OPERATING INSTRUCTIONS

ZF-INTARDER
3rd Generation

BUSES, TRUCKS
Copyright © ZF Friedrichshafen AG

This document is protected by copyright. Complete or partial reproduction

or dissemination of this document is prohibited without the consent of
ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution.

This document is a translation of the German original.

 Table of Contents

1 Preface.................................................................. 4 6 Maintenance ......................................................... 26

1.1 Product designation............................................... 5 6.1 Oil level check ....................................................... 26
6.2 Type plate .............................................................. 27
2 Safety Instructions................................................ 7 6.2.1 Type plate: ZF-Intarder........................................... 27
2.1 General safety instructions ..................................... 7 6.2.2 Type plate: EST electronic control unit.................... 27
2.2 Signal words and symbols ..................................... 11 6.3 Oil drain................................................................. 28
2.3 Product-related safety instructions ......................... 12 6.4 Truck: oil drain, oil overflow, and oil filler plugs ...... 29
6.4.1 ZF-Ecosplit ............................................................ 29
3 Description ........................................................... 14 6.4.2 ZF-AS Tronic.......................................................... 30
3.1 Structure of the ZF-Intarder.................................... 15 6.4.3 TraXon ................................................................... 31
6.5 Bus: oil drain, oil filler, and oil overflow plugs......... 32
4 Technical Data ...................................................... 16 6.5.1 ZF-AS Tronic.......................................................... 32
6.5.2 ZF-EcoShift............................................................ 33
5 Operation.............................................................. 20 6.6 Oil filter change ..................................................... 34
5.1 Operating functions ............................................... 20 6.7 Oil fill ..................................................................... 35
5.1.1 Operation with Bremsomat function “B”................. 20 6.7.1 Oil fill after oil change ............................................ 35
5.1.2 Operation in braking steps 1 – 5 ............................ 22 6.7.2 Oil fill after repairs.................................................. 37
5.2 Initial startup of the vehicle at low temperatures .... 23 6.8 Engine coolant....................................................... 39
5.2.1 Vehicle with ZF-Ecosplit 4 or ZF-EcoShift .............. 23 6.8.1 Monitoring and change intervals ............................ 39
5.2.2 Vehicle with ZF-AS Tronic or TraXon ...................... 24 6.8.2 Draining residual coolant at heat exchanger .......... 40
5.2.3 Temperature influence on ZF-AS Tronic and 6.9 Bleeding the ZF-Intarder ........................................ 41
TraXon ................................................................... 25
5.2.4 Storage of ZF-AS Tronic and TraXon....................... 25

EN 6093.758.101c - 2014-08 3
Preface

1 Preface

Please read the operating instructions carefully. The operating instructions contain important information about safety, operation,
and maintenance of the ZF product. Prior to the initial operation, please also note the special instructions provided by the body or
vehicle manufacturer.

Object of documentation is a volume-produced ZF product. State of design acc. to date of issue.

The figures illustrate the operation or workflow and may deviate from your ZF product. Illustrations and figures are not drawn to
scale; no conclusions about size and weight can be drawn.

As a result of type variety, images shown in these operating instructions may deviate from your ZF product. Partly, figures only
show exemplary standard versions.

Regular maintenance and servicing ensures the service life and operational reliability of your ZF product. Therefore, observe the
maintenance instructions and maintenance intervals. The ZF Service Centers' specialists are available to assist you in carrying out
maintenance work or to help if any other problems arise.

ZF Friedrichshafen AG

4 EN 6093.758.101c - 2014-08
 Preface

1.1 Product designation

The operating instructions cover the following types of transmission:

Truck:
TD = Truck Direct drive
TO = Truck Overdrive

ZF-Ecosplit, 4th generation TraXon

12-speed: 16-speed: Model range 12.1: Model range 12.2: Model range 16:
12 S 2131 TD 16 S 1631 TD 12 TX 1411 TD 12 TX 2421 TD 16 TX 1641 TD
12 S 2331 TD 16 S 1831 TO 12 TX 1611 TD/TO 12 TX 2621 TD 16 TX 1841 TD
12 S 2831 TD 16 S 1931 TD 12 TX 1811 TD/TO 12 TX 2821 TD/TO 16 TX 2041 TD
16 S 2231 TD/TO 12 TX 2011 TD/TO 12 TX 3021 TO 16 TX 2241 TD
16 S 2331 TD 12 TX 2211 TD/TO 12 TX 3221 TO 16 TX 2441 TD
16 S 2531 TO 12 TX 2411 TO 12 TX 3421 TO 16 TX 2641 TD
16 S 2731 TO 12 TX 2611 TO 16 TX 2841 TD

