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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