ZF-ECOMAT 2 HP502C HP592C HP602C EST 46C EST 47C Stage 1-2 Repair Manual 4149751601e – PDF DOWNLOAD

REPAIR MANUAL

011356

ZF-ECOl~AT 2 HP 502 C / HP 592 C / HP 602 C EST 46 C / EST 47 C Stages 1-2 4149 751 601e

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Subject to alterations in design

Copyright by ZF These repair instructions are protected by copyright. Any reproduction and dissemination in whatever form – also in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or electronic reproduction or as a storage in data-processing equipment or data networks without approval by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law.

Printed in Germany

Edition:

2001 - 03

4149 751 601e

HP 502 C / HP 592 C / HP 602 C

Contents Page

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions for repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Expendables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Arrangement of peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cutaway views of Ecomat transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch and brake combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 6 7 9 11 12 15 19 20 22

1.

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11

Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adding oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking oil level at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking oil level when cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking oil level with engine off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking oil level on versions with heat exchanger higher than center line of transmission . . . . . . . . . . .

Changing oil at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-4

2.

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

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

2.2 Renewing retarder solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Renewing accumulator solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Renewing accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Renewing temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 Renewing output sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.1 Renewing retarder resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 Removing and fitting oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8 Renewing turbine sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9 Renewing complete hydraulic control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.10 Changing complete oil level display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.11 Renewing impulse sensor for speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.12 Renewing output flange and/or radial seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.13 Pressure tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 2-3 2-4 2-5 2-6 2-7 2-11 2-13 2-17 2-23 2-28 2-32 2-33 2-37

Contents

HP 502 C / HP 592 C / HP 602 C Page

3.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

3.1 3.2 3.3

Terminal tester concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test instructions for test cable 1 PO1 138 153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Annex Description/menus for “ZF Testman”

3-1 3-2

4.

Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

Hydraulic circuit diagram without NBS 4149 700 026 / 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Hydraulic circuit diagram with NBS 4149 700 026 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Connection diagram 6029 729 041 / 1 to 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Electrical circuit diagram n 6029 729 040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Pin pattern 6029 729 072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

HP 502 C / HP 592 C / HP 602 C

Preface This repair manual is intended for skilled personnel 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 not contained in this manual.

We recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on a regular basis at our After-Sales Service training centers.

Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Continually trained personnel 2. Specified equipment, e.g. special tools 3. Genuine ZF spares, to our latest specifications

All work performed at these service points is carried out conscientiously and with utmost care.

Repair work carried out at ZF service points is subject to the contractual conditions prevailing in the individual case.

ZF FRIEDRICHSHAFEN AG C.V./Special Transmissions Service Plant 2 Tel.: (0 75 41) 77-0 Fax: (0 75 41) 77-5726

Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner and any consequential costs are excluded from the contractual liability agreement. Exclusion of liability also applies if genuine ZF spares are not used.

5

Important information

HP 502 C / HP 592 C / HP 602 C

SAFETY NOTICE

GENERAL INFORMATION

Companies repairing ZF units are responsible for their own work safety.

Read this manual carefully before starting any tests or repair work.

To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to.

Before starting work, mechanics must familiarize themselves with these regulations.

Personnel required to carry out repairs on ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that their repair staff is properly trained.

The following safety instructions appear in this manual:

NOTE Refers to special processes, techniques, data, use of auxiliary equipment, etc.

CAUTION This is used when incorrect, unprofessional working practices could damage the product.

DANGER This is used when lack of care could lead to personal injury or death.

CAUTION Pictures, drawings and components do not always represent the original object, but are used to illustrate working procedures.

Pictures, drawings and components are not to scale.

Conclusions about size and weight should not be drawn (even within a complete illustration).

Always follow the working steps as described in the text.

After completion of repair work and testing, skilled staff must satisfy themselves that the product is functioning correctly.

THREATS TO THE ENVIRONMENT !

Lubricants and cleaning agents must not be allowed to enter the soil, ground water or sewage system.