ZF-AS Tronic
12-speed: 16-speed:
12 AS 1631 TD 12 AS 2531 TO 16 AS 2231 TD
12 AS 1931 TD/TO 12 AS 2541 TD/TO 16 AS 2631 TO
12 AS 2131 TD/TO 12 AS 2741 TO
12 AS 2141 TD 12 AS 2941 TO
12 AS 2331 TD/TO 12 AS 3141 TO
12 AS 2341 TD

EN 6093.758.101c - 2014-08 5
Preface

Bus:
BD = Bus Direct drive
BO = Bus Overdrive

ZF-EcoShift
6-speed:
6 S 1311 BD/BO
6 S 1611 BD/BO
6 S 1911 BO
6 S 2111 BO

ZF-AS Tronic
12-speed:
12 AS 2001 BO
12 AS 2301 BO
12 AS 2701 BO

6 EN 6093.758.101c - 2014-08
 Safety Instructions

2 Safety Instructions

2.1 General safety instructions

Read all safety instructions. Failure to comply with safety instructions may lead to material damage, serious injury, possibly even to
death.

Intended use/liability/guarantee/warranty
The ZF product is designed and produced in line with state-of-the-art technology and is safe to operate. However, this product
may cause hazardous situations if used incorrectly by unauthorized, untrained, and uninstructed specialized staff or if not used for
its intended purpose.

We offer guarantee for the ZF product in accordance with our Terms and Conditions. Warranty claims cease to apply if damage
and secondary damage result from incorrect and unprofessionally performed work. Work that is performed by unauthorized,
untrained, and uninstructed specialized staff leads to ceasing of all warranty claims.

We offer warranty for the ZF product in accordance with our Terms and Conditions.
Damage, secondary damage, defects, and possibly resulting costs are excluded from contractual liability or warranty in the event
of non-compliance with one of the following points:
▪ All work must be performed in a professional manner.
▪ Work must only be performed by trained, instructed and authorized specialized staff.
▪ Only genuine ZF spare parts may be used which have been tested and released by ZF.
▪ Only genuine ZF accessories may be used which have been tested and released by ZF.

EN 6093.758.101c - 2014-08 7
Safety Instructions

▪ Only genuine ZF special tools may be used which have been tested and released by ZF.
▪ Revisions and modifications on the ZF product must be approved by ZF.

In case of damage, immediate action is mandatory in order to restore full functionality and safety/operational safety of the ZF
product and to minimize the extent of damage. In the event of non-compliance, ZF will not accept liability or warranty claims.

In case of damage, contact ZF Services and have the following data available:
▪ Product type, product parts list number, and serial number
▪ Total mileage
▪ Damage history
▪ Damage pattern

Specialized staff
Work must only be performed by trained and instructed specialized staff. As a result of specialized training and practical
experience, the specialized staff must be capable of detecting risks and avoiding possible dangers which may be caused by the
operation, maintenance, and repair of the ZF product.

To avoid injury to personnel and damage to ZF products, all safety regulations and legal requirements must be adhered to. The
specialized staff must have read and understood these regulations prior to beginning work.

Country-specific safety, accident prevention, and environmental regulations apply irrespective of the instructions provided in this
document.

8 EN 6093.758.101c - 2014-08
 Safety Instructions

Safety-relevant workwear is to be used for all work. Depending on the type of work, additional protection, e. g. protective
goggles, protective gloves, a hard hat, and a skirt, is to be used. The workwear must fit properly and be tight so that it cannot get
caught in turning or protruding parts.

After completion of repair work and inspections, the specialized staff must ensure that the ZF product is again functioning
perfectly and is safe to operate.

Handling of ZF products
Impermissible superstructures, add-ons, modifications, and changes to the ZF product may affect the ZF product’s operational
safety and are only permitted with the approval of ZF Friedrichshafen AG.

Unless explicitly permitted, no work may be performed while the engine is running.
Secure the engine against unintentional setting off and the vehicle against moving.
Attach a “Do not operate” sign which is visible for everyone!
Keep uninvolved parties away.

Increased risk of injury at contact with cooled down or heated parts. Only touch parts when wearing suitable protective gloves.

