Edition August 1997

Subject to technical change without notice

The integrated Retarder for

ZF transmissions
Truck: ECOSPLIT Bus: 8 S 180
ECOMID
6 S 1600
AS TRONIC
6085 758 001c

Preface

Before using the ZF-Intarder for the first time, the driver
is requested:
to carefully read the operating instructions in this booklet 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.

Skilled ZF Customer Service personnel are available to maintain

your 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 standard
version. Customer-specific differences are possible.

to comply with specific vehicle manufacturer instructions.

All such instructions are binding in all cases.
We wish you safe and pleasant driving with your ZF-Intarder.

ZF Friedrichshafen AG
Commercial Vehicle Transmissions Division
D-88038 Friedrichshafen
Tel.: (0 75 41) 77-0
Fax: (0 75 41) 77-80 00

Safety Instructions

The following safety instructions appear in these Operating

Instructions:

NOTE
Refers to special processes, techniques, data, use of auxiliary
equipment, etc.

CAUTION
This 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) is
intended to provide a convenient summary of the key
operating steps.
It does not substitute these Operating Instructions.

Contents

Intarder Safety Instructions

Description

Operation

Maintenance

Contents

Intarder safety instructions . . . . . . . . . . . . . . . . . 5

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.1

Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.2

Information plate for oil change . . . . . . . . . . . . . . . 12

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.3

Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.1

Intarder master switch . . . . . . . . . . . . . . . . . . . . . . 7

4.4

Oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.2

Intarder pilot lamp . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.5

Trucks: plugs for oil drain, oil overflow and oil fill . . 14

3.3

Bremsomat function . . . . . . . . . . . . . . . . . . . . . . . . 8

4.6

Buses: plugs for oil drain, oil overflow and oil fill . . 16

3.4

Braking level selector without push-button . . . . . . . 9

4.7

Oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.5

Braking level selector with push-button . . . . . . . . . 10

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

Intarder Safety Instructions

1.

General Intarder safety instructions

NOTES
Use of the Intarder does not affect the operation of
your transmission.
when the clutch is depressed (to change gear),
the Intarder braking force is sustained.

DANGER
On black ice or wet road surfaces, exercise great
care when using the ZF-Intarder. The Intarder only
acts on the drive axle(s)
Your vehicle is liable to skid!
RISK OF ACCIDENTS!

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 is
reached, 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).

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 Intarder
braking action is interrupted whenever ABS is
activated. When ABS is deactivated, the Intarder
resumes its most recent operating mode.
If your vehicle also has an exhaust brake, this can
be applied in addition to the Intarder.
5

Description

Description
3
The ZF-Intarder is an integral hydrodynamic transmission
brake which operates without incurring mechanical
wear.

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 uniform
and, 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 temperatures
thanks to constant, integral cooling

001 537
001
537

21

22

23

Fig. 1
ZF-Intarder layout (shown here with the ZF-Ecosplit.):
3 = Transmission output flange
21 = Spur gearing
22 = Stator
23 = Rotor

Operation

Operation

3.1

Intarder master switch

3.2

Intarder pilot lamp

The Intarder pilot lamp gives the driver a continuous
indication of the Intarder status.

The master switch (98) switches the Intarder on and

off, even while driving. The master switch is installed in
the dashboard.

NOTE
If the Intarder functions do not correspond to the LED
displays shown below, there is a fault in the electrical
system. Take your vehicle straight to a ZF specialist
workshop!

95
91

1
2
3
4
5

3 sec

The pilot lamp lights up for 3 seconds

Once the ignition has been switched on and
the Intarder master switch is in "ON" position,
the Intarder system automatically checks
that the pilot lamp is functioning correctly.
If the braking level selector is actuated, the
lamp does not go out.

90
001 484

Fig. 2 Dashboard (example)

95 = Intarder pilot lamp
91 = Braking level selector with Bremsomat pushbutton
98 = Intarder master switch

The pilot lamp flashes continuously when

the Intarder is engaged
Fault in the electrical system. Take your
vehicle straight to the nearest ZF specialist
workshop.

Operation

3.3

Bremsomat function
Using this function enables you to maintain roadspeed at
a chosen fixed level when negotiating downhill gradients.
The Intarder ECU automatically sets the braking torque
level required.
NOTES
If, on downhill gradients, the required braking
power is greater than the maximum Intarder
braking power, apply the exhaust brake or service
brake as well.

If the current roadspeed is lower than the roadspeed stored in memory, the Intarder remains inoperative. Once the roadspeed reaches the stored value,
the Intarder becomes operative again.
If both Tempomat (cruise control) and Bremsomat (braking control) have been programmed:
CAUTION
Ensure that the roadspeed programmed in the Tempomat
is lower than the roadspeed programmed in the
Bremsomat.
Otherwise both functions will work against each other!

