagon bolts (3)

2 3
and lift off the fitting.
012374
16 Unscrew and remove the eight hexagon bolts (1)

and remove the heat exchanger bracket (2).
012375
3-4
3.2 Heat Exchanger - Install
1 Place the heat exchanger bracket (2) on the trans-

mission. Screw in the eight M10x60 hexagon
bolts (1) with washers (Spec List 6030 010 026),
position the bracket horizontally in relation to the
transmission and tighten the bolts.
012375
2 Insert two new O-rings (1) in the groove on the

socket and coat with Vaseline.
3 Fit a new gasket (2) on the heat exchanger

flanging face.
2
012376
4 Attach the fitting (1) as illustrated using three

M8x60 hexagon bolts with washers.
012377
3-5
5 Insert two new O-rings (1) in the grooves on the

pipe and coat with Vaseline.
012374
6 Insert the pipe (1) into the fitting as illustrated. Fit

the bracket (2) using two M8x22 hexagon bolts.
7 Insert the pipe (3) into the fitting.

2
3
012373
8 Fit the bracket (1) using two M8x16 socket head

screws and washers.
01272
3-6
9 Insert two new O-rings (1) in the grooves on each

pipe and coat with Vaseline.
1
012371
10 Align the pipes with the holes in the fitting and

slide the fitting onto the pipes.
CAUTION
Do not strike the pipes with the hammer as this could
damage the pipes.
012378
11 Fit the bracket (1) using two M8x22 hexagon

bolts.
012370
3-7
12 Affix a new gasket to the fitting using Vaseline.
012369
13 Insert two new O-rings (1) in the transmission

holes.
012368
14 Fit the two inserts (1) in the holes as illustrated.
012367
3-8
15 Place the heat exchanger onto the bracket on the

transmission complete with the pipes and the
fitting. Align the fitting with the holes in the
transmission.
NOTE
Make sure the gasket is correctly positioned on the
fitting. 1
16 Insert the seven M8x45 socket head screws into
the fitting (1) and tighten them.
012379
17 Insert the four M10x22 hexagon bolts with

washers (1). Align the heat exchanger with the
holes while doing this.
0121364
18 Mount the bracket (1) as follows:
012365
3-9
19 Insert the M8x55 screw with washer (1) into the

bracket (2). Place the pipe (3) and washer (4) on
the screw (1). Insert the screw into the hole in the
bracket (5) complete with the bracket, pipe and 2
washers. Secure using the M8 lock nut with
washer (6).
Tightening torque: 23 Nm 1
3 4 5 6
012380
3-10
HP 502 / HP 552 / HP 592 / HP 602 Converter
4 Converter - Remove and Install, Dismantle and

Assemble
4.1 Converter - Remove

1
NOTE
Depending on the transmission type, the converter
fitted may be a ZFW 380-30 or a ZFW 360-10 (the
illustration shows a 380-30 converter). The
removal procedure is the same for both converter
types.
1 Rotate the transmission in the assembly stand so

that the converter is facing upwards.
NOTE
Measure and note down the distance "F" (see 012590
4.2.2) before removing the converter.
2 Attach bracket brace 1X56 137 658 (1) to the

converter and the transmission housing.
2
3 Unscrew and remove the screw plug (2).
012381
4 Screw holding device 1X56 137 158 (1) into the

converter circuit cover and tighten it by hand.
NOTE
Make sure the rubber washer is fitted on the
1
holding device thread.
012382
4-1
Converter HP 502 / HP 552 / HP 592 / HP 602
NOTE
It is possible to use ZF mechanical holding device
1X56 136 864 together with hexagon insert 1X56
136 863 instead of the pneumatic holding device.
5 Connect compressed air unit 1X56 137 130 to

holding device 1X56 137 158.
6 Turn the regulator (1) anti-clockwise a few times.

2
7 Open the stopcock (2). The lever must be 1
horizontal.
8 Use the regulator (1) to set a pressure of 1.5 bar.
008427
9 Insert 1/2" socket wrench extension (1) and

undo the socket head screw. 1
NOTE
Use a suitably long grip. The M16 socket head
2
screw is tightened to 190 Nm in the turbine shaft.
10 Close the stopcock.
11 Unscrew and remove holding device 1X56 137

158 (2) from the converter circuit cover.
012592
12 Unscrew the socket head screw (1) and remove it

from the converter.
012383
4-2
13 Screw lifting device 1X56 136 862 into the

converter and tighten it by hand.
14 Remove bracket brace 1X56 137 658.
15 Carefully remove the converter from the

transmission.
NOTE
Before lifting out the converter completely, raise it
to just above the turbine shaft. Then tilt the
converter slightly so that the oil can drain out.
012589
16 Unscrew and remove the lifting device.
17 Turn the converter over and remove the shim(s)

(1) from the converter or from the turbine shaft.
1
! DANGER
The converter weighs approx. 60 kg. Before removing
the lifting device, secure the converter to prevent it
from rolling away.
012384
18 Remove the spacer ring (1) from the stator hollow

shaft.
003 339
003339
4-3
4-4
4.2 Converter - Install
4.2.1 Converter End Play - Measure

converter so that the converter turbine wheel is
clamped tight.
2 Turn the converter over.
!DANGER
The converter weighs approx. 60 kg. Secure the
converter to prevent it from rolling away.
012385
3 Measure the distance "C" between the spur gear

end face and the turbine wheel.
4 Note down distance "C".
012386
5 Measure the distance "B" between the end face of

the spur gear and the end face of the internal sprag
race.
6 Note down distance "B".
012387
4-5
7 Calculate the theoretical distance "D" between the

end face of the internal sprag race and the end
face of the turbine wheel as follows.
C–B=D
Note down distance "D".
D B
C
001580
001580
8 Check the rectangular-section ring (1) for damage.

Renew it if necessary.
9 Align the rectangular-section ring centrally.

NOTE
The rectangular-section ring has hooked ends.
10 Slide the spacer ring (2) onto the stator hollow

shaft so that there is no end play.
2

turbine shaft. 008436
12 Tighten the lifting device by hand until there is no

end play on the turbine shaft.
13 Place a depth gauge in the recess of the lifting

device on the end face of the turbine shaft.
14 Measure the distance "A" between the end face of

the turbine shaft and the spacer ring (1) on the
stator hollow shaft.
1
15 Note down distance "A".
16 Unscrew the lifting device from the turbine shaft.

003 348
003348
4-6
17 Calculate the shim thickness "S" (1).