EN 6093.758.101c - 2014-08 9
Safety Instructions

Handling operating fluids and consumables

Increased risk of injury at contact with heated, cooled down, or caustic operating fluids and consumables (e. g. lubricants,
cleaning agents, nitrogen).
▪ Prevent skin contact.
▪ Do not drink.
▪ Do not inhale vapors.
▪ Keep away from ignition sources, do not smoke.

Store operating fluids and consumables in suitable and correctly labeled containers. Use suitable protective clothing, protective
gloves, and protective goggles/face protection. Pay attention to manufacturer’s and accident prevention regulations.
Immediately seek medical assistance after contact with heated, cooled down, or caustic operating fluids and consumables.

Environment
Operating fluids and consumables must not be allowed to enter the soil, groundwater, or sewage system.
▪ Ask your local environmental protection agency for the safety data sheets of the relevant ZF products and observe these
requirements.
▪ Collect operating fluids and consumables in a sufficiently large container.
▪ Dispose of operating fluids and consumables, waste, containers, soaked cleaning cloths, contaminated filters etc. in
accordance with the regulations of the environmental protection laws.
▪ Pay attention to manufacturer’s and accident prevention regulations.

When selecting operating fluids and consumables, bear in mind health risks, environmental compatibility, disposal regulations,
and country-specific possibilities for approved disposal.

10 EN 6093.758.101c - 2014-08
 Safety Instructions

2.2 Signal words and symbols

This document contains particularly highlighted safety instructions which start with one of the following signal words depending
on the danger’s severity.

Describes a hazardous situation that leads to serious injuries or death, if not prevented.

Describes a hazardous situation that may lead to serious injuries or death, if not prevented.

Describes a hazardous situation that may lead to slight to moderate injury, if not prevented.

Describes a situation that may lead to material damage, if not prevented.

EN 6093.758.101c - 2014-08 11
Safety Instructions

In addition, the following symbols are used:

Refers to additional safety-related information.

Reference is made to special processes, techniques, use of resources, etc.

2.3 Product-related safety instructions

Risk of accident!
The vehicle might start skidding in case of icy roads, rainy road surfaces, or in unladen condition (tractor operation only).
 Make cautious use of the Intarder.

▪ If your vehicle is equipped with an ABS or EBS brake system*, then, the Intarder braking process may be affected or
interrupted for as long as these systems are active. Subsequently, the last engaged Intarder operating mode will become active
again.
▪ Intarder use does not affect the operation of your ZF transmission. When the clutch is engaged (to change gears), the braking
force of the Intarder is unimpaired.
▪ If your vehicle is equipped with an engine brake, then the latter can be operated in addition to the Intarder.

* ABS = Anti-lock braking system, EBS = Electronic braking system

12 EN 6093.758.101c - 2014-08
 Safety Instructions

Prior to and during downhill travel, you have to ensure that the engine speed does not fall below n = 1600 rpm. Depress
clutch only briefly for gear change. Avoid coasting downhill or driving downhill with depressed clutch pedal because
otherwise adequate cooling of the engine cooling water is not ensured.
 Shift down into a lower gear in order to increase the speed and thus the water pump and bleeder performance.
If, nevertheless, the max. cooling water temperature is reached, then the Intarder electronics will automatically control the
Intarder and reduce the brake torque to the highest still permissible brake torque (controlled Intarder reduction).
 The reduced braking performance must be accounted for by adjusting the driving style (selection of gear, engine brake or
service brake).

EN 6093.758.101c - 2014-08 13
Description

3 Description

The Intarder is a wear-free operating, hydrodynamic additional brake integrated into the transmission. The Intarder contributes to
a smoother and more efficient driving style.

The advantages of the Intarder are:

▪ High braking performance
▪ Short response times
▪ Shared oil supply with the transmission and thus common oil change
▪ Low weight
▪ Low constant transmission operating temperatures thanks to integrated, continuous cooling
▪ Transmission oil reaches operating temperature faster, since the transmission is heated by the coolant via the heat exchanger
▪ Reduced wear of wheel brakes
– when decelerating from high speeds
– when traveling on downhill gradients

14 EN 6093.758.101c - 2014-08
 Description

3.1 Structure of the ZF-Intarder

1 3
2

8
8 4

3
7
6 7
5 6
4
5

Fig. 3.1 On the left: Structure of the Intarder in trucks; on the right: Structure of the Intarder in buses
029013/029014

1 PTO connection 5 Rotor

2 Output flange 6 Stator
3 Electronic control unit (EST), Intarder 7 Idling speed reduction device
4 Heat exchanger 8 Gear ratio