Operation

3.4

Braking level selector without push-button

0
VB= Bremsomat
1
004 406

3
4
5

BREMSOMAT - CONSTANT ROADSPEED:

Setting and maintaining roadspeed:
Engage Level B = activate
Acknowledgement: pilot lamp is lit continuously
when Intarder is active

NOTE
When cornering, in dangerous situations or when faced
with 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 set
roadspeed 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

The current roadspeed is now stored in the ECU. The

Bremsomat only functions in Level B. It is not active in other
levels. In Bremsomat mode, the required braking torque is
automatically set (infinitely variable).

NOTE
If the Bremsomat is re-activated after the accelerator is
depressed, move braking level selector to Position B via
Position 0.

Operation

3.5

Braking level selector with push-button

0
1
2
001 753

4
5
6

BREMSOMAT - CONSTANT ROADSPEED:

Storing roadspeed:
Briefly press the push-button on the braking level
selector switch (regardless of the position it is in 0-6) as soon as the desired roadspeed is displayed on
the speedometer.
The current roadspeed is now stored in the ECU.

Stopping (Bremsomat):
Engage Level 0 = activate
Acknowledgement: pilot lamp flashes four
times
If the Intarder is active, the pilot lamp is
continuously lit

10

Lamp goes out: the Intarder is no longer providing braking power; however, Bremsomat
mode is still active. Current roadspeed is lower
than the stored roadspeed.
NOTES
The Bremsomat only functions in Level 0. It is not
active in other levels. During Bremsomat mode, the
required braking torque is set automatically (infinitely
variable).
When cornering, in dangerous situations or when
faced with an obstruction, roadspeed can be reduced by actuating the braking level selector.
As soon as the braking level selector is moved back
into position 0, roadspeed control is only effective at
the 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 continuously
lit

Maintenance

Maintenance

CAUTION
These maintenance instructions REPLACE the corresponding sections in the maintenance instructions for
your transmission.

NOTES
To prevent measuring errors, always check level of
oil in transmission with ZF-Intarder with:
vehicle on level ground
engine switched off
cool transmission oil (< 40 C).

4.1

Following each oil level check, also inspect the

transmission, Intarder, oil/water heat exchanger and
relevant coolant pipes for any possible leaks.

Oil level check

Check the oil level at regular intervals!

DANGER !
The transmission will be damaged if it is not filled
with enough oil. Risk of accidents!
CHECK:

Park vehicle (do not use Intarder beforehand).

CAUTION
Do not operate the ZF-Intarder immediately before stopping the vehicle to check the oil level. This will ensure that
the correct oil level can be read.

Open the oil overflow plug in order to check the oil

level.
If the oil level has fallen below the edge of the overflow
hole, add more oil until oil overflows.

11

Maintenance

4.2

Oil change information plate

4.3

An oil change information plate is attached to the oil

overflow plug.

Type plate
The type plate contains important details about the
Intarder. It is attached to the side of the Intarder
housing.

Do not remove the plate from the plug.

Always give the following information when making
enquiries, ordering parts or requesting repairs:
1. Intarder parts list number
2. Intarder serial number

ZF FRIEDRICHSHAFEN AG

1.

1.

EINFUELLEN BIS
UEBERLAUF

FILL UP TO
OVERFLOW

2.

2.

PROBEFAHRT OHNE
RETARDERBETRIEB

TEST RUN WITHOUT

ACTUATING THE
RETARDER

3.
NACHFUELLEN BIS
UEBERLAUF

MADE IN GERMANY

OIL CHANGE
SAE 30

3.
FILL AGAIN UP TO
OVERFLOW

MODEL
PARTS
LIST NO.
SERIAL
NO.

001 269

OEL WECHSEL
SAE 30

CUSTOMER
SPEC.NO.

INTARDER IT 151
6085 XXX XXX
XXX XXX
XXXXX

1
2

000 555

Example of type plate

12

Maintenance

4.4

Oil drain
NOTES
Drain the used oil into a suitable container and
dispose of correctly.
Change the oil after a long drive while the oil
is still warm and flows easily.

CAUTION
Do NOT operate the Intarder immediately before stopping
the vehicle to change the oil! This ensures that the correct
amount of oil will be drained.

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!

Park the vehicle on level ground and turn off the

engine.

To drain the oil, unscrew the drain plugs from the

transmission (item 1) and from the oil filter housing
(item 2).

DANGER !
Hot transmission oil can cause SERIOUS BURNS !

13

Truck Maintenance - Plugs for Oil Drain, Oil Fill and Oil Overflow

4.5

Trucks - plugs for oil drain, oil fill and oil overflow

Fig. 1
Ecosplit- transmission
16 S 151 IT
16 S 181 IT
16 S 221 IT
16 S 251 IT

Fig. 2
Ecomid 9/16 S 109 transmission with ZF-INTARDER

004 710

004 702

9
004 703

14

004 714

Truck Maintenance - Plugs for Oil Drain, Oil Fill and Oil Overflow

Fig. 3
ASTRONIC transmission - 12 AS 1800/ 16 AS 2200 with
ZF-INTARDER (View from
underneath transmission)

