05:08-53

Issue 2 en

ZF automatic gearbox

ZF 4/5HP500, 590 and 600

Work description

Scania CV AB 2000, Sweden

1 712 625
Contents

Contents
Preface ...................................................................................3
Safety directions........................................................3

Towing ...................................................................................4

Component location ...................................................................................5

Special tools ...................................................................................6

Renewing sensors and solenoid

valves ...................................................................................9

Renewing frequency sensors .................................................................................12

Renewing end yoke seal Removal ..................................................................16

Fitting......................................................................18

Renewing accumulator .................................................................................20

Renewing service brake valve

potentiometer .................................................................................22

Basic setting of service brake valve

potentiometer .................................................................................24

Checking and setting the throttle

actuation sensor .................................................................................25

Renewing the drive mode selector .................................................................................28

Renewing the retarder switch .................................................................................28

Checking oil level .................................................................................29

Changing oil and filter .................................................................................32

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 Preface

Preface

This booklet contains instructions for simpler

mechanical work on automatic gearboxes
ZF 4/5HP500, 590 and 600. These are
manufactured by ZF. The gearboxes are very
similar and those difference that do exist are of
little significance for the purposes of this
description.
If a fault is suspected in the gearbox, the vehicle
should be driven to the nearest Scania
workshop. The Scania workshop personnel have
the training and appropriate equipment to
establish whether the fault lies in the gearbox, its
control unit or somewhere else. Once the fault
has been accurately located, they can decide on
the most suitable course of action.
As Scania does not manufacture these
gearboxes, Scania cannot assume complete
responsibility for their servicing. This booklet
describes the work that falls within Scania's area
of responsibility and that can be carried out by
most workshops. For major repairs or overhaul,
please refer to the ZF service organisation.

Safety directions
The person carrying out the work on the gearbox
bears responsibility for ensuring that it is carried
out in a safe and correct way.
To avoid injury to persons and damage to
products, it is vital to follow the instructions
given as well as the applicable safety
regulations.
The person carrying out work on the gearbox
must first obtain sufficient knowledge on how
the work is to be carried out and how potential
risks should be avoided.
Neither Scania nor ZF can assume any
responsibility for damage or costs incurred due
to incorrectly carried-out work or the use of
non-original parts.
It is therefore important to read this booklet
carefully.

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Towing

Towing
Disconnect the gearbox electrical connection
(Cannon connector)
Use a towing bar when towing.
The vehicle cannot be tow-started.

IMPORTANT! The gearbox is not lubricated

when the vehicle is being towed, as the oil pump
requires the engine to be running.

If the gearbox is intact, the bus can be towed

with the engine turned off, the gearbox in
neutral and the propeller shaft in place.
Towing can be carried out for a maximum of Cannon connector location on K/L buses.
2 hours at low vehicle speed, 25 km/h.
If the gearbox is broken, the bus can be
towed, but the propeller shaft or both drive
shafts must be removed, or the drive wheels
lifted.
When towing the vehicle with the engine off,
check that the parking brake is not applied.
When the engine is not running, there is no
steering servo and brake pressure.
Remember that equipment such as fans and
lighting use large amounts of power and can
drain the battery in one or two hours. Cannon connector location on N buses.
Follow the instructions for towing in the
Operator's manual.

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 Component location

Component location

6 7

5 4 9
8

11 10
1
2
3

118 441

1 Gearbox control unit

2 ABS control unit
3 Retarder control unit
4 Gearbox
5 Throttle actuation sensor
6 Oil temperature warning lamp
7 Drive mode selector
8 Retarder lever with indicator lamp
9 Automatic retarder operation switch.
Alternative switch location is in the central
electric unit
10 Accelerator pedal sensor (under floor)
11 Service brake valve (under floor)

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Special tools

Special tools

Number Description Illustration Tool board

82 303 Adapter

82 320 Plate 82 320

112 653
87 596 Slide hammer 87 596 D2

00 1610

98 405-1 Fixture part F1

98 405-2 Fixture part F1

98 450 Shank R2, AD2, AM1

00 1633

98 450

99 001 Adapter 99 001 AD1

00 1562

99 003 Hydraulic cylinder 99 003 H1

109 403

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 Special tools

Number Description Illustration Tool board

99 004 Hydraulic pump 99 004
H1

110 188
99 005-1 Pusher adapter 99 0051 H1

111 423
99 006 Threaded rod 99 006
H1

110 189
99 012 Threaded rod 99 012 H1
109 431

99 040 Adapter 99 040

110 995

99 124 Puller 99 124

110 253

99 129 Counterhold 99 129

00_1616

99 160 Drift 99 160

108 783

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Other tools

Other tools
Number Description
548 010 Sealing compound
587 084 Torque wrench
587 313 Gearbox jack or component hoist 587 500.
587 538 Temperature gauge
ZF 1P01 137 833 Measuring rod, ZF tool.
ZF 1x56 136 824 Drift, ZF tool