EN 6093.758.101c - 2014-08 15
Technical Data

4 Technical Data
Truck Oil quantity after Tightening torque in [Nm]
Oil change Repair for position Filter Oil grade/
Ecosplit Transmission type approx. approx. 1 2 4 5 6 7 3 oil change intervals

12 S 2131 TD
16 S 1631 TD 17.0 dm3 23.0 dm3

No.: 0501.215.163
16 S 1831 TO

12 S 2331 TD
12 S 2831 TD For TE-ML List of
Lubricants, refer to

9.5 ±1
60 ±6

60 ±6

23 ±2

60 ±6

60 ±6
16 S 1931 TD 18.5 dm3 25.5 dm3
16 S 2231 TD/TO transmission type plate.
16 S 2331 TD
16 S 2531 TO

16 S 2731 TO 19 dm3 26.5 dm3

1 Oil drain location, transmission 5 Plug for oil overflow and oil fill after the oil change
2 Oil drain location, Intarder 6 Oil filler plug after repair
3 Suction filter 7 Screw for mounting the temperature sensor
4 Screws for mounting the suction filter

The correct oil quantity depends on the oil level check result after the test run (refer to Chapter 6.7, Oil fill).

16 EN 6093.758.101c - 2014-08
 Technical Data

Truck Oil quantity after Tightening torque in [Nm]

Oil change Repair for position Filter Oil grade/
1,
AS Tronic Transmission type approx. approx. 1a, 1b 2 4 5 6 7 3 oil change intervals

12 AS 1631 TD
12 AS 1931 TD/TO
12 AS 2131 TD/TO 17.5 dm3 22.0 dm3

No.: 0501.215.163
12 AS 2331 TD/TO
12 AS 2531 TO

For TE-ML List of

12 AS 2141 TD
Lubricants, refer to

9.5 ±1
23 ±2

60 ±6
60 ±6

60 ±6
60 ±6
12 AS 2341 TD transmission type plate.
12 AS 2541 TD/TO 18.5 dm3 23.0 dm3
12 AS 2741 TO
12 AS 2941 TO

16 AS 2231 TD
18.5 dm3 23.0 dm3
16 AS 2631 TO

1, 1a, 1b Oil drain location, transmission 5 Plug for oil overflow and oil fill after the oil change
2 Oil drain location, Intarder 6 Oil filler plug after repair
3 Suction filter 7 Screw for mounting the temperature sensor
4 Screws for mounting the suction filter

The correct oil quantity depends on the oil level check result after the test run (refer to Chapter 6.7, Oil fill).

EN 6093.758.101c - 2014-08 17
Technical Data

Truck Oil quantity after Tightening torque in [Nm]

Oil change Repair for position Filter Oil grade/
TraXon, transmission type approx. approx. 1 2 4 5 6 7 3 oil change intervals

Model range 12.1

12 TX 1411 TD 12 TX 2211 TD/TO
12 TX 1611 TD/TO 12 TX 2411 TO 19.0 dm3 22.5 dm3
12 TX 1811 TD/TO 12 TX 2611 TO

No.: 0501.215.163
12 TX 2011 TD/TO

Model range 12.2

For TE-ML List of
12 TX 2421 TD 12 TX 3021 TO
19.0 dm3 23.5 dm3 Lubricants, refer to
12 TX 2621 TD 12 TX 3221 TO

60 ±6

9.5 ±1
60 ±6

60 ±6
23 ±2

60 ±6
transmission type
12 TX 2821 TD/TO 12 TX 3421 TO
plate.

Model range 16
16 TX 1641 TD 16 TX 2441 TD
16 TX 1841 TD 16 TX 2641 TD 20.5 dm3 24.5 dm3
16 TX 2041 TD 16 TX 2841 TD
16 TX 2241 TD

1 Oil drain location, transmission 5 Plug for oil overflow and oil fill after the oil change
2 Oil drain location, Intarder 6 Oil filler plug after repair
3 Suction filter 7 Screw for mounting the temperature sensor
4 Screws for mounting the suction filter

The correct oil quantity depends on the oil level check result after the test run (refer to Chapter 6.7, Oil fill).