004 512

Alternative: Heat exchanger for truck transmissions

(Ecosplit, Ecomid, ASTRONIC).
Heat exchanger attached horizontally below

9
009 5521

1 = Transmission oil drain point

2 = Intarder housing oil drain point
3 = Intarder housing oil filter cover
4 = Oil overflow plug & oil fill after oil
change
9 = Oil fill plug after repair
4

004 5 11

See table on page 21 for tightening torques

15

Bus Maintenance - Plugs for Oil Drain, Oil Fill and Oil Overflow

4.6

Buses - plugs for oil drain, oil fill and oil overflow

004 705

004 714

Fig. 4
8 S 180 transmission with ZF-INTARDER

9
3

16

Bus Maintenance - Plugs for Oil Drain, Oil Fill and Oil Overflow

Fig. 5
6 S 1600 transmission with ZF-INTARDER

009 413

009 553

4
1 = Transmission oil drain point
2 = Intarder housing oil drain point
3 = Intarder housing oil filter cover
4 = Oil overflow plug & oil fill after oil
change
9 = Oil fill plug after repair
See table on page 21 for tightening torques
17

Maintenance

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!

Ecosplit / ASTRONIC

Ecomid/ 8 S 180/ 6

Unscrew plug(s) (10) from oil filter housing cover (3)

10
3

000 529

Remove cover (3) with fitted filter.

Remove filter from filter
cover.

Remove cover (3) and

remove filter from filter
housing.

(Caution: some oil will remain in the

oil filter housing!)
Check O-Ring (8) on filter cover. If damaged, discard and
fit a new, greased O-ring.

10

004 706

Firmly attach magnet (5) to new filter.

Grease O-Ring (7) on new filter.
000 552

5
004 467

18

Fit filter housing cover (3)

to the new filter (6). Fully
insert complete unit into
filter housing.

Insert new filter (6) into

filter housing.

Mount cover (3) using bolts (10).

See table on page 21 for tightening torques.

004 707

5
004 467

Maintenance

4.8

Oil fill
after oil change

after repair

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.
Open oil overflow plug (4).

Open oil fill plug (9).

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.

Insert oil fill plug (9) with new seal ring and tighten.

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)
Test drive:
Do NOT actuate Intarder.

Test drive:
At start of test, actuate Intarder ONCE BRIEFLY (level 6)

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.
19

Maintenance

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-inhibiting
antifreeze)
recommended quantity of corrosion-inhibiting
antifreeze:
50 - 60 % by volume. Check using a coolant
densimeter.
Corrosion inhibiting antifreeze
Base fluid: ethylene glycol with corrosion inhibitors

4.10 Transmission breather

Pressure differences are balanced by means of a breather
valve.
NOTE
Ensure that the valve is always in good working order. The
breather must be kept clean and must not be covered by a
plastic cap. Do not directly spray with water jet (water in
transmission = risk of corrosion).

e
h
h
?YY(+@V'?V
h
gY?(YY(@@(@@@@@@@@@@@'@V'@?V'V?
'@g
Ve?Y(@@@@@@@@@'V
@'@V'??Y((@@@@@@@@@@@@@@@@@@@@@@&*W
@@@@@@@@@@@@@@@@@@@@@@@@@@@@&@W&W?
@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@&&@WW&?W?
@@@@@@@@@@@@@@@@@@@@&W
@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@'@'V@V'??

4.9

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 form
or if the concentration falls abruptly.
20

004 711

Maintenance

Oil quantity after

BUS

TRUCK

Transmission
type
Ecosplit
16 S 151 IT
16 S 181 IT
16 S 221 IT
16 S 251 IT

Oil change
interval

Oil class

acc. to
TE-ML 02

Oil change

Repair

app. 11.0 dm3

app. 12.0 dm3
app. 12.0 dm3
app. 12.0 dm3

app. 18.5 dm3

app. 21.5 dm3
app.21.5 dm3
app.21.5 dm3

Filter No.

6085 298 026

6085 298 026
6085 298 026
6085 298 026

Tigntening torque [Nm]

for item
1
2
4
9
10
M 38
120
or 60
M 24
60

acc. to
transmission app. 12.0 dm3 app. 21.0 dm3 6085 298 026 120
type
app.12.5 dm3 app. 22.0 dm3 6085 298 026

Ecomid
9 S 109 IT
16 S 109 IT

60

60

23

60

60

60

23

Astronic
Tutella ZC 90
or
12 AS 1800 IT
16 AS2200 IT TE-ML 02

app. 12.0 dm3 app. 21.0 dm3 6085 298 026

app. 13.0 dm3 app. 23.0 dm3 6085 298 026

60

60

60

60

23

8 S 180 IT

app. 12.0 dm3 app. 21.0 dm3 6085 298 026 120

60

60

60

23

app. 13.5 dm3 app.21.5 dm3 6085 298 026 120

60

60

23

6 S 1600 IT

acc. to
TE-ML 02

Item 1 = Transmission oil drain plug

Item 2 = Intarder housing oil drain plug
Item 4 = Oil overflow/oil fill after oil change

Item 9 = Oil fill plug after repair

Item 10 = Bolts for oil filter cover
app. = approximately
21