D –A = E
Distance "E" plus the specified converter end play
(distance "G" = 0.3 to 0.4 mm) gives the required
shim thickness "S" (1). E + 0.3 to 0.4 mm = S
Calculation example:
C = 174.7 mm D = 119.50 mm
– B= 55.2 mm – A = 118.30 mm
D = 119.5 mm E = 1.20 mm
* + G = 0.35 mm
S = 1.55 mm
CAUTION
Distance "G" must be added and not subtracted.
Otherwise the bearings will be damaged!
Shims WTB 0730 005 591 are available in

thicknesses ranging from 2.6 mm to 1.0 mm, in 0.1
to 0.3 mm steps.
NOTE
Thicker shims mean greater play.
18 Thinly coat the shim (1) with grease and affix it.
1
19 Center the shim.
20 Center the rectangular-section ring (2).
21 Thinly coat the contact surface of the sealing ring

(see arrow) with oil.
003 349
003349
4-7

converter.
23 Carefully lower the converter so that it is centered

on the turbine shaft. Fit the converter so that there
is no end play.
012588
24 Loosen lifting device 1X56 136 862 by

unscrewing it a few turns.
CAUTION
Take care not to damage the sealing ring. Ensure the
shim is correctly positioned on the turbine shaft.
NOTE
The turbine shaft and stator hollow shaft splines
must mesh inside the converter. Rotate the
converter slightly if necessary. The gear on the
converter must also mesh with the input gear of
the primary pump.
012589
NOTE
The example illustrated shows the ZFW 360-10
converter.
008440
4-8
4.2.2 Converter Installation Dimension - Measure
1 Make sure the converter is fitted correctly and

without any end play.
2 Measure the distance "F" between the converter

flanging face and the transmission flanging face.
3 Measure the distance at several points around the

edge and calculate the average value.
NOTE
Distance "F" must be X ± 0.5 mm. Ecomat
transmissions can be equipped with different types
of converter. The table below gives the
distance "F" (converter installation dimension) for
each converter type.
012581
ZFW 360-10 ZFW 380-30

X = 71.25 mm Außen Ø
X = 77.00 mm X = 77.00 mm
X = 81.25 mm X = 81.25 mm
X = 86.25 mm
F
F
If the distance "F" is between X + 0.5 mm and

X – 0.5 mm, then the setting is correct.
4 If the distance is less than X – 0.5 mm, fit a

second spacer ring on the stator hollow shaft.
5 If the distance is more than X + 0.5 mm, remove

the spacer ring.
NOTE
The spacer ring is 1 mm thick.
001581
CAUTION
If the distance “F”is changed by adding/removing a
spacer ring on the stator hollow shaft, the shim on the
turbine shaft must also be changed accordingly.
Otherwise the bearings will be damaged!
6 Unscrew and remove lifting device 1X56 136 862

from the converter.
1
7 Screw the M16 socket head screw (1) into the con-
verter
8 Re-check the installation dimension.
012383
4-9
9 Attach brace bracket 1X56 137 658 in the

transmission housing and bolt it to the converter.
10 Screw holding device 1X56 137 158 into the

converter circuit cover and tighten it by hand.
NOTE
Ensure rubber washer is fitted on the holding
device thread.
11 Connect compressed air unit 1X56 137 130 to hol- 2

ding device 1X56 137 158. 1
12 Turn the regulator (1) anti-clockwise a few times.
13 Open the stopcock. Move the lever (2) to the

horizontal position.
008443
15 Insert 1/2" socket wrench extension and tighten

the hexagon socket head screw;
tightening torque: 180 - 190 Nm 4
16 Close the stopcock.
17 Remove holding device 1X56 137 158 (4) from

the converter circuit cover.
012592
18 Fit a new copper sealing washer on the screw plug

(1).
19 Tighten the M33x2 screw plug;

tightening torque: 190 - 210 Nm
1
012381
4-10
4.3 Converter - Dismantle

4.3.1 ZFW 380-30 Converter - Dismantle
1 Place the converter on planks or wooden blocks.
2 Unscrew and remove all the M10 socket head 2

screws (1).
3 Attach the hoisting rope to lifting device 1X56

136 862 and lift the circuit cover (2) off the
impeller using the hoist.
! DANGER 1
The turbine wheel is only held by the bearing seat in
the circuit cover. Only lift the circuit cover as high as
necessary and immediately lay it to one side next to
012385
the impeller.
4 Remove the shim (1), housing disc (2), axial

needle cage (3) and shaft disc (4) from the stator.
CAUTION 1 2 3 4
Do not mix up the bearing assemblies when
installing. The shaft and housing discs must not be
mixed up with any other bearing assemblies. Clearly
mark all the parts.
012390
5 Remove the complete stator from the impeller,

rotate it through 180° and lay it to one side.
6 Remove the shaft disc (1) from the stator.
012391
4-11
7 Remove the roller bearing (1) and the housing disc

(2).
CAUTION
The shaft and housing discs must not be mixed up
1 2
with any other bearing assemblies. Clearly mark all
the parts.
012392
8 Unscrew and remove the twelve M8 Torx-

Powerlok screws.
9 Slightly raise the impeller and knock out the spur

gear using a plastic-tip hammer.
012393
10 Remove the O-ring (1) and the gasket (2) from the
spur gear.
3
11 Knock out the roll pins (3) if necessary.
2
1
012394
4-12
4.3.2 ZFW 360-10 Converter - Dismantle
1 Turn the converter over and place it on planks.
2 Unscrew and remove all the M8 and M10 socket

head screws (1).
3 Force the circuit cover off the impeller by

screwing in lifting device 1X56 136 862.
CAUTION 1
Do not strike the circuit cover or the impeller.
008446
4 Remove the roller bearing and the shaft disc from

the stator.
008448
5 Unscrew and remove the twelve M8 socket head

screws (1).
6 Slightly raise the impeller (2) and knock out the

spur gear (3) using a plastic-tip hammer
NOTE 1
Knock out the roll pins if necessary.
2 3
008447
4-13
7 Remove the housing disc (1) from the spur gear 2

(2).
8 Remove the O-ring (3) and the gasket (4) from the
spur gear.
CAUTION
The shaft and housing discs must not be mixed up
with any other bearing assemblies. Clearly mark all 3 1
the parts.
008449
9 Remove the complete stator from the turbine

wheel.
10 Remove the shaft disc (1) from the stator.
11 Remove the needle bearing (2) from the turbine

wheel.
008450
12 Remove the housing disc (1) and the shim (2)

from the turbine shaft.
CAUTION
Do not mix up the bearing assemblies when
installing.
008451
4-14
4.3.3 Stator - Dismantle

(ZFW 380-30 and 360-10)
1 Place the stator (1) on a support. 3 2
2 Place a suitable pad (2) on the internal sprag race

(3). 1
3 Press the internal sprag race out of the stator.
008452
4 Remove the rollers (1) from the internal sprag

race.
5 Remove the ring (2) from the internal sprag race.
2
008453
6 Press the internal sprag race (1) out of the ball

bearing (2).
2
! DANGER
Do not clean bearings using compressed air. The
bearing races could come loose and damage the
bearing due to lack of lubrication.
1
008454
4-15
7 Place the stator (1) on the press using a suitable

support (2).
8 Use a suitable pad (3) to press the ball bearing out

of the stator.
3
CAUTION
The diameter of the pad must match the outside
diameter of the bearing.
1
008455
9 Remove the ball bearing (1) and the ring (2) from
the stator. 1
008457
4-16
4.3.4 Stator - Assemble

(ZFW 380-30 and 360-10)
1 Insert the ring in the stator.
2 Place the stator and ball bearing in the press using

a suitable support.
3 Use special tool 1X56 137 152 to press the

bearing in as far as it will go.
008456
4 Insert support 1X56 137 152 into the press with

the hollow facing upwards.
5 Turn the stator over and place it on support 1X56 1

137 152.
6 Insert the internal sprag race (1) into the stator

with the longer collar facing downwards and press
it in.
NOTE
Using support 1X56 137 152 ensures that the
internal sprag race is fitted in the correct position.
008459
7 Insert the rollers in the stator.