• Ask your local environment agency for safety information on the relevant products and adhere to their requirements.

• Collect used oil in a suitably large container.

• Dispose of used oil, dirty filters, lubricants and cleaning agents in accordance with environmental protection guidelines.

• When working with lubricants and cleaning agents always refer to the manufacturer’s instructions.

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

6

HP 502 C / HP 592 C / HP 602 C In case of doubt always turn to the relevant department within ZF After-Sales Services for advice.

All work on transmissions is to be performed expertly and under clean conditions.

Use specified tools to dismantle and assemble transmissions.

After removing the transmission from the vehicle, clean thoroughly with a suitable cleaning agent before opening.

Pay particular attention to the projections and recesses of housings and covers when cleaning.

Parts joined with Loctite are easier to separate if warmed with a fan heater.

Instructions for repairs GASKETS, LOCKING PLATES Parts which cannot be removed without being damaged must always be replaced with new parts (e.g. gaskets and locking plates).

SHAFT SEALS Always change shaft seals with rough, ripped or hardened packing washers. Seal contact surfaces must be totally clean and in perfect condition.

RE WO R K I N G CLEANING PARTS Remove remains of old gaskets on all seal-faces.

Carefully remove burrs or similar patches of roughness using an oil-stone.

Lube bores and grooves must be free of anti-corrosion agents and foreign matter; check for perfect passage.

Carefully cover opened transmissions to prevent foreign matter from entering.

Rework may be carried out on seal contact surfaces using plunge-cut grinding only, never use an emery cloth. Ensure that there are no traces of grinding or riffling.

If rework is needed on distance washers, shims etc. because of clearance settings, ensure that the reworked areas contain no face runout and have the same surface quality.

TRANSMISSION ASSEMBLY REUSING PARTS Parts such as ball or roller bearings, multi-discs, thrust washers etc., must be inspected by a competent person, who should decide whether or not they can be re-used.

Replace parts which are damaged or have suffered from excessive wear.

Find a clean site to assemble the transmission. Gaskets are installed without the use of sealing compound or grease. When measuring silicon-coated gaskets, take care not to include the silicon layer in the measurement.

During assembly, comply with all adjustment data, checking data and tightening torques in the Repair Manual.

7

Instructions for carrying out repairs BEARINGS If bearings are mounted in heated condition, they are to be heated evenly (e.g. heating cabinet).

Temperature should be at ca. 85 °C and must not exceed 120 °C. Each mounted bearing must be oiled with operating oil.

SEALING If a specific sealing agent* is to be used for sealing, comply with the manufacturer’s directions for use.

Apply a thin layer of sealing agent to the surfaces and spread evenly. Do not allow sealing to enter oil ducts and bores. On oil-carrying ducts and bores, wipe off the sealing agent on the surfaces to be sealed near apertures to ensure that no sealing agent enters the oil feeds when the surfaces are sealed.

HP 502 C / HP 592 C / HP 602 C d) Dual shaft seals have two sealing lips. The dust-proof sealing lip (X) must face outwards. ;

e) Fill the gap between the sealing lips so it is 60% filled with grease (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 (makes fitting easier). Press the seal shaft with mounting or faceplate onto the relevant installation depth plan.

R E TAI NI NG AG E NT S Retaining agents* may only be used in places as specified in the parts list.

Always comply with manufacturer’s directions for use when using retaining agents (e.g. Loctite).

During assembly, comply with all adjustment data, checking data and tightening torques.

SHAFT SEALS a) Apply a light coat of sealing agent* on outer edge of shaft seals with “steel surround”.

TRANSMISSION OIL b) Never apply sealing agent to shaft seals with “rubber surround”, but apply a thin coat of Vaseline 8420 to the outer edge or wet with a lubricant, e.g. a water-soluble, concentrated washing-up liquid (e.g.

Pril, Coin, Palmolive). c) Shaft seals with steel and rubber surrounds should be treated on the outer edge of the rubber surround as described above in section b).