If tool ZF 1P01 137 833 is unavailable, a

measuring rod can be manufactured locally by
turning a rod to 16 mm diameter for a length of
approximately 35 mm and slip on a 15.7 x 1 mm
retaining ring.

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 Sensors and solenoid valves

Renewing sensors and solenoid valves

Preparatory work
For checking solenoid valves and sensors, see Retarder solenoid valves
Workshop Manual section 05, Automatic
Gearbox, ZF 4/5HP500, 590 and 600, IMPORTANT! Depressurise the compressed
Troubleshooting. air system when working on the retarder and
accumulator solenoid valves.
IMPORTANT! Always renew O-rings or
copper washers before installing components.

Speedometer drive
When renewing the mechanical drive for
the speedometer, the ten-digit number on
the gearbox type plate must be stated when
ordering spare parts.
The end play should be 0.1 0.3 mm,
which is measured with a sliding caliper.
The backlash should be 0.1 0.2 mm,
which is checked by hand.

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Sensors and solenoid valves

Components
Pos. Description Remarks
1 Retarder solenoid valve V503 Mark up the electrical and pneumatic connections of the
solenoid valve.
2 Retarder solenoid valve V504 Mark up the electrical and pneumatic connections of the
solenoid valve.
3 Pressure regulator for retarder -
setting 1
4 Pressure regulator for retarder -
setting 2
5 Pressure regulator for retarder -
setting 3
6 Electrical connections -
7 Pneumatic connections -
8 Bolt Tightening torque 23 Nm.
9 Bolt Tightening torque 23 Nm.
10 Accumulator solenoid valve -
V502
11 O-ring IMPORTANT! Renew the O-ring. Lubricate the O-ring
with automatic transmission fluid.
12 Bolt Tightening torque 23 Nm.
13 Retarder solenoid valve V501 -
14 O-ring IMPORTANT! Renew the O-ring. Lubricate the O-ring
with automatic transmission fluid.
15 Temperature sensor T505 Tightening torque 35 Nm.
16 Copper washer IMPORTANT! Renew the copper washer.
17 Electrical connection catch Pull out the catch before disconnecting the electrical
connection.
18 Speedometer sensor T20 -
19 Speedometer mechanical drive. Remove the speedometer electrical connection and sensor.
Ensure that the copper washer is also removed. Tightening
torque 120 Nm. Refer to Preparatory Work.
20 Copper washer IMPORTANT! Renew the copper washer.

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 Sensors and solenoid valves

Gearbox sensors and valves

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Frequency sensors

Renewing frequency sensors

Output shaft or turbine frequency sensor

Note: When renewing the turbine frequency

sensor. Drain the oil from the gearbox and
remove the oil sump.

When working on the output shaft

frequency sensor or the turbine frequency
sensor, remove the propeller shaft. Refer to
Workshop Manual group 6. This is in order
to allow the output shaft to be turned by
means of the driver.
The distance between the frequency
sensors and the pulse wheels should be
0.6 - 0.8 mm, which is measured using a
sliding caliper or ZF measuring rod
1P01 137 833.
When installing the sensor, turn the driver
until the pulse wheel in question is in the
correct position.

IMPORTANT! After installing the output shaft

frequency sensor nAB or turbine frequency
sensor nT, rotate the pulse wheel 2-3
revolutions in order to check that the frequency
sensor does not touch the pulse wheel.

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 Frequency sensors

Frequency sensor shims

To calculate the appropriate thickness,

measurement 'D' on the shim or a combination
of shims, use the formula D = (A + C) -B. Then
select the appropriate shim or combination of
shims.

Size ZF part number

0.6 mm 0730 003 049
0.8 mm 0730 003 050
1.0 mm 0730 003 069
1.2 mm 0730 003 068
1.4 mm 0730 003 067
1.8 mm 0730 003 066
2.0 mm 0730 003 065
2.2 mm 0730 003 064
2.4 mm 0730 003 063
2.6 mm 0730 003 062
2.8 mm 0730 003 061
3.0 mm 0730 003 300

Place the shims on the frequency sensor. If

necessary, apply high-temperature oil (part no.
33 243) sparingly on the shims to keep them in
place on the sensor during installation.