NOTE
After insertion, moderately oil the rollers and
rotate the stator several times.
8 Insert the ring (1) in the stator.
008460
4-17
9 Insert support 1X56 137 152 in the press and

place the stator on the support complete with the
ball bearing.
10 Place second support 1X56 137 152 onto the ball

bearing.
11 Press the ball bearing into the stator.

NOTE
Ensure that the hollows on both supports 1X56
137 152 are facing the stator. Using the supports
ensures that the bearing is fitted in the correct
position.
008458
4-18
4.3.5 Turbine Wheel and Circuit Cover on

ZFW 380-30 Converter - Dismantle
1
1 Remove the gasket (1).
012395
2 Lever the turbine wheel (1) off the circuit cover

using suitable pry-bars.
012396
3 Remove the rectangular-section ring (1) from the

groove.
NOTE
The rectangular-section ring has sharp edges.
Press one end of the rectangular-section ring into
the groove using your thumb.
Slide your index finger along to the other end of
the ring until the ring comes out.
1
012397
4-19
4 Force the ball bearing (1) off the turbine wheel

using two assembly levers.
NOTE 2
Do not remove the disc (2) unless it is damaged.
012398
5 If necessary, knock the disc (2) out of the turbine

wheel from the rear using a suitable punch (see
step 4).
012399
6 Unscrew and remove the twelve M10 hexagon

2
bolts (1) from the circuit cover and remove the end 1
disc (2).
012400
4-20
7 Remove the inner and outer discs (1) from the

circuit cover.
1
NOTE
The compression springs (2) are located on the
last outer disc.
8 Remove the compression springs (2) with the last

outer disc.
9 Remove the twelve rollers (3).
3
2
012401
10 Remove the disc spring (1).
11 Grip the plate piston (2) with pliers. Tap the 1

circuit cover with a plastic-tip hammer to loosen
and remove the plate piston.
012402
12 Hook a suitable tool (0.5 - 0.75 mm thick) under

the rectangular-section ring (2) and carefully 11
remove it from the plate piston.
!DANGER
The grooved edge of the plate piston may be sharp.
Wear protective gloves.
2
13 Apply pressure on both sides of the rectangular-
section ring (1) (see arrows). Then grasp the
bulging section of the ring and remove it from the
groove.
The removal procedure is the same for all outer

rectangular-section rings.
001569
001569
4-21
4-22
4.3.6 Circuit Cover and Turbine Wheel on

ZFW 380-30 Converter - Assemble
1
NOTE
Thoroughly clean all the components and dry
them using compressed air. Use lint-free cloths
only when wiping off the rectangular-section
2
rings.
1 Check the rectangular-section rings for damage

and renew them if necessary.
2 Coat the inner rectangular-section ring (2) and the

outer rectangular-section ring (1) with Vaseline
and insert them into the plate piston.
008468
NOTE
Stretch the inner rectangular-section ring a little
before installing it so that it sits firmly in the base 2
of the groove.
CAUTION
Insert the plate piston (1) into the circuit cover
without tilting it. Ensure that the rectangular-section
rings are firmly seated in the base of the groove all
the way around.
3 Tap around the edge of the plate piston with a 1

plastic-tip hammer. Make sure that the plate piston
is correctly positioned.
4 Place the disc spring (2) onto the plate piston with
the camber facing downwards.
012403
5 Insert the twelve rollers (1) into the holes around

the edge.
1
012404
4-23
6 Use a straight edge to check that the outer and inner

discs are flat and not distorted. Perform a visual
check. Check the discs against the end disc or a flat
surface.
CAUTION
Replace any discs that are dished or corrugated.
Maximum permitted wear is 0.3 mm. Replace lined
discs that have damaged or blackened linings.
Replace inner discs that have damaged tooth flanks.
Maximum permitted wear per tooth flank is 0.2 mm.
008469
7 Insert the first outer disc (1) so that the holes slide
over the rollers. 5 4 3 1
8 Place the four springs (2) over the rollers and onto
the outer disc at 90° intervals. Check the position
of the springs in relation to the countersink on the
circuit cover.
9 Insert the inner disc (3).
10 Insert the two outer discs (4).
11 Insert the inner disc (5) in the circuit cover.
2
012405
NOTE
Insert the two outer discs (4) so that the tooth
spaces for the springs (see arrow) and bores are
lying above the remaining rollers.
012406
4-24
12 Insert the two M10 threaded pins at an angle.
13 Line up the holes on the end disc with the holes in

the circuit cover. Fit the end disc over the threaded
pins and onto the springs in the circuit cover.
012407
14 Screw in the twelve M10x35 hexagon bolts;

2
NOTE
Before tightening the hexagon bolts, tap the plate
piston fully home with a plastic-tip hammer.
15 Use a feeler gauge (1) to measure the play

between the last inner disc and the end disc (2).
1
Note down as distance “A".
16 The disc play (distance "A") may be between 0.5

mm and 1.1 mm.
012408
NOTE
If the disc play is less than 0.5 mm or more than
1.1 mm, fit new outer discs as necessary. Then
re-measure distance "A".
A
Outer discs can be supplied in the following

thicknesses:
A
4139 334 202 = 3.0 mm
004 234
4139 334 206 = 3.5 mm
004234
4-25
17 Turn over the turbine wheel. Knock the spacer

disc (1) into the turbine wheel as far as it will go
(if it was previously removed). 1
2
18 Strike the spacer disc at four points around the
edge to secure it.
NOTE
Install the spacer disc with the holes facing
upwards.
19 Knock the ball bearing (2) onto the turbine wheel

using a suitable piece of pipe. 3
20 Insert the rectangular-section ring (3) in the

groove and hook in the open ends of the ring.
012409
! DANGER
The rectangular-section ring has sharp edges. Wear
protective gloves.
1
21 Align the inner discs. The discs have to cover each
other.
22 Insert the turbine wheel (1) in the circuit cover.
CAUTION
Ensure that the teeth on the turbine wheel mesh in
the gaps on the inner discs. Rotate the turbine wheel
back and forth until it engages. Ensure that the
turbine wheel is fully engaged and inserted as far as it
will go. If necessary, tap the edge of the inner teeth 012410
with a plastic-tip hammer. Take care not to damage

the inner discs.
4-26
4.3.7 Turbine Wheel and Circuit Cover on

ZFW 360-10 Converter - Dismantle
1 Lever the turbine wheel (1) out of the circuit cover

