Description

ZF HP 500, HP 590, HP 600 Repair Manual – Factory OEM Specs for Ecomat Transmissions

I’ve seen transmissions grenaded because some guy pulled a torque value off a forum. If you’re inside an Ecomat HP 500, HP 590, or HP 600 – long version, Stage 3 – you need the real data. This is the OEM repair manual ZF sent to dealers. 338 pages. No aftermarket shortcuts. Every tightening torque, every clearance, every step for disassembly and assembly is in here the way ZF wrote it.

338 Pages of Factory Repair Data

The manual starts with the basics: transmission cross sections for 5-speed and 6-speed, overview, tightening torques (page 1-11), adjustment data (page 1-12), spring table, and a list of special tools you’ll need. Don’t skip the safety notice on page 1-7. ZF doesn’t waste space. Every page has a specific job – no fluff. Then it dives into 12 main chapters covering every major component from the assembly jig to the output end cover.

Transmission Disassembly and Assembly

Chapters 10 through 12 cover the output, intermediate housing, and the mechanical part of the transmission. You’ll find procedures for removing and installing the output flange, measuring end float of the sun gear, adjusting disc play of brakes F and G, and removing planet carriers II and I. There’s a separate procedure for the HP 600 version where the planet carriers have different specs. If you’re rebuilding one of these, you need the exact steps – not a generic description. This manual gives you the order and the clearances.

What Tightening Torques and Adjustment Data Are Included?

Page 1-11 lists every bolt torque in the transmission. Bolts for the oil pan, retarder accumulator, output flange – all in Nm with imperial equivalents. Page 1-12 gives adjustment data like end float ranges and disc play. I’ve used aftermarket books that got these wrong and caused leaks or clutch slipping. You won’t have that problem here. The data came straight from ZF’s engineering – same as the dealerships got.

Retarder Accumulator: Step-by-Step Removal and Installation

Chapter 2 is four sections long. It covers removing and installing the solenoid valve, then the accumulator itself, including the side-mounted cooler variant. It even walks through dismantling and reassembling the accumulator with spring checks. If you skip the preload measurement, you’ll have a leak or no retarder function. The manual tells you exactly which special tool to use – no guessing.

Check the Hydraulic Control Unit Before Reassembly

Chapter 8 is the biggest in the book – the hydraulic transmission control unit. You’ll find step-by-step removal and installation, then disassembly into sub-assemblies. Throttle valve, valve block B, valve block A – each one gets its own dismantling and assembling sequence. If you mix up the valve body bolts, you’ll create cross leaks and shift problems. The manual calls out the exact order and torque for each valve block.

Related manuals you should check: ZF HP 500, HP 590, HP 600 1995 Operators Manual – OEM Factory Specs for daily operation specs. For newer variants, look at ZF HP 500, HP 590, HP 600, HP 502, HP 592 2004 User Manual – Factory Specs. And if you work on medium-duty ZF automatics, ZF 6WG 310 1999 Repair Manual – Factory Specs for 6WG 310 is worth a browse.

Does this manual cover the torque converter?

Yes. Chapter 4 covers removal, installation, measuring end float and installation depth, complete disassembly, assembly, and leak checking. It even tells you how to measure thrust bearing clearance after reassembly.

Is this manual for the HP 502?

No. Only HP 500, HP 590, HP 600 long version.

How do I check the retarder accumulator?

Section 2.4 walks through dismantling and assembling the retarder accumulator. You’ll need the spring table to check free length and installed force. The manual lists every spring part number and the allowable compression range. If the spring is collapsed, the accumulator won’t hold pressure. You can find the detailed procedure starting at section 2.4 – makes sure you have the special tool ZF calls out before you open it.

Are wiring diagrams included?

This repair manual focuses on mechanical and hydraulic components. For electrical diagnostics, refer to the vehicle manufacturer’s wiring schematics or the ZF electronic control unit documentation.

I’ve been turning wrenches for 28 years. When a ZF Ecomat comes in with a hard shift or no reverse, I don’t reach for a Chilton. I grab this manual. The torque converter installation procedure alone has saved me from pulling a unit twice. If you’re serious about doing this job right, Access the Factory Manual and keep it on your bench. It’s easier to flip through the PDF than to argue with a transmission that’s half-assembled with wrong specs. Automotive Industry Overview Automotive Industry Overview