18 EN 6093.758.101c - 2014-08
 Technical Data

Buses Oil quantity after Tightening torque in [Nm]

Oil change Repair for position Filter Oil grade/
1,
Transmission type approx. approx. 1a, 1b 2 4 5 6 7 3 oil change intervals

AS Tronic
12 AS 2001 BO

No.: 0501.215.163
12 AS 2301 BO 19.0 dm3 22.5 dm3

12 AS 2701 BO
For TE-ML List of
Lubricants, refer to

9.5 ±1
60 ±6

60 ±6

23 ±2

60 ±6

60 ±6
EcoShift transmission type plate.
6 S 1311 BD/BO

6 S 1611 BD/BO 18.5 dm3 21.7 dm3

6 S 1911 BO

6 S 2111 BO

1, 1a, 1b Oil drain location, transmission 5 Plug for oil overflow and oil fill after the oil change
2 Oil drain location, Intarder 6 Oil filler plug after repair
3 Suction filter 7 Screw for mounting the temperature sensor
4 Screws for mounting the suction filter

The correct oil quantity depends on the oil level check result after the test run (refer to Chapter 6.7, Oil fill).

EN 6093.758.101c - 2014-08 19
Operation

5 Operation 5.1.1 Operation with Bremsomat function “B”

(Bremsomat operation is vehicle-dependent)
5.1 Operating functions
With the Bremsomat function “B”, you can keep your vehicle's
0 Intarder OFF speed constant at a desired value when driving downhill.
The Intarder electronics automatically set the required brake
B Automatic adjustment of the braking performance torque.
(Bremsomat) to the driving speed Upon actuation of the accelerator pedal, the Bremsomat
function is automatically interrupted and the current speed is
1-5 Manual setting of a defined brake torque set after the accelerator pedal is released.

Activating the Bremsomat function “B”

▪ Set the braking step lever in position “B”

0 0
B B
1 1
2 2
3
3
4 4
5 5
031020
Fig. 5.1 Fig. 5.2
031022

20 EN 6093.758.101c - 2014-08
 Operation

Deactivating the Bremsomat function “B” ▪ If, during downhill driving, the required braking
performance is higher than the currently available
▪ Operate accelerator pedal in position “B”. (As soon as
braking performance of the Intarder, then, the
accelerator pedal is no longer operated, Bremsomat is
engine or service brake must be activated in
reactivated at new current speed.)
addition.
or ▪ If the current driving speed is smaller than the set
speed, the Intarder will remain inoperable. Once the
▪ Set the braking step lever in
speed reaches the saved value again, the Intarder
– position 0 or
becomes active again.
– position 1 – 5 (= brake step mode)

0
B
1
2
3
4
5

031023
Fig. 5.3

EN 6093.758.101c - 2014-08 21
Operation

5.1.2 Operation in braking steps 1 – 5 Deactivating a braking step

▪ Set the braking step lever in
A defined brake torque is assigned to each of the braking
– position 0 or
levels 1 – 5. The defined braking performance increases from
– position B (= Bremsomat function).
1 to 5.
▪ If the required braking performance is higher than
Activating a braking step
the currently available braking performance of the
▪ Set the braking step lever in the desired position 1 – 5. Intarder, then, the engine or service brake must be
activated in addition.
▪ Consider the Intarder safety instructions.
0
B
1
2
3
4
5 0
B
1
2
031018
Fig. 5.4
3
4
5
031019
Fig. 5.5

22 EN 6093.758.101c - 2014-08
 Operation

5.2 Initial startup of the vehicle at low temperatures

5.2.1 Vehicle with ZF-Ecosplit 4 or ZF-EcoShift

Transmission below
temperature* down to –20 °C ‒20 °C to ‒40 °C ‒40 °C
-20°
-20° -40°
-40°

Oil grade according to approved ZF List of Lubricants TE-ML (refer to transmission type plate) Consultation with
OEM in case of
temperatures below
Engine start permitted permitted
–40 °C.
To be considered At transmission temperatures down to Warm-up phase of at least 15 minutes,
for starting –20 °C, the transmission is operable and with increased idling speed of approx.
all functions are provided. 1500 rpm.
Transmission in Neutral.
Alternatively, the transmission can be
preheated. This can e. g. be done using
hot air which must not exceed a
temperature of 110 °C on the transmission.
Do not heat on the mechanic
components, the EST electronic control
unit, and the Intarder heat exchanger.

Limitations Longer shifting times can be expected. Warm-up phase required.

* Transmission temperature may deviate from outside temperature.