(2) using suitable pry-bars.
008462
2 Remove the rectangular-section ring (1) from the

groove.
NOTE
The rectangular-section ring has sharp edges.
Press the end of the rectangular-section ring into
the base of the groove using your thumb. Slide
your index finger to the other end of the ring until 1
the ring comes out.
008463
3 Force the ball bearing (1) off the turbine wheel (2)
using two assembly levers.
NOTE 3
Do not remove the disc (3) unless it is damaged. 1 2
008461
4-27
4 Knock the disc (3) out of the turbine wheel from

the rear using a suitable punch (see step 3).
008464
5 Unscrew and remove the twelve hexagon bolts (1)

from the end disc (2) and remove the end disc.
008466
6 Remove the inner and outer disc from the circuit

cover.
7 Remove the disc spring (1).

1
8 Remove the rollers.
008465
4-28
9 Grip the plate piston (1) with a pair of pliers.
10 Tap the mating face (2) of the circuit cover with a

plastic-tip hammer to loosen and remove the plate
1
piston.
008467
11 Hook a suitable tool (0.5 - 0.75 mm thick) under

the inner rectangular-section ring (2) and carefully
remove it from the plate piston. 11
!DANGER
The grooved edge of the plate piston may be sharp.
Wear protective gloves. 2
12 Apply pressure on both sides of the outer

rectangular-section ring (1) (see arrows). Grasp
the bulging part of the ring and remove it from the
groove.
001569
The removal procedure is the same for all

rectangular-section rings. 001569
4-29
4-30
4.3.8 Circuit Cover and Turbine Wheel on

ZFW 360-10 Converter - Assemble
1
NOTE
Thoroughly clean all the parts and blast them with
compressed air. Only use lint-free cloths when
wiping the rectangular-section rings.
2
1 Check the rectangular-section rings for damage
and renew them if necessary.
2 Coat the inner rectangular-section ring (2) and the

outer rectangular-section ring (1) with Vaseline
and insert them into the plate piston.
NOTE
Slightly stretch the inner rectangular-section ring 008468
before installing it so that it locates firmly against

the groove base.
CAUTION
Insert the plate piston (1) in the circuit cover without
tilting it. Ensure the rectangular-section rings are
firmly located against the groove base all the way aro-
und.
3 Tap the edge of the plate piston with a plastic-tip

hammer. Ensure that the plate piston is inserted as
far as it will go.
2
4 Insert the twelve rollers (2) into the holes around 1
the edge.
008470
5 Place the disc spring on the plate piston with the
camber facing downwards.
6 Use a straight edge to check that the outer and

inner discs are flat and not distorted. Perform a
visual check. Check the discs against the end disc
or a flat surface.
CAUTION
Replace dished or corrugated discs. Maximum
permitted wear is 0.3 mm. Replace lined discs that
have damaged or blackened linings. Replace inner
discs that have damaged tooth flanks. Maximum
permitted wear per tooth flank is 0.2 mm.
008469
4-31
7 Insert the outer disc (1).
8 Insert the inner disc (2).
9 Depending on the version, insert one or two outer

discs (3).
10 Insert the inner disc (4) into the circuit cover.

4
NOTE
Insert the outer discs (3) so that the holes slide
3
over the rollers.
2
1
008471
11 Insert the end disc (1) into the circuit cover.

1
12 Align the holes in the end disc with the holes in
the circuit cover.
13 Tighten the M8 hexagon bolts;

NOTE
Before tightening the hexagon bolts, tap the plate
piston once again with the plastic-tip hammer to
ensure it is inserted as far as it will go.
008472
14 Use a feeler gauge (1) to measure the play

between the last inner disc and the end disc (2)
and note it down as distance “A".
15 The disc play may be between 0.5 and 1.1 mm.
008473
4-32
NOTE
If the disc play is less than 0.5 mm or more than
1.1 mm, install new outer discs as necessary.
Then re-measure distance "A".
A
Outer discs can be supplied in the following thicknesses:
A
4139 334 005 = 3.5 mm
4139 334 006 = 4.0 mm
001 570
001570
16 Turn over the turbine wheel and drive the spacer

disc (1) into the turbine wheel as far as it will go
(if it was removed beforehand). 1
17 Use a caulking tool to secure the spacer disc at

four points around the edge.
NOTE
Install the spacer disc with the holes (2) facing
upwards.
008474
18 Knock the ball bearing onto the turbine wheel

using a suitable piece of pipe.
1
19 Inset the rectangular-section ring (1) in the groove
and hook in the open ends of the ring.
! DANGER
The rectangular-section ring has sharp edges. Wear
protective gloves.
008475
4-33
20 Align the inner discs. The discs must cover each

other. 1
21 Insert the turbine wheel (1) into the circuit cover.
CAUTION
The teeth on the turbine wheel must engage in the
gaps on the inner discs. Rotate the turbine wheel
back and forth until it engages. Ensure that the
turbine wheel is fully engaged and inserted as far as it
will go. If necessary, tap the edge of the inner teeth
with a plastic-tip hammer. Take care not to damage
the inner discs.
008476
4-34
4.4 Converter - Assemble

4.4.1 ZFW 380-30 Converter - Assemble
1 2
1 Clean the spur gear. Use an oil stone to rub the
mating surface.
2 Insert a new O-ring (1) in the spur gear.
3 Place a new gasket (2) on the mating face of the

spur gear and align it with the holes.
012394
4 Align the spur gear with the holes in the impeller.
5 Insert the spur gear in the impeller.
012411
6 Turn over the impeller complete with the spur

gear.
7 Knock in the two roll pins (10x20 and 6x20) if

they were removed previously.
8 Insert twelve new M8x28 Torx-Powerlok screws

and tighten them;
CAUTION
Always use new Powerlok screws. The countersunk
screwhead bores in the impeller must be flat. If
required, sink once by max. 0.5 mm.
012393
4-35
9 Prepare the bearing pack for the spur gear. Check

the markings!
NOTE
The shaft disc (1) is recognizable by the "WS"
marking, the housing disc (2) by the "GS" mar-
king. 1
008478
10 Insert the housing disc ("GS") into the spur

gear.
CAUTION
The chamfered side must be facing the spur gear.
012412
11 Place the roller bearing onto the housing disc in

the spur gear.
012413
4-36
12 Place 0.5 mm-thick shim (1) onto the ball bearing

on the stator (3). 3
13 Place the shaft disc ("WS") (2) onto the shim on

the stator with the chamfer facing downwards. 2 1
012414
14 Insert the complete stator (1) into the impeller.