IMPORTANT! Grease must never be used

inside automatic gearboxes.

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Frequency sensors

Components
Pos. Description Remarks
1 Nut Tightening torque 6 Nm.
2 Cover plate -
3 O-ring IMPORTANT! Renew the O-ring. Lubricate the O-ring with
automatic transmission fluid.
4 Stud -
5 Output shaft frequency IMPORTANT! Ensure that all shims are also removed.
sensor Tightening torque 50 Nm.
6 Shims During installation, check the dimensions; refer to Frequency
sensor shims
7 Gearbox oil sump. Remove the tray by means of component hoist 587 500 or
gearbox jack 587 313 and 98 405-1, 98 405-2 and hoist plate
82 320. Tightening torque 23 Nm.
8 Plug Tightening torque 90 Nm.
9 Turbine frequency sensor IMPORTANT! Ensure that all shims are also removed. When
fitting, measure dimension B using tool ZF 1P01 137 833; refer to
Other Tools and Frequency Sensor Shims. Tightening torque
50 Nm.
10 Shims During installation, check the dimensions; refer to Frequency
Sensor Shims.
11 Bolt 2 bolts for the oil sump nearest the engine are fitted with copper
washers and must be renewed during installation. The remaining
bolts are fitted with steel washers. Tightening torque 23 Nm.

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 Frequency sensors

Renewing frequency sensors

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Driver

Renewing end yoke seal

Removal
Remove the propeller shaft. Refer to
Workshop Manual group 6.

IMPORTANT! Take care not to damage the

splines of the output shaft or driver.

Components
Pos. Description Remarks
1 Lock washer Use a cold chisel to remove the lock washer.
2 Bolt Use 98 450 and 99 129 as a counterhold.
3 Pressure plate Tap out the pressure plate using a plastic mallet.
4 End yoke Mark up the position of the end yoke in relation to the
output shaft. Use tools 99 001, 99 003, 99 006, 99 124
and hydraulic pump 99 004.
5 Sealing ring Use tool 87 596. IMPORTANT! Take care not to
damage the surface where the sealing ring is situated.

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 Driver

Removing the driver and seal

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Driver

Fitting

IMPORTANT! Take care not to damage the

splines of the output shaft or driver.

Warm the end yoke to 100-110C. Check

the temperature using temperature gauge
587 538. Do not heat the end yoke further as
this would damage the sealing ring.
Components
Pos. Description Remarks
1 Output shaft Fit the adapters 82 303 and 99 040.
2 Sealing ring IMPORTANT! Do not lubricate the sealing ring with
grease or oil, as this could result in leakage. Use tool
ZF 1x56 136 824. The distance from the bearing to the
outer edge of the sealing ring should be 14 - 15 mm.
3 End yoke Warm the end yoke to 100-110C. Apply oil to the
splines. Install the end yoke using 99 003, 99 004,
99 005-1 and 99 012.
4 Pressure plate Apply sealing compound 584 010.
5 Bolt IMPORTANT! Renew the bolts. Use 99 129 and
98 450 as a counterhold. Tightening torque 60 Nm; use
torque wrench 587 084.
6 Lock washer IMPORTANT! Renew the lock washer. Tap the lock
washer into place using drift 99 160 and shank 98 450.

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 Driver

Fitting the seal and driver

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Accumulator

Renewing the
accumulator

IMPORTANT! Depressurise the

compressed air system before working on
the retarder and accumulator solenoid
valves.

IMPORTANT! Always renew O-rings or

copper washers before installing
components.

Pos. Description Remarks

1 Bolt Tightening torque 23 Nm.
2 Accumulator solenoid valve V502 Mark up the electrical and pneumatic
connections of the solenoid valve.
3 Bolt Tightening torque 23 Nm.
4 Nut Tightening torque 23 Nm.
5 Internal hexagon bolt Tightening torque 23 Nm.
6 Accumulator -
7 O-ring IMPORTANT! Renew the O-rings
Lubricate the O-rings with automatic
transmission fluid.

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 Accumulator

Renewing the accumulator

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Service brake valve

Renewing service brake valve potentiometer

The potentiometer is located in the micro switch

housing on top of the service brake valve
housing.
Depressurise the compressed air system.

