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The integrated Retarder for
ZF transmissions
Truck: ECOSPLIT Bus: 8 S 180ECOMID 6 S 1600
ASTRONIC
6085 758 001cSubject to technical change without notice
Edition August 1997
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Preface
1
Before using the ZF-Intarder for the first time, the driver
is requested:
to carefully read the operating instructions in this boo-
klet in order to ensure correct and effective use of the
Intarder.
to comply with maintenance instructions in order to
ensure that the Intarder continues to function properly.
to comply with specific vehicle manufacturer instructions.All such instructions are binding in all cases.
Skilled ZF Customer Service personnel are available to maintainyour transmission and ZF-Intarder and to assist you with any
problems.The relevant addresses are included in the "ZF Directory"(order No. 0000 762 703a), which can be sent on request
NOTE
This Operating Instructions booklet deals with the standardversion. Customer-specific differences are possible.
We wish you safe and pleasant driving with your ZF-Intarder.
ZF Friedrichshafen AG
Commercial Vehicle Transmissions DivisionD-88038 Friedrichshafen
Tel.: (0 75 41) 77-0Fax: (0 75 41) 77-80 00
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The following safety instructions appear in these OperatingInstructions:
NOTE
Refers to special processes, techniques, data, use of auxiliaryequipment, etc.
CAUTIONThis 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
NOTE
The attached fold-out sheet (brief operating instructions) isintended to provide a convenient summary of the keyoperating steps.It does not substitute these Operating Instructions.
!
Safety Instructions
2
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Contents
1Intarder Safety Instructions
2Description
3Operation
4Maintenance
3
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1 Intarder safety instructions . . . . . . . . . . . . . . . . . 5
2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Intarder master switch . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Intarder pilot lamp . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Bremsomat function . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Braking level selector without push-button . . . . . . . 9
3.5 Braking level selector with push-button . . . . . . . . . 10
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Information plate for oil change . . . . . . . . . . . . . . . 12
4.3 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5 Trucks: plugs for oil drain, oil overflow and oil fill . . 14
4.6 Buses: plugs for oil drain, oil overflow and oil fill . . 16
4.7 Oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.8 Oil fill after oil change / repair . . . . . . . . . . . . . . . . 19
4.9 Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.10 Transmission breather . . . . . . . . . . . . . . . . . . . . . . 20
4.11 Tables: oil quantities, tightening torques . . . . . . . . . 21
Contents
4
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1. General Intarder safety instructions
NOTES
Use of the Intarder does not affect the operation ofyour transmission.
when the clutch is depressed (to change gear),the Intarder braking force is sustained.
DANGER
On black ice or wet road surfaces, exercise greatcare when using the ZF-Intarder. The Intarder only
acts on the drive axle(s)
Your vehicle is liable to skid!
RISK OF ACCIDENTS!
Switch the Intarder master switch off to prevent
operator error! This applies especially to vehicles
without ABS.
If your vehicle is equipped with ABS, the Intarderbraking action is interrupted whenever ABS isactivated. When ABS is deactivated, the Intarderresumes its most recent operating mode.
If your vehicle also has an exhaust brake, this canbe applied in addition to the Intarder.
CAUTION
Prior to and while on downhill gradients, ensure that the
engine speed does not fall below 1600 rpm. Otherwise,
there is no guarantee that the engine coolant will be
sufficiently cooled.
If necessary, shift down one gear in order to increase
engine speed and, therefore, increase water pump
power and fan power.
If, despite these measures, the max. coolant temperature isreached, the Intarder automatically resets the highest
permitted level of braking torque (Intarder reset).
Take account of the reduced braking power by adapting
your driving style accordingly (gear selection, exhaust
brake or service brake).
!
Intarder Safety Instructions
5
1
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2 Description
The ZF-Intarder is an integral hydrodynamic transmissionbrake which operates without incurring mechanicalwear.
It reduces wear on the wheel brakes when the vehicle is retarded at high roadspeeds when the vehicle is negotiating downhill gradients
In addition, the ZF-Intarder helps ensure a more uniformand, therefore, more cost effective driving style.
Major benefits of the ZF-Intarder include:
high braking power
fast response times
an oil supply shared with the transmission; therefore,a single oil change is all that is required
lightweight design
low steady-state transmission operating temperaturesthanks to constant, integral cooling
Fig. 1ZF-Intarder layout (shown here with the ZF-Ecosplit.):
3 = Transmission output flange21 = Spur gearing
22 = Stator
23 = Rotor
Description
6
001 537
21 22 23
3
001 537
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Operation
7
301
2
3
4
5
6
90
95
91
3 Operation
3.1 Intarder master switch
The master switch (98) switches the Intarder on andoff, even while driving. The master switch is installed inthe dashboard.
