The service manual deals with the ZF Ecomat HP500/HP590 4- and 5- speed version, including optional “Neutral at Bus Stop” (NBS) function. The manual lists all the procedures required for disassembly and subsequent assembly of the transmission. When repairing the transmission, take extreme care with regard to cleanliness and workmanship. The transmission should only be disassembled to replace damaged parts. Cover and housing parts that are in contact with gaskets must be loosened by tapping with a plastic mallet once the nuts or bolts have been loosened. Use suitable extraction devices to remove parts such as bearings, bearing races etc., which are tightly fitted to the shafts. Perform disassembly and assembly work in a clean working environment. Use the special tools which have been specifically developed. Before reinstalling parts, clean the contact surfaces of the housing and cover to remove any gasket residue. Remove any burrs or similar areas of roughness using an oil stone. Wash housings and the cover plate with a suitable cleaning agent, paying particular attention to corners and angles. Renew damaged and severely worn components. Expert personnel shall assess whether parts subject to normal wear, such as bearings, thrust washers etc., should be reinstalled. Always renew parts such as sealing rings, fixing plates and split pins etc. Also renew shaft sealing rings which have worn or torn sealing lips. Take particular care to ensure that no metal shavings or other foreign bodies are left inside the housing. Check lubrication oil bores and grooves to ensure they are perfectly clear. Lubricate all bearings with oil before installing them. NOTE: Only use an industrial oven or hot-air blower to heat up parts such as bearings, housings, etc.
CAUTION When reassembling the transmission, obser ve the torques and adjustment data listed in the intructions exactly. Unless otherwise stated, tighten bolts and nuts as listed in the standard table contained in this manual. Do not use liquid sealant compounds in this transmission, because they can cause malfunctions in the control section. Never use molycote grease. Never wash lined disks. Only clean discs using a leather cloth.
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DANGER Observe the manufacturer’s instructions when using cleaning agents.