1
CAUTION
The longer collar (2) of the internal sprag race must
face the impeller. When inserting the stator,
ensure that the internal sprag race, bearings and
discs do not fall out of the stator.
NOTE
Place support 1X56 137 152 onto the stator 2
bearing. Use a plastic hammer to tap in the stator
and complete bearing pack as far as they will go.
012415
15 Prepare the marked bearing pack.

1 2 3
16 Place the shaft disc (1) onto the stator.
17 Place the needle cage (2) onto the shaft disc.
18 Place the housing disc (3) onto the needle

cage.
012416
4-37
4-38
4.4.2 Axial Bearing End Play on ZFW 380-30

Converter - Measure and Adjust
1 Place the measuring blocks on the mating face of

the impeller.
2 Place the measuring bar on the measuring

blocks.
3 Place a depth gauge on the measuring bar and

measure distance "A" between the measuring bar
and the impeller mating face (without gasket).
Note down dimension "A".
NOTE
The measuring bar must not lie on the stator.
012417
4 Move the depth gauge to the center.
5 Measure the distance "B" between the measuring

bar and the face of the housing disc (1).
6 Note down distance "B" and subtract it from

distance “A".
1
Distance "A" – Distance "B" = Distance "C"
012418
7 Place a new gasket (1) on the circuit cover mating

face.
8 Place the measuring apparatus on the circuit cover

gasket.
9 Use a depth gauge to measure the distance "D"

between the measuring bar and the circuit cover
mating face (with gasket).
10 Note down distance "D".

1
012419
4-39
11 Measure the distance "E" between the measuring

bar and the shim (1) on the turbine wheel.
12 Note down distance "E" and subtract it from

distance "D".
Distance "D" – Distance "E" = Distance "F" 1

Subtract distance "F" from distance “C"
Distance "C" – Distance "F" = Distance "G"
13 Calculate the required shim thickness "S" as

follows:
G – (0.10 to 0.30 mm) = S

0.10 to 0.30 mm = End play of axial bearing
Calculation example: 012420
G = 1.40 mm
–*H = 0.20 mm
S = 1.20 mm
*H = average of 0.10 mm and 0.30 mm end play
Shim thickness "S" = 1.20 mm
CAUTION
The figures used in this calculation are purely
theoretical.

thicknesses ranging from 2.0 mm to 1.0 mm, in
0.10 mm steps.
012421
14 Insert the shim (1) into the turbine wheel.
15 Remove the upper housing disc from the stator. 1 2 3
16 Insert the housing disc (2) into the turbine wheel

with the chamfered side facing the shim.
17 Remove the needle cage (3) from the stator and

place it on the housing disc in the turbine wheel.
012422
4-40
18 Remove the complete stator (1) from the impeller

and insert it into the turbine wheel with the short
collar of the internal sprag race facing the turbine 1
wheel.
NOTE
Coat all the bearings with oil before installation.
012423
19 Remove 0.5 mm shim (1), shaft disc (2) and roller

bearing (3) from the impeller.
1 2 3
012424
20 Place 0.5 mm shim, shaft disc onto the stator with

the chamfered side facing the stator. 1
21 Place the roller bearing (1) onto the shaft disc on

the stator.
22 Place the gasket (2) on the circuit cover and align

it with the holes.
012425
4-41
23 Fit the impeller (1) and align it with the holes in

the circuit cover.
24 Screw the four M10x55 socket head screws (2)

(90° apart) into the impeller via the holes in the
circuit cover and tighten them.
2
1654
NOTE
Ensure that there is no play between the impeller
and the circuit cover once they have been screwed 1
together.
25 Check the end play on the internal sprag race (1).

To do this, grasp the internal sprag race with both
hands and move it back and forth. You must be
able to feel the end play.
012427
26 Turn over the converter.

1
! DANGER
The converter weighs approx. 60 kg. Screw the M10
hook into the tapped hole on the impeller and slightly
raise the converter using a rope and hoist in order to
turn it over. Then secure the converter to prevent it
from rolling away.
27 Insert and tighten all 48 M10x55 socket head

screws (1). Tightening torque: 65 Nm
012428
4-42
4.4.3 ZFW 360-10 Converter -Assemble

2
1 Clean the spur gear. Rub the mating face (1) with
an oil stone.
2 Prepare the bearing pack for the spur gear. Check 1

the markings!
3 Insert the housing disc "GS" (2) into the spur

gear.
CAUTION
The chamfered side must face the spur gear. 3
NOTE
2
The housing disc (2) is recognizable by the "GS"
marking, the shaft disc (3) by the "WS" marking. 008477/008478
4 Insert a new O-ring (1) into the spur gear (2). 1
5 Place a new gasket (3) on the mating face of the

spur gear (2) and align it with the holes 3
6 Align the spur gear with the holes in the impeller.
008479
7 Insert the spur gear into the impeller.
NOTE
Drive in the roll pins if necessary.
8 Turn over the impeller complete with the spur

gear.
9 Insert and tighten twelve new Torx-Powerlok scr- 1

ews;
CAUTION
Always use new Powerlok screws. The countersinks in
the screwhead bores in the impeller must be flat. Sink
once (max. 0.5 mm) if necessary.
008480
4-43
10 Place the roller bearing (1) onto the housing disc

in the impeller.
11 Place the shaft disc (2) onto the roller bearing with
the chamfer facing upwards.
12 Place a 0.5 mm-thick shim (3) onto the shaft disc.
2 3
1
008481
13 Insert the complete stator (1) into the impeller.

2
CAUTION
The longer collar (2) of the internal sprag race must
face the impeller. When inserting the impeller, ensure 1
that the internal sprag race bearings do not fall out of
the stator.
NOTE
Place support 1X56 137 152 onto the stator
bearing. Knock in the stator and complete bearing
pack as far as they will go by tapping with a
plastic-tip hammer.
008482
14 Prepare the marked bearing pack.
15 Place the shaft disc (1) onto the stator.
16 Place the needle cage (2) onto the shaft disc.
17 Place the housing disc (3) onto the needle cage.
008483
4-44
4.4.4 Axial Bearing End Play on ZFW 360-10

Converter - Measure and Adjust
1 Place a new gasket (3) on the mating face.