Fig. 2 Dashboard (example)
95 = Intarder pilot lamp
91 = Braking level selector with Bremsomat pushbutton98 = Intarder master switch
3.2 Intarder pilot lamp
The Intarder pilot lamp gives the driver a continuousindication of the Intarder status.
NOTE
If the Intarder functions do not correspond to the LEDdisplays shown below, there is a fault in the electricalsystem. Take your vehicle straight to a ZF specialistworkshop!
The pilot lamp lights up for 3 seconds
Once the ignition has been switched on andthe Intarder master switch is in "ON" position,the Intarder system automatically checksthat the pilot lamp is functioning correctly.If the braking level selector is actuated, thelamp does not go out.
The pilot lamp flashes continuously when
the Intarder is engaged
Fault in the electrical system. Take yourvehicle straight to the nearest ZF specialistworkshop.
001 484
3 sec
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3.3 Bremsomat function
Using this function enables you to maintain roadspeed ata chosen f ixed level when negotiating downhill gradi-ents.The Intarder ECU automatically sets the braking torquelevel required.
NOTES
If, on downhill gradients, the required braking
power is greater than the maximum Intarderbraking power, apply the exhaust brake or service
brake as well.
If the current roadspeed is lower than the roads-peed stored in memory, the Intarder remains inope-rative. Once the roadspeed reaches the stored value,the Intarder becomes operative again.
If both Tempomat (cruise control) and Bremso-
mat (braking control) have been programmed:
CAUTION
Ensure that the roadspeed programmed in the Tempomatis lower than the roadspeed programmed in the
Bremsomat.
Otherwise both functions will work against each other!
Operation
8
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3.4 Braking level selector without push-button
BREMSOMAT - CONSTANT ROADSPEED: Setting and maintaining roadspeed:
Engage Level B = activate
Acknowledgement: pilot lamp is lit continuouslywhen Intarder is active
The current roadspeed is now stored in the ECU. TheBremsomat only functions in Level B. It is not active in otherlevels. In Bremsomat mode, the required braking torque isautomatically set (infinitely variable).
NOTE
When cornering, in dangerous situations or when facedwith obstructions, roadspeed can be reduced by actuating the
braking level selector.As soon the braking level selector is returned to setting "B"(= Bremsomat), the roadspeed control assumes the newly setroadspeed level.
Cancelling the Bremsomat function:
Move braking level selector into position 0, into position B and depress accelerator into position 1 - 5
Pilot lamp OFF in positions 0 and B
RETARDATION: Move braking level selector into position 1 - 5, depending
on level of braking torque required.
Acknowledgement: pilot lamp continuously lit
NOTE
If the Bremsomat is re-activated after the accelerator isdepressed, move braking level selector to Position B viaPosition 0.
Operation
9
3
0
V
1
2
3
4
5
004
406
B= Bremsomat
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3.5 Braking level selector with push-button
BREMSOMAT - CONSTANT ROADSPEED: Storing roadspeed:
Briefly press the push-button on the braking levelselector switch (regardless of the position it is in -0-6) as soon as the desired roadspeed is displayed onthe speedometer.
The current roadspeed is now stored in the ECU.
Stopping (Bremsomat):
Engage Level 0 = activate
Acknowledgement: pilot lamp flashes fourtimes
If the Intarder is active, the pilot lamp iscontinuously lit
Lamp goes out: the Intarder is no longer provi-ding braking power; however, Bremsomatmode is still active. Current roadspeed is lowerthan the stored roadspeed.
NOTES
The Bremsomat only functions in Level 0. It is notactive in other levels. During Bremsomat mode, therequired braking torque is set automatically (infinitelyvariable).
When cornering, in dangerous situations or whenfaced with an obstruction, roadspeed can be redu-ced by actuating the braking level selector.As soon as the braking level selector is moved backinto position 0, roadspeed control is only effective atthe roadspeed stored previously.
Cancelling the Bremsomat function:
Re-press push-button (regardless of selector position).
Indicator lamp OFF
RETARDATION: Depending on desired level of braking torque, move
braking level selector into position 1-6.
Acknowledgement: pilot lamp continuouslylit
Operation
10
0
1
2
3
4
5
6
001
753
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4 Maintenance
CAUTION
These maintenance instructions REPLACE the corre-
sponding sections in the maintenance instructions for
your transmission.
4.1 Oil level check
DANGER !
The transmission will be damaged if it is not filled
with enough oil. Risk of accidents!
CAUTION
Do not operate the ZF-Intarder immediately before stop-
ping the vehicle to check the oil level. This will ensure that
the correct oil level can be read.