After completing repairs, fill transmissions with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and List of Lubricants TE-ML (refer to identification plate) which are available from any ZF After-Sales Service Point. After filling the transmission with oil, tighten the screw plugs at the oil filling point and the oil overflow to the specified torques.

* refer to expendable material

8

HP 502 C / HP 592 C / HP 602 C

Tightening torques

Tightening torques for nuts and bolts, extract from ZFN 148 This standard applies to bolts acc. to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and to nuts acc. to DIN 934.

This Standard contains data on tightening torques (MA) for bolts and nuts in strength categories 8.8, 10.9 and 12.9 and nuts in strength categories 8, 10 and 12.

Surface condition of bolts: thermally blackened and oiled or galvanized and oiled or galvanized, chrome-plated and oiled.

Tighten screws with a calibrated torque spanner.

NOTE Irregular tightening torques are listed separately in the Repair Manual.

Regular screw thread

Fine screw thread

Size

Size

Bolt Nut

Tightening torque MA (Nm) for 8.8 10.9 8 10

12.9 12

Bolt Nut

Tightening torque MA (Nm) for 8.8 10.9 8 10

12.9 12

M 4 M 5 M 6

2.8 5.5 9.5

4.1 8.1 14

4.8 9.5 16.5

M 8x1 M 9x1 M 10 x 1

24 36 52

36 53 76

43 62 89

M 7 M 8 M 10

15 23 46

23 34 68

28 40 79

M 10 x 1.25 M 12 x 1.25 M 12 x 1.5

49 87 83

72 125 122

84 150 145

M 12 M 14 M 16

79 125 195

115 185 280

135 215 330

M 14 x 1.5 M 16 x 1.5 M 18 x 1.5

135 205 310

200 300 440

235 360 520

M 18 M 20 M 22

280 390 530

390 560 750

460 650 880

M 18 x 2 M 20 x 1.5 M 22 x 1.5

290 430 580

420 620 820

490 720 960

M 24 M 27 M 30

670 1000 1350

960 1400 1900

1100 1650 2250

M 24 x 1.5 M 24 x 2 M 27 x 1.5

760 730 1100

1100 1050 1600

1250 1200 1850

M 27 x 2 M 30 x 1.5 M 30 x 2

1050 1550 1500

1500 2200 2100

1800 2550 2500

Edition: August 1991 / checked 1997 9

Tightening torques

HP 502 C / HP 592 C / HP 602 C

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 cast and aluminum alloys.

The values are based on experience and are intended as reference values for the fitter.

The values for the tightening torque MA apply analogously for screw plugs according to DIN 908 and DIN 910, as the thread geometries are almost identical.

General rule: Screw/bolt class 5, ZFN 148-1 Screw/bolt material: steel acc. to DIN 7604. Surface condition: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled.

The tightening torques MA were determined for screwing into steel, grey cast and aluminum alloys.

The values are based on experience and are intended as reference values for the fitter.

General rule: screw/bolt class 5, ZFN 148-1 Material: 9SMnPb28K acc. to DIN 1651 Surface condition: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled.

Screw plugs (DIN 908, 910, 7604) Dimensions

M 8x1 M 10 x 1 M 12 x 1.5 M 14 x 1.5 M 16 x 1.5 M 18 x 1.5 M 20 x 1.5 M 22 x 1.5 M 24 x 1.5 M 26 x 1.5 M 27 x 2 M 30 x 1.5 M 30 x 2 M 33 x 2 M 36 x 1.5 M 38 x 1.5 M 42 x 1.5 M 42 x 2 M 45 x 1.5 M 45 x 2 M 48 x 1.5 M 48 x 2 M 52 x 1.5 M 60 x 2 M 64 x 2 * DIN 7604 Form C

10

Union screws (DIN7643)

Tightening torque screwed into steel/gray cast Al alloy 20 25 / 30* 35 35 40 50 55 60 / 80* 70 80 / 105* 80 100 / 130* 95 120 130 140 150 145 160 150 170 160 180 195 205