2
2 Place the measuring blocks (1) onto the impeller
mating face.
3 Place the measuring bar (2) on the measuring
blocks.
4 Place a depth gauge on the measuring bar and 1
measure distance “A” between the measuring bar
and the impeller mating face with fitted gasket.
NOTE 3
The measuring bar must not lie on the stator.
008485
5 Move the depth gauge to the center.
6 Measure distance "B" between the measuring bar

and the face of the housing disc (1).
7 Note down distance "B" and subtract it from

distance "A".
Distance "A" - Distance "B" = Distance “C"
1
008484
8 Place the measuring apparatus on the circuit cover

mating face.
NOTE
Do not fit a gasket on the circuit cover when
taking measurements.
9 Determine distance "D" between the measuring

bar and the circuit cover mating face using a depth
gauge.
10 Note down distance "D".
008486
4-45
11 Determine distance "E" between the measuring

bar and the shim (1).
12 Note down distance "E" and subtract it from

distance "D".
Distance "D" - Distance "E" = Distance "F"

Subtract distance "F" from distance "C"
Distance "C" - Distance "F" = Distance "G"
13 The required shim thickness "S" is calculated as

follows: 1
G - (0.1 to 0.3 mm) = S
0.1 to 0.3 mm = End play on the axial bearing
Calculation example G = 1.4 mm

– H = 0.2 mm 008487
S = 1.2 mm
*H = Average of 0.1 mm and 0.3 mm end play
CAUTION
The figures used in the calculation example are
purely theoretical.
Shims are available in the following thicknesses in 0.2

mm steps: 1
0630 000 219 = 1.0 mm
0630 004 152 = 1.2 mm
0630 004 154 = 1.4 mm
0630 004 156 = 1.6 mm
0630 004 158 = 1.8 mm
0630 004 127 = 2.0 mm
0730 000 982 = 2.2 mm
008488
14 Insert the shim (1) in the turbine wheel.
15 Remove the upper housing disc from the stator.
16 Insert the housing disc (2) into the turbine wheel

with the chamfered side facing the shim (1).
17 Remove the needle cage from the stator and insert 2

it into the turbine wheel. 1
008489
4-46
18 Remove the complete stator (1) from the impeller

and insert it into the turbine wheel with the short
collar of the internal sprag race facing the turbine
wheel.
NOTE
Coat all the bearings with oil before installation. 1
19 Remove the shaft disc (2) from the impeller and 2

place it on the stator with the chamfered side
facing the stator.
008490
20 Remove the roller bearing (1) from the impeller

and place it on the stator.
008491
21 Place the gasket (1) on the circuit cover.
22 Screw two M8 threaded pins (2) 1X56 136 821

into the circuit cover flange at two-opposite-facing
points. 2
2
008492
4-47
23 Place the impeller (1) onto the circuit cover.
24 Unscrew and remove the M8 threaded pins (2)

1X56 136 821.
2
008493
25 Fit washers on each of the 36 M8 socket head

screws (1).
26 Tighten the socket head screws;

1
008494
27 Check the end play on the internal sprag race (1).
28 Grasp the inside of the internal sprag race with

both hands and move it back and forth. You must
be able to feel the end play.
008495
4-48
4.5 Converter Leak-tightness - Check

(ZFW 380-30 and 360-10)
1 Insert forcing device 1X56 137 129 into the

converter on the spur gear end.
012429
2 Screw the lock nut onto the forcing device.
!DANGER
The converter weighs approx. 60 kg.
012430
3 Lower the converter into a basin using lifting gear

so that the mating face (1) between the impeller
and the spur gear is just about in the water.
1
4 Connect compressed air unit 1X56 137 130 to the
forcing device.
CAUTION
The water in the basin must contain 1 part antifreeze
to 120 parts water. Water temperature = 20°C.
003 127
003127
4-49
5 Turn the regulator (1) anti-clockwise.
6 Open the stopcock (2).

11 22
CAUTION
The converter must be absolutely leak-tight.
003126
8 Close compressed air device 1X56 137 130 and

remove it from forcing device 1X56 137 129.
9 Lift the converter out of the basin using lifting

gear and lay it to one side on the work surface.
10 Detach the converter from the lifting gear and turn

it over.
1
11 Screw off the lock nut (1).
012430
12 Place the converter on the circuit cover and

remove forcing device 1X56 137 129 from the
converter.
NOTE
Dry the converter using compressed air. Lightly
coat the spur gear with oil.
012429
4-50
HP 502 / HP 552 / HP 592 / HP 602 Cover Plate
5 Cover Plate - Remove and Install
5.1 Cover Plate - Remove
-Remove the converter, see section 4.1

1
NOTE
Tilt the transmission to drain the oil before
removing the cover plate. 2
1 Unscrew the hollow screws (1).
2 Remove the hollow screws, sealing rings and oil 1

pipe (2) from the cover plate.
013106
NOTE
The type of cover plate varies depending on the
transmission type and the converter version.
The transmission version with ZFW 360-10

converter has a 125x150x10 shaft seal (1) on the 1 2
cover plate and hexagon bolts at position (2) (see
figure 008501)
008501
The version with ZFW 380-30 converter has a

142x162x10 shaft seal (1) and socket head screws
at position (2) (see figure 013107)
013107
5-1
Cover Plate HP 502 / HP 552 / HP 592 / HP 602
3 Unscrew and remove from the cover plate the

eight M8 socket head screws (1) (ZFW 380-30) or
M8 hexagon bolts and sealing rings (ZFW 360-
10).
4 Unscrew and remove the eleven M8 hexagon bolts

(2).
5 Unscrew and remove the fifteen M8 socket head 3

screws (3) and sealing rings from around the edge
of the cover plate.
1 2
013107
6 Screw the three threaded spindles (1) from

extractor 1X56 136 815 into the tapped holes
provided.
1 2
7 Place the bars (2) from extractor 1X56 136 815
onto the threaded spindles and screw on the
tommy nuts (3). 3
8 Tighten the tommy nuts evenly, alterating between

the bars, and pull out the cover plate.
9 Undo extractor 1X56 136 815 and remove it from

the cover plate.
013108
5-2
HP 502 / HP 552 / HP 592 / HP 602 Cover Plate
5.2 Cover Plate - Install
1 Check the shaft seal (1) for damage.
2 If necessary, press the shaft seal out of the cover

plate from the rear.
1
3 Insert a new O-ring (2) in the cover plate.
4 Thinly coat the O-ring and the mating face of the

cover plate with Vaseline.
2
013109
5 Screw a stay-bolt into the control insert (for fixing

purposes) and insert the cover plate in the correct
position.
6 Knock in the cover plate by evenly tapping around

the edge with a plastic-tip hammer. Ensure the
cover plate is inserted as far as it will go.
CAUTION
Place a new copper seal, washer and new copper seal
(in this order) under the socket head bolts at each of
the three tapped bolt holes (see arrows).
This is a special seal combination.
7 Tighten the fourteen M8x130 socket head screws

(1) around the edge of the cover plate. Make sure
that new copper seals are fitted. 013110
8 Tighten one M8x35 socket head screw (2) with

new copper seal.
2
9 Tighten the eight M8x85 socket head screws (380-
30) or hexagon bolts (360-10) (3) with new
copper seals.
10 Tighten the eleven M8x20 hexagon bolts (4) with 4

new copper seals.
1
Tightening torque for all hexagon bolts and socket 3
head bolts on the cover plate: 23 Nm
013107
5-3
Cover Plate HP 502 / HP 552 / HP 592 / HP 602
11 Insert the oil pipe (1).
12 Tighten the hollow screws (2).