Pos. Description Remarks

1 Pneumatic connections Mark the respective pipes.
2 Connector -
3 Bottom plate Lift out the brake pedal and service brake valve as one
unit.
4 Bolt -
5 Retaining ring -
6 Cover -
7 Spring -
8 Screw -
9 Cable connection IMPORTANT! The micro switches are on the inside.
Take care not to break off their tabs.
10 Micro switches
11 Potentiometer Note the colour of the cables and how they are
connected.

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 Service brake valve

Renewing service brake valve potentiometer

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Service brake valve

Basic setting of service brake valve potentiometer

The potentiometer is located in the micro switch

housing on top of the service brake valve
housing.
Adjust the potentiometer by means of the
adjustment screw that affects the position of the
potentiometer in the valve housing.

IMPORTANT! In order to access the adjusting

screw, the brake pedal and service brake valve
must be removed as one unit, and then the brake
pedal bottom plate must be removed from the
micro switch housing.

After adjustment, check the brake signals. Refer

to group 5, Automatic Gearbox, ZF 4/5HP500,
590 and 600, Troubleshooting.
Conditions:
The potentiometer must be connected to the
retarder control unit.
The brake pedal must be fully released.
The brake valve must be supplied with full
air pressure.
Adjustment
1 Connect a voltmeter between pin 9 on the
retarder control unit and earth.
2 The output signal of the potentiometer
should be 0.12-0.5 V. Adjust if necessary.

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 Throttle actuation sensor

Checking and adjusting the throttle actuation sensor

Note: Applies only to vehicle with mechanical

throttle control.
2 1

IMPORTANT! If the throttle actuation sensor is

set incorrectly, the gearbox may be damaged.

The throttle actuation sensor setting should be

checked:
following servicing or repair work to the
engine or gearbox.

104 695
in the event of hard gear changing or too
long slip times. 4 3
Conditions 1 Throttle actuation sensor
1 Engine and gearbox must be at operating 2 Injection pump
temperature. 3 Throttle cable
2 Engine idle and full throttle speeds must be 4 Link
correctly set. Refer to Workshop Manual
group 14, Mechanical Throttle Control,
Function and Work Description.
3 The throttle control must be correctly set.
When the pedal is in released position, the
pump arm must rest on the idling stop and
when the pedal is completely depressed, but
not in kick-down position, the pump arm
must rest against the full throttle stop.

! WARNING!

Turn off the main power switch or there

will be risk of electric shocks as the
throttle actuation sensor is located close
to the electrical connections on the
starter motor.

4 Turn off the main power switch.

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Throttle actuation sensor

5 Feel with your fingers to check that the mark

on the back of the load sensor arm is aligned
with the idling mark on the housing.

103 894
Requires two persons
6 Press the pump arm towards the full throttle

103 893
stop and hold it there. Alternatively, ask a
colleague to press the accelerator pedal to full
throttle position, but not to kick-down, and Throttle actuation sensor, idle speed position
keep it there.

7 Check that the mark on the arm is aligned

with the full throttle mark on the housing.
103 895

8 Adjust if necessary.
Throttle actuation sensor, full throttle position

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 Throttle actuation sensor

Using the ZF 55-pin connector box, part no.

1P01 137 834, the values for idle speed and full
throttle can be measured by means of a
multimeter.
Connect the ZF 55-pin connector box according
to the section 'Test Instructions' in Workshop
Manual group 5, Automatic Gearbox. ZF,
ZF 4/5HP500, 590 and 600, Troubleshooting.
Measure between connection 24 (+) and
18 (-) in the ZF 55-pin connector box.
Idle speed:
With idle speed and accelerator pedal fully
released.
The value should be 1.1 - 1.2 V.
Full throttle
With full throttle.
The value should be 3.8 - 4.2 V.

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Drive mode selector, Retarder switch

Renewing the drive mode selector

The drive mode selector is fitted with catches
securing it to the instrument panel.
Press in the catches and press out the drive
mode selector from the back of the instrument
panel.

118 612
Renewing the retarder switch

The switches are fitted with a catch to secure them

to the instrument panel.

Push down the catch so that the switch can be

pressed out.

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 Oil level

Checking oil level

Both a too high and a too low oil level can
damage the gearbox. If the oil level is too low,
the discs in the clutches will start to slip,
whereby they will rapidly be worn out. If the
oil level is too high, it will start to froth and
overheat.