10 15 / 20* 25 25 30 35 45 50 / 65* 60 70 / 90* 70 90 / 130* 85 110 115 120 130 125 140 130 145 135 150 165 175

Pipe outer diameter

Thread

Tightening torque MA in Nm

4-5

M8x1

20 - 25

6

M 10 x 1

25 - 35

8

M 12 x 1.5

30 - 40

10

M 14 x 1.5

35 - 40

12

M 16 x 1.5

45

15

M 18 x 1.5

50

18

M 22 x 1.5

60

22

M 26 x 1.5

90

28

M 30 x 1.5

130

35

M 38 x 1.5

140

Status: October 1995

HP 502 C / HP 592 C / HP 602 C

Expendables

Description ZF reference no.

Name

Approx. quantity

Application

Grease 0750 199 001

for example: Spectron FO 20

General assembly aid

Sealing compound 0666 790 017

WEVO-L100

Screwing connection on output flange

Grease 0671 190 016

Industrial grade Vaseline 8420

General assembly aid

Transmission oil

refer to TE-ML14 List of Lubricants

General assembly aid

Remarks

NOTE: Inquire about the size of bundles that can be delivered before placing any orders!

11

Adjustment data

HP 502 C / HP 592 C / HP 602 C

Description

Dimension

Measurement device

Remarks

01. Internal resistance of solenoid valves for clutches and brakes in transmission

R = approx. 67 ohm at 68 °F (20 °C)

Ohmmeter and test cable 1P01 138 153 or terminal tester 6008 006 002

Resistance rises with temperature to approx. 74 Ohm when transmission at operating temperature.

02. Internal resistance of inductive sensors (speed sensors) nT and nOut

R = 1080 ± 40 ohm at 68 °F (20 °C)

Ohmmeter

Resistance rises with temperature to approx. 1350 Ohm when transmission at operating temperature.

03. Tightening torque for M14x1.5 temperature sensor

26 ft-lbs 35 Nm

Torque wrench

Renew copper sealing ring.

04. Tightening torque for M22x1.5 oil drain plug in oil pan

37 ft-lbs 50 Nm

Torque wrench

Renew copper sealing ring.

05. Clearance between inductive sensor - output and face end gears on planetary carrier

0.02 - 0.027" 0.5 - 0.7 mm

Depth gauge, slider gauge 1X56 138 149 /1X56 138 150

Adjust clearance with shims

06. Clearance between inductive sensor - turbine and pulse sensor ring

0.024 - 0.03" 0.6 - 0.8 mm

Depth gauge, slider gauge 1X56 138 149 / 1X56 138 150

Adjust clearance with shims

07. Tightening torque for M6 fixing bolts on inductive sensor

7 ft-lbs 9.5 Nm

Torque wrench

Do not overtighten

08. Clearance between speedo sensor and toothedring on output

0.027 - 0.055" 0.7 - 1.4 mm

Depth gauge

Clearance is supplied, check value.

09. Tightening torque for speedo sensor

26 ft-lbs 35 Nm

Torque wrench

Do not overtighten.

10. Insertion depth of shaft seal in output cover

0.55 - 0.59" 14 - 15 mm

12

Use to 1X56 136 824 This gives correct insertion depth.

HP 502 C / HP 592 C / HP 602 C

Adjustment data

Description

Dimension

Measurement device

Remarks

11. Tightening torque for M6 hex nuts on inductive sensor cover-output

5 ft-lbs 6 Nm

Torque wrench

Do not overtighten

12. Tightening torque for M12 hex bolts at output flange

44 ft-lbs 60 Nm

Torque wrench

Secure with lock plate Use to 1X56 136 471

13. Tightening torque for M42x2 screw plug in duct plate

67 - 74 ft-lbs 90 - 100 Nm

Torque wrench

14. Tightening torque for M10x1 screw plugs on the pressure measuring points

9 ft-lbs 12 Nm

Torque wrench

Do not overtighten

13

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• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

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