CAUTION 2
Fit a new copper seal under the bolt head and the
pipe connection at each hollow screw connection.
1
013106
13 Fit the shaft seal as follows:
14 Lightly lubricate the outside edge of the shaft seal.
NOTE
Use water-soluble concentrated washing-up liquid
as a lubricant.
15 Grease the sealing lip(s) with Vaseline. 1
16 Position the shaft seal against the hole with the

sealing lip(s) facing the cover plate.
17 Knock in the 142x162x10 shaft seal (ZFW 380-

30) as far as it will go using punch 1X56 137 382
(1).
013111
Knock in the 125x150x10 shaft seal (ZFW 360-

10) as far as it will go using punch 1X56 136 605
(1).
008507
5-4
HP 502 / HP 552 / HP 592 / HP 602 Oil Pan
6 Oil Pan - Remove and Install
6.1 Oil Pan - Remove 2
1 Unscrew the four M8 hexagon bolts (1) and

remove them together with the washers.
1
2 Remove the cover (2) from the filter housing.
011578
3 Pull the screen filter (1) off the intake pipe.
4 Unscrew the thirty three M8 hexagon bolts (2) 1

from around the edge of the oil pan and remove
them together with the washers. 2
5 Remove the oil pan (3) and gasket from the trans-
mission. 3
011579
CAUTION
If the transmission is fitted with a converter drain
valve, take care not to damage the actuation pin (1)
for the converter drain valve when removing the oil
pan. 1
016072
6-1
Oil Pan HP 502 / HP 552 / HP 592 / HP 602
6-2
HP 502 / HP 552 / HP 592 / HP 602 Oil Pan
6.2 Oil Pan - Install
1 Place a new gasket (1) on the mating face.
011602
2 Before fitting the oil pan, check that serrated ring

ZA 5 (1) is securely engaged in the groove of the
actuation pin for the converter drain valve. 1
016073
3 Check that the actuation pin (1) for the converter

drain valve can move freely.
016072
6-3
Oil Pan HP 502 / HP 552 / HP 592 / HP 602
4 Place the oil pan on the transmission.
NOTE
Make sure that the gasket is not displaced when
fitting the oil pan.
5 Insert the M8x60 hexagon bolts (1) with washers 2

into the oil pan and tighten them; 1
CAUTION
Fit new copper seals on the two central hexagon bolts
(2) at the front of the oil pan. Use steel washers for the
rest of the oil pan hexagon bolts.
011601
6 Lightly coat the O-ring (1) in the screen filter with

Vaseline. 1
008513
7 Push the screen filter (1) onto the intake pipe as

far as it will go.
1
011579
6-4
HP 502 / HP 552 / HP 592 / HP 602 Oil Pan
8 Insert a new O-ring (1) into the cover (2).
9 Lightly coat the O-ring with Vaseline.

1
010483
10 Place the cover (1) onto the oil pan.
11 Tighten the M8x80 hexagon bolts (2) with was-

hers;
011605
12 Insert and tighten the oil drain plug (1).

CAUTION
Always use the original oil drain plug in
transmissions with converter drain valve. The drain
plug controls and closes the converter drain valve.
011578
6-5
Oil Pan HP 502 / HP 552 / HP 592 / HP 602
6-6
HP 502 / HP 552 / HP 592 / HP 602 Inductive Pickup
7 Inductive Pickup - Remove and Install
7.1 Inductive Pickup - Remove

1
1 Unscrew and remove the screw plug (1).
011607
2 Remove the cable plug (1) from the inductive

pickup.
These are flat-pin plugs that are pulled out
straight. 1
3 Unscrew and remove the Torx screw (2) and take
out the inductive pickup.
2
011608
4 Remove the O-ring (1), shims (2) and Torx screw

(3) from the inductive pickup (4).
4
1 2 3
011776
7-1
Inductive Pickup HP 502 / HP 552 / HP 592 / HP 602
7-2
7.2 Inductive Pickup - Install
1 Turn the output flange using an assembly lever. At

the same time, use a small screwdriver to establish 1
the position of the projections on the pulse
generator ring (1).
011783
2 When one of these projections is located under the

inductive pickup insert bore, measure the distance
“a” between the inductive pickup (3) and one of 1 2 4
the projections on the pulse generator ring (1).
CAUTION
It is important to measure one of the projections on 5
the pulse generator ring. Otherwise, the projection
will damage the inductive pickup when the engine is
started.
3
011622
3 Insert measuring rod 1X56 138 149 into the

inductive pickup bore and attach it (1).
Tightening torque: 9.5 Nm
011784
7-3
4 Move the sensor (1) until it stops against the

projection on the pulse generator ring and secure 1
by tightening the screw (2).
5 Unscrew and remove the measuring rod mounting 2

bolt (3) and carefully pull out the measuring rod.
011785
6 Measure the distance between the face of the

sensor and the contact face on the measuring rod
bracket and note it down as dimension "b"
b
011778
7 Screw the inductive pickup into the test device

1X56 138 150.
011779
7-4
8 Measure the distance between the contact face of

the inductive pickup and the contact face of the
inductive pickup bracket and note it down as
dimension “c”.
The inductive pickup dimension "a" must be 0.6 - 0.8

mm. c
Set using shims
Equation:
c-b=d
d + a = shim thickness "S"
Measuring example:
Distance "c" = 52.6 mm
Distance "b" = 50.9 mm 011780
Distance "a" = 0.7 mm (0.6 - 0.8 mm)
1 2 4
Calculation example:
52.6 mm - 50.9 mm = 1.7 mm
1.7 mm + 0.7 mm = 2.4 mm
5
Calculated shim thickness "S" = 2.4 mm

thicnkesses ranging from 0.80 to 6.00 mm in 3
0.1mm steps.
1 Pulse generator ring

2 Holding plate a
3 Inductive pickup
4 Shims 011622
5 Torx screw with washer

2
9 Insert the Torx screw (1) with washer into the bore
on the inductive pickup (2). Slide the selected
shims (3) onto the socket head screw and secure
using the O-ring (4).
4 3 1
011776
7-5
10 Insert the inductive pickup and secure using the

M6x45 Torx screw (1).
2
11 Fit the cable plug (2) on the inductive pickup.
011610
12 Insert the M42x2 screw plug into the duct plate

and tighten it.
Tightening torque: 90 - 100 Nm
011607
Install the oil pan, see section 6.2.
011578
7-6
HP 502 / HP 552 / HP 592 / HP 602 Hydraulic Control Unit
8 Hydraulic Control Unit - Remove and Install,

Dismantle and Assemble
8.1 Hydraulic Control Unit - Remove
1 Unscrew and remove the two M8 hexagon bolts