Methods of checking
The oil level in the gearbox must be checked at
least once a week. The check can be carried
under three different conditions:
1 At operating temperature with the engine at
idle speed (oil temperature 80 - 90C).
2 When the oil is cold and with the engine
idling (fluid temperature 20 - 30C).
3 The level will be higher when the engine is
stopped than when it is running, as the oil
pump is not operating. This can be used as
a rough check after a long stationary period
or after changing oil to make sure there is
oil in the gearbox so that the engine can be
started without any risk.
When checking the oil level at operating
temperature, the bus should first be driven for
approx 30 minutes, repeatedly changing gear
up and down. The gearbox will then have
attained operating temperature even when the
outdoor temperature is well below 0C.

IMPORTANT! It is the oil level at operating

temperature that applies. If the oil level is
checked with the oil cold, e.g. after a long
stationary period or after changing oil, a final
check must be made at operating temperature.
The oil level can only be checked correctly at
operating temperature.

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Oil level

Dipstick Checking with cold oil

The dipstick is located in the oil filler pipe. To Oil temperature 20 - 30C.
access the oil filler, open the rear hatch or remove
the cover in the floor, depending on the type of The drive mode selector must be in position
bus. N.
Start the engine and run it at idling speed for 3 - 5
IMPORTANT! Observe strict cleanliness. The minutes.
gearbox is very sensitive to contaminants. Clean
the dipstick and the area around it. The oil level must be between the two lower
marks, "cold" or "30C".
Always check the oil level under the following
basic conditions: If the oil does not reach up to the bottom mark,
the oil must be topped up immediately.
The bus must be on a level surface.
Check the oil level at operating temperature as
The parking brake must be applied. described above.

Pull out the dipstick and wipe it dry. Reinsert the

dipstick, pull it out and read off the oil level.

Checking at operating temperature

Oil temperature 80 - 90C.
The engine must be idling.
The drive position selector must be in
position N.
The oil level must be between the two upper
marks, "hot" or "85C". The oil level should be
close to the top mark after filling.
Top up or drain off oil as necessary. 1 litre of oil
corresponds to approximately 10 mm on the
dipstick.

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 Oil level

A Dipstick location on K/L buses

B Dipstick location on N buses
1 Marks for checking at operating temperature
2 Marks for checking with cold oil

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Oil and filter

Changing oil and filter

The automatic transmission fluid should be
changed at the intervals recommended in the
inspection programme in Workshop Manual
group 0.
Oil grade:
ATF Dexron II D.
Or according to ZF recommendations.
The filter must be renewed at every oil change.
Change the oil whilst at operating temperature.

IMPORTANT! Observe strict cleanliness. The

gearbox is very sensitive to contaminants.

1 Clean around the oil plug and oil filter

cover.

VIKTIGT! Help protect the environment. Use a

suitable container when changing the oil. 1 Oil plug
2 Oil filter cover
1 Place a suitable container below. Unscrew
the oil plug, making sure the copper washer
is also removed.
Allow all the oil to drain out.

! WARNING!

Beware of hot oil. Wear protective gloves and

goggles during oil change.

2 Remove the cover.

Remove the old filter and discard it.
104 699

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 Oil and filter

3 If the suction pipe comes out with the filter,

the O-ring on the suction pipe must be
discarded. If this is the case, fit a new
O-ring in the seat in the gearbox and then
refit the suction pipe.

104 701
4 Check that the O-ring on the new oil filter is
in place and not damaged. Check that the
contact surfaces are clean and not damaged. 1
Apply automatic transmission fluid
sparingly on the O-ring and fit the filter.
5 Renew the O-ring in the cover.
Fit the cover and tighten the bolts to 23 Nm.
Fit the oil plug together with a new copper
washer.
Tighten to 50 Nm.
2

104 702

1 Filter O-ring
2 Cover O-ring

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Oil and filter

6 Remove the cover in the floor over the

gearbox on K/L buses.
Open the rear hatch on N buses.
Clean the dipstick and the area around it.

Oil capacity approximately

15 litres

104 703
IMPORTANT! Observe strict cleanliness. The Dipstick location on K/L buses
gearbox is very sensitive to contaminants.

103 855
Dipstick location on N buses

7 Remove the dipstick.

Pour in maximum 10 litres of automatic
transmission fluid.
8 Start the engine and run it at idle speed.
Immediately start slowly to pour in
approximately 4 litres of ATF.

9 Check the oil level with cold oil as

described in the section "Checking With
Cold Oil".
10 Drive the bus until the gearbox has reached
104 700

operating temperature and check the oil

level according to the section "Checking
With Warm Oil".

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