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

Description

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

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

Language : English
Pages : 94
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

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

PREFACE:

This repair manual is intended for skilled personnel trained by ZF Friedrichshafen AG to carry out
mainte- nance 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:

• Repair work carried out at ZF service points is subject to the contractual conditions prevailing in
  the individual case.
• Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner
  and any consequential costs are excluded from the con- tractual liability agreement. Exclusion of
  liability also applies if genuine ZF spares are not used.

TABLE OF CONTENTS:

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

REPAIR MANUAL, Stages 1-2................................................................................... 1
	HP 502 C / HP 592 C / HP 602 C EST 46 C / EST 47 C Stages 1-2, 4149 751 601e............................ 1
	Contents................................................................................................ 3
	Preface................................................................................................. 5
	Important information................................................................................... 6
	Instructions for repairs................................................................................ 7
	Instructions for carrying out repairs................................................................... 8
	Tightening torques...................................................................................... 9
	Expendables.............................................................................................11
	Adjustment data.........................................................................................12
	Special tools...........................................................................................15
	Arrangement of HP peripheral equipment..................................................................19
	Cutaway view............................................................................................20
	ZF Ecomat transmission, 4-speed version.................................................................20
	ZF Ecomat transmission, 5 & 6-speed version.............................................................21
	Clutch combination......................................................................................22
	1. Maintenance..........................................................................................23
		1.1 Oil change intervals............................................................................23
		1.2 Oil capacities..................................................................................23
		1.3 Oil grade.......................................................................................23
		1.4 Checking oil level..............................................................................24
		1.5 Operating temperature...........................................................................24
		1.6 Adding oil......................................................................................24
		1.7 Checking oil level at operating temperature.....................................................24
		1.8 Checking oil level when cold....................................................................25
		1.9 Checking oil level with engine off..............................................................25
		1.10 Checking oil level on versions with heat ex-changer higher than center line of transmission....25
		1.11 Changing oil at operating temperature..........................................................26
	2. Overhaul.............................................................................................27
		2.1 Renewing filter.................................................................................27
		2.2 Renewing retarder solenoid valve................................................................29
		2.3 Renewing accumulator solenoid valve.............................................................30
		2.4 Renewing accumulator............................................................................31
		2.5 Renewing temperature sensor.....................................................................32
		2.6 Renewing output sensor..........................................................................33
		2.6.1 Renewing retarder resistor....................................................................37
		2.7 Removing and fitting oil pan....................................................................39
		2.8 Renewing turbine sensor.........................................................................43
		2.9 Renewing complete hydraulic control module......................................................49
		2.10 Changing complete oil level display............................................................54
		2.11 Renewing pulse sensor..........................................................................58
		2.12 Renewing output flange and/or shaft seal.......................................................59
		2.13 Pressure tests.................................................................................63
		Pressure table:.....................................................................................64
	3. Troubleshooting......................................................................................65
		3.1 Terminal tester concept.........................................................................65
		3.2 1PO1 138 153 test cable.........................................................................66
		Resistance measurements.............................................................................67
		Table of tolerance Temperature sensor NTC - Sensor B14..............................................68
		Characteristics Resistance/Temperature..............................................................68
		DIAGNOSTIC TOOL Installation and menus..............................................................69
			Contents........................................................................................71
			Preface.........................................................................................72
			Safety notice...................................................................................73
			Contents of Testman / System components.........................................................74
			Testman software installation...................................................................75
			Additional settings.............................................................................76
			Installation of the diagnosis software Connecting up a programming tool.........................77
			DPA 04 I description............................................................................78
			DPA 04 I programming Selecting COM port.........................................................79
			Starting the Testman............................................................................80
			Start-up logo...................................................................................81
			Product menu / Contents.........................................................................82
			Repair aid / Contents...........................................................................83
			Technical data..................................................................................84
	4. Diagrams.............................................................................................85
		Hydraulic circuit diagram without NBS 4149 700 026/1................................................85
		Hydraulic circuit diagram with NBS 4149 700 026/2...................................................86
		EST 46 C, Connection diagram 6029 729 041/1.........................................................87
		EST 46 C, Connection diagram 6029 729 041/2.........................................................88
		EST 47 C, Connection diagram 6029 729 041/3.........................................................89
		EST 47 C, Connection diagram 6029 729 041/4.........................................................90
		EST 46 / 47 C, Electrical circuit diagram 6029 729 040..............................................91
		EST 46 / 47 C, Pin pattern 6029 729 072.............................................................92
		Hydraulic 2, Position locked........................................................................93
		Hydraulic 1, Position opened........................................................................94

Need help? Contact: [email protected]

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.V