(1) and washers from the Kostal socket.
011624
2 Disconnect the flat-pin plug for the inductive

pickup (1) and the flat-pin plug for the retarder
resistor (2) from the valve body using a
screwdriver and separate from the sockets.
5
NOTE
The sump temperature sensor is integrated in the
plug (3). Only remove if necessary.
3 Remove the cables (4) from the protective 4 3

sleeve (5). 1 2
015825
4 If the transmission is fitted with an oil level

indicator, pull the protective cap (1) off the plug
and disconnect the plug (2) from the oil level
ECU.
2
1
015826
8-1
Hydraulic Control Unit HP 502 / HP 552 / HP 592 / HP 602
5 Unscrew and remove the 39 M8 Torx screws from

the shift control (1).
015827
!DANGER
Watch out for sharp edges.
The hydraulic control unit weighs approx. 18 kg.
6 Remove the complete hydraulic control unit.
CAUTION
Make sure that the shift control cable terminals do
not get caught and torn off in the transmission.
NOTE
The figures, drawings and parts illustrated do not
always depict the original, they are merely
intended to show the work involved. For
example, the hexagon bolts illustrated (on the shift
control) have been replaced by Torx screws. 011630
8-2
8.2 Hydraulic Control Unit - Install
1 Insert the hydraulic control unit into the

transmission.
NOTE
The Kostal socket (see arrow) must be inserted in
the seat of the transmission housing.
!DANGER
Watch out for sharp edges.
The hydraulic control unit weighs approx. 18 kg.
CAUTION
Do not trap the cables.
015827
2 Insert the new M8x35 Torx screws (1); however,

do not tighten them as yet.
1
NOTE
The 9 shorter Torx screws (1) are inserted in the
indented areas.
3 Insert the thirty M8x43 Torx screws (2). 2

Tighten all the Torx screws, including those
inserted in step 2 (see above); tightening torque:
23 Nm
NOTE
Work from the center of the control unit outwards
when tightening these screws.
015827
4 Install the inductive pickup (1) if it was removed

previously, see section 7.2.
1
NOTE
The gap to the inductive pickup only needs to be
re-adjusted if the shift control is renewed.
5 Screw the M42x2 screw plug (2) into the duct 2

plate if it was removed previously, see section 7.2.
011611/011607
8-3
6 If the transmission is fitted with an oil level

indicator, insert the plug (1) into the oil level ECU
socket.
1
CAUTION 3
The oil level ECU (2) is very sensitive and must not be
bent when inserting the plug. Hold the rear of the 2
ECU firm when inserting the plug.
7 Place the protective cap (3) over the plug on the

oil level ECU.
NOTE
The protective cap must engage.
015828
8 Connect the flat-pin plug on the side of the shift

control as illustrated.
1 Inductive pickup output plug

2 Retarder resistor plug 5
3 Sump temperature sensor
4
NOTE
The sump temperature sensor is integrated in the
plug (3).
1 2
9 Insert the temperature sensor cable (4) into the
protective sleeve (5). 3
015825
10 Attach the Kostal socket using two M8x20

hexagon bolts and washers.
011624
8-4
8.3 Oil Level Indicator - Remove and Install

8.3.1 Oil Level Indicator - Remove
Installation position of the complete oil level

indicator (1).
015829
1 Unscrew and remove the two M6 Torx screws (1)

from the oil level ECU.
CAUTION
Handle the oil level ECU carefully since it is very
sensitive to shocks and impact.
1
015830
2 Unscrew and remove the two M6 Torx screws (1)

and take out the oil level indicator complete with 1
the holding plate, sensor and oil level ECU.
NOTE
Do not undo the M6 Torx screw (2).
015831
8-5
8.3.2 Oil Level Indicator - Install
1 In the case of new oil level sensors that have not

yet been set, straighten the lock (1) and remove it
from the holding plate (2) and the sensor (3).
1
2
3
015832
2 Insert new oil level sensors that have not yet been
set or locked complete with the holding plate and 1
attach using two M6x30 Torx screws (1).
015833
CAUTION
The holding plate Torx screws each have two O-rings 1
fitted for damping purposes.
Check to ensure that the O-rings are correctly seated. 3 2
4
1 Torx screw
2 Washer
3 O-ring 9 x 2.5 5
4 Holding plate 6
5 O-ring 14 x 2.5
6 Bushing
7 O-ring for locking
7 Dim. X =
5.0 +3 mm
015834
8-6

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REPAIR MANUAL

HP 502 / HP 552 / HP 592 / HP 602

4149 751 604

1 Assembly Stand - Insert and Remove Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2 Retarder Accumulator - Remove and Install, Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . 2-1

3 Heat Exchanger - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4 Converter - Remove and Install, Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5 Cover Plate - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6 Oil Pan - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7 Inductive Pickup - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

9 Retarder Valve - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

10 Output Cover - Remove and Install, Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

11 Mechanical Transmission Section - Remove and Install ................................................................... 11-1

13 D Brake - Remove and Install ............................................................................................................. 13-1

This manual is intended for skilled personnel who have

This manual deals with the standard ZF product in

However, due to continuing development of the product,

Service points equipped by ZF Friedrichshafen AG all

2. Specified equipment, e.g. special tools

3. Genuine ZF spares, to our latest specifications

All work performed at these service points is carried out

Repair work carried out at ZF service points is

Damage resulting from work performed by non-ZF

SAFETY NOTI CE G ENER AL I NFO RMATI O N

To avoid injury to personnel and damage to pro-

After completion of repair work and testing, skilled staff

! THREATS TO THE ENVIRONMENT !

Remove the old remains of gaskets from mating faces. RE WO RK I NG

BEARINGS d) Duo shaft seals have two packing

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

a) Apply a light coat of sealing agent on outer edge of TRANSMISSION OIL

* refer to expendable material

Tightening torques for nuts and bolts, extract from

Metric coarse pitch thread Metric coarse 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

Screw plugs DIN 908, 910 and 7604

Screw plugs (DIN 908, 910, 7604) Union screws (DIN7643)

Dimensions Tightening torque Pipe Thread Tightening-

Description Name Approx. Application Remarks

Grease For example:

Sealing compound WEVO-L100

Jointing compound Loctite no.: 648 1g Threaded bush on

Sealing band Elring Pife / 300 mm

Surface sealer Loctite no.: 574 80 mm3 Slotted nut on

Grease Vaseline 8420

Operating oil See TE-ML14

1 Input 15 Inductive pickup “output”

Designation Dimension Measuring device Comments

01. Converter installation 2.81 ± 0.02" Depth gauge Installation dimensions

06. Tightening torque of Torque wrench

07. Tightening torque of M16 Between Torque wrench Use counter-support

Designation Dimension Measuring device Comments

Designation Dimension Measuring device Comments

19. Tightening torque of M6 Between Torque wrench

20. Tightening torque of M6 5 ft-lbs Torque wrench Do not exceed specified

Designation Dimension Measuring device Comments

29. Tightening torque of M8 26 ft-lbs Torque wrench