NOTES
To prevent measuring errors, always check level ofoil in transmission with ZF-Intarder with:
vehicle on level ground engine switched off cool transmission oil (< 40 C).
Following each oil level check, also inspect thetransmission, Intarder, oil/water heat exchanger andrelevant coolant pipes for any possible leaks.
Check the oil level at regular intervals!
CHECK:
Park vehicle (do not use Intarder beforehand).
Open the oil overflow plug in order to check the oillevel.
If the oil level has fallen below the edge of the overflow
hole, add more oil until oil overflows.
!
Maintenance
11
4
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4.2 Oil change information plate
An oil change information plate is attached to the oiloverflow plug.
Do not remove the plate from the plug.
4.3 Type plate
The type plate contains important details about theIntarder. It is attached to the side of the Intarderhousing.
Always give the following information when makingenquiries, ordering parts or requesting repairs:
1. Intarder parts list number
2. Intarder serial number
Example of type plate
Maintenance
12
OEL WECHSEL
SAE 30
1.
EINFUELLEN BIS
UEBERLAUF
2.
PROBEFAHRT OHNE
RETARDERBETRIEB
3.
NACHFUELLEN BIS
UEBERLAUF
OIL CHANGE
SAE 30
1.
FILL UP TO
OVERFLOW
2.
TEST RUN WITHOUT
ACTUATING THE
RETARDER
3.
FILL AGAIN UP TO
OVERFLOW 001
269
SERIAL
NO.
CUSTOMER
SPEC.NO.
ZF FRIEDRICHSHAFEN AG
MODEL
PARTS
LIST NO.
MADE IN GERMANY
INTARDER
6085 XXX XXX
IT 151
XXX XXX
XXXXX
1
2
000 555
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4.4 Oil drain
NOTES
Drain the used oil into a suitable container anddispose of correctly.
Change the oil after a long drive while the oilis still warm and flows easily.
CAUTION
Do NOT operate the Intarder immediately before stopping
the vehicle to change the oil! This ensures that the correctamount of oil will be drained.
Park the vehicle on level ground and turn off theengine.
To drain the oil, unscrew the drain plugs from thetransmission (item 1) and from the oil filter housing(item 2).
DANGER !
Hot transmission oil can cause SERIOUS BURNS !
After draining the oil, clean the drain plugs (magnets)and renew the seal rings.
Insert new filter.
Re-insert the drain plugs.
CAUTION
Do not exceed the drain plug tightening torques (TA)
specified in the table on page 21. Otherwise, damage to
the transmission may result!
!
Maintenance
13
4
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4.5 Trucks - plugs for oil drain, oil fill and oil overflow
Fig. 1Ecosplit- transmission
16 S 151 IT16 S 181 IT16 S 221 IT16 S 251 IT
Fig. 2Ecomid 9/16 S 109 transmission with ZF-INTARDER
Truck Maintenance - Plugs for Oil Drain, Oil Fill and Oil Overflow
14
1
2 3
004 702
4
9
004
703
1004 710
004 714
3
4
2
9
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Truck Maintenance - Plugs for Oil Drain, Oil Fill and Oil Overflow
15
4
3 2 1004
512
4
9
004 5 11
1 = Transmission oil drain point
2 = Intarder housing oil drain point
3 = Intarder housing oil filter cover
4 = Oil overflow plug & oil fill after oilchange
9 = Oil fill plug after repair
See table on page 21 for tightening torques
009 5521
Fig. 3ASTRONIC transmission - 12 AS 1800/ 16 AS 2200 with
ZF-INTARDER (View fromunderneath transmission)
Alternative: Heat exchanger for truck transmissions(Ecosplit, Ecomid, ASTRONIC).
Heat exchanger attached horizontally below
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4.6 Buses - plugs for oil drain, oil fill and oil overflow
Fig. 48 S 180 transmission with ZF-INTARDER
Bus Maintenance - Plugs for Oil Drain, Oil Fill and Oil Overflow
16
1
32
004
705
4
9
004
714
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Bus Maintenance - Plugs for Oil Drain, Oil Fill and Oil Overflow
17
4
Fig. 56 S 1600 transmission with ZF-INTARDER
1 = Transmission oil drain point
2 = Intarder housing oil drain point
3 = Intarder housing oil filter cover
4 = Oil overflow plug & oil fill after oilchange
9 = Oil fill plug after repair
See table on page 21 for tightening torques
009
413
4
9
1
3
009 553
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4.7 Oil flter change
NOTE: renew the oil filter during every oil change (for order No., see table on page 21).
DANGER: Hot transmission oil can cause serious burns!!
Maintenance
10
000 552
000 529(Caution: some oil will remain in the
oil filter housing!)
Check O-Ring (8) on filter cover. If damaged, discard andfit a new, greased O-ring.
Grease O-Ring (7) on new filter.
Mount cover (3) using bolts (10).See table on page 21 for tightening torques.
7 5
004 467
83
33
6 7 56
004 70610
004 7076 8
004 467
Remove cover (3) with fit-
ted filter.Remove filter from filtercover.
Unscrew plug(s) (10) from oil filter housing cover (3)
Remove cover (3) and
remove filter from filterhousing.
Firmly attach magnet (5) to new filter.
Insert new filter (6) into
filter housing.
Fit filter housing cover (3)
to the new filter (6). Fullyinsert complete unit intofilter housing.
Ecosplit / ASTRONIC Ecomid/ 8 S 180/ 6
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4
4.8 Oil fill
after oil change
Open oil overflow plug (4).
See table on page 21 for tightening torques.
Perform a brief test drive (at least 1 minute at a minimum speed of 10 km/h)
End of test drive
Bring vehicle to a standstill. Do not actuate Intarder! Open overflow plug (4).Do not remove instruction plate.
CAUTION
Re-check oil level and, if necessary, top up oil until oil overflows.
Close oil overflow plug (4), ensuring new seal ring is fitted.
Add oil through overflow hole until oil overflows.Add oil through oil fill hole.
Insert oil overflow plug (4) with new seal ring and tighten.
Test drive:Do NOT actuate Intarder.
Test drive:At start of test, actuate Intarder ONCE BRIEFLY (level 6)
Insert oil fill plug (9) with new seal ring and tighten.
NOTES
Always fill the transmission and Intarder with oil while the vehicle is standing on level ground with the engine switched off.Drain used oil. See table on page 21 for oil grades and quantities.
after repair
Maintenance
Open oil fill plug (9).
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4.9 Engine coolant
CAUTION
Always follow vehicle manufacturer instructions when
topping up engine coolant! This is to avoid damage to the
oil/water heat exchanger.
Engine coolant
(mixture of tap water and corrosion-inhibitingantifreeze)
recommended quantity of corrosion-inhibitingantifreeze:50 - 60 % by volume. Check using a coolantdensimeter.
Corrosion inhibiting antifreeze
Base fluid: ethylene glycol with corrosion inhibitors
Tap water
pH value 6.5 - 8.0; total hardness 3 - 10 dH
Effective life of coolant: 2 years max.
NOTE
After this period, always change the coolant.Immediately change the coolant if sludge begins to formor if the concentration falls abruptly.
4.10 Transmission breather
Pressure differences are balanced by means of a breathervalve.
NOTE
Ensure that the valve is always in good working order. Thebreather must be kept clean and must not be covered by aplastic cap. Do not directly spray with water jet (water intransmission = risk of corrosion).
20
Maintenance
004 711
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Transmission
type
Ecosplit
16 S 151 IT
16 S 181 IT
16 S 221 IT
16 S 251 IT
Ecomid
9 S 109 IT
16 S 109 IT
Astronic
12 AS 1800 IT
16 AS2200 IT
8 S 180 IT
6 S 1600 IT
4
Maintenance
TRUCK
BUS
Item 1 = Transmission oil drain plug
Item 2 = Intarder housing oil drain plug
Item 9 = Oil f ill plug after repairItem 10 = Bolts for oil f ilter cover
Oil class
acc. to
TE-ML 02
Tutella ZC 90or
TE-ML 02
acc. toTE-ML 02
Oil change
interval
acc. totransmission
type
Oil change
app. 11.0 dm3
app. 12.0 dm3
app. 12.0 dm3
app. 12.0 dm3
app. 12.0 dm3
app.12.5 dm3
app. 12.0 dm3
app. 13.0 dm3
app. 12.0 dm3
app. 13.5 dm3
Repair
app. 18.5 dm3
app. 21.5 dm3
app.21.5 dm3
app.21.5 dm3
app. 21.0 dm3
app. 22.0 dm3
app. 21.0 dm3
app. 23.0 dm3
app. 21.0 dm3
app.21.5 dm3
Filter No.
6085 298 026
6085 298 026
6085 298 026
6085 298 026
6085 298 026
6085 298 026
6085 298 026
6085 298 026
6085 298 026
6085 298 026
1
M 38
120
or
M 24
60
120
60
120
120
2
60
60
60
60
-
4
60
60
60
60
60
9
60
60
60
60
60
10
23
23
23
23
23
Oil quantity after Tigntening torque [Nm]
for item