EN 6093.758.101c - 2014-08 23
Operation

5.2.2 Vehicle with ZF-AS Tronic or TraXon

Outside temperature/
transmission down to ‒20 °C -20° ‒20 °C to ‒30 °C ‒30 °C to ‒40 °C
temperature*
-30°
-20°
-30° -40°

Oil grade according to approved ZF List of Lubricants TE-ML (refer to transmission type plate)

Engine start permitted permitted Transmission must be preheated

before the engine is started.

To be considered for At transmission temperatures Transmission in Neutral. This can be done e. g. using hot
starting down to –20 °C, the Warm-up phase of at least air which must not exceed
transmission is operable and all 15 minutes, with increased idling 110 °C on the transmission.
functions are provided. speed of approx. 1500 rpm. Do not heat at mechatronics
components and the EST
Intarder.

Limitations Longer shifting times are to be Warm-up phase required. ∙ Moving the vehicle is not
expected at temperatures permitted without preheating.
around –20 °C. ∙ Warm-up phase required.

* Transmission temperature may deviate from outside temperature.

24 EN 6093.758.101c - 2014-08
 Operation

5.2.3 Temperature influence on ZF-AS Tronic and 5.2.4 Storage of ZF-AS Tronic and TraXon
TraXon
The transmissions may be stored at temperatures between
Air leakage on the transmission system will significantly –40 °C and 80 °C. Standard corrosion protection is effective
increase at temperatures below –20 °C. It is not sure that for 6 months.
the clutch can be opened for the engine to start in this
temperature range. In this case, the engine-based starter must
be able to overcome the drag torque of the transmission in
addition to that of the engine. It is substantially influenced by
the temperature and the viscosity of the oil grades.

EN 6093.758.101c - 2014-08 25
Maintenance

6 Maintenance Check oil level:

▪ Stop and park the vehicle without actuating the Intarder.
This chapter REPLACES the respective chapters of
the basic transmission's Operating Instructions! ▪ Open oil overflow plug (5) (see Chapter 6.4 and 6.5).
▪ If the oil level has fallen below the oil overflow opening,
oil must be refilled through the oil overflow opening until it
6.1 Oil level check overflows.
Screw the oil overflow plug (5) back in with a new sealing
The following points are to be observed: ring (Tightening torques, see Chapter 4, Technical Data).
▪ To check the oil level, the Intarder must not be activated
anymore shortly before stopping the vehicle.
This ensures that the correct oil volume is reached in the
transmission.
▪ In order to avoid incorrect measurements, the oil level
check of the transmission with Intarder must be performed
when
– the vehicle is parked on level ground
– the engine is switched off, and
– the transmission oil has cooled down (< 40 °C).
▪ Check the oil level at regular intervals.
▪ Pay particular attention to possible leakages on:
– the transmission,
– the Intarder,
– the oil/coolant heat exchanger,
– corresponding coolant pipes.

26 EN 6093.758.101c - 2014-08
 Maintenance

6.2 Type plate 6.2.2 Type plate: EST electronic control unit

6.2.1 Type plate: ZF-Intarder Key data of the EST:

1. EST parts list [BoM] number
The type plate contains the Intarder’s key data. The type plate
2. Barcode, consisting of ZF no. and serial no.
is located on the side of the Intarder housing.
3. Data Matrix Code
The following information must always be stated when making
4. Intarder serial number
inquiries, placing orders, or carrying out repairs:
The Intarder serial number at the Intarder and EST type
1. Intarder type
plates must match.
2. Intarder version
3. Intarder parts list [BoM] number 5. General certification number by the Federal Motor
4. Intarder serial number Transport Authority
5. Intarder ratio 6. Customer number, if available
7. Software no.
ZF FRIEDRICHSHAFEN AG 8. EST serial number
MADE IN GERMANY 9. EST designation
1 2 1
MODEL 9
PARTS LIST NO. SERIAL NO. DMC
3 4 2
CUSTOMER DE STEUERUNG EST XX ZF-NR.6070 0XX XXX
SPEC. NO. 8 SER.NR. XXXXXXXX
TOTAL 5 SPEEDO 7 SOFTWARE NR. 6070 1XX XXX
RATIO 3
RATIO 6 KUNDEN NR. XXXXXX
n= xn
P.T.O. N ENGINE 24 VDC
OIL CAPACIT OIL GRADE SEE AGGREGAT INTARDER 3 SER.NR. XXXXXXXX 4
IN LITERS LUBRIC. LIST TE-ML
035590_2
5 E1 XX-XXXX ZF Friedrichshafen AG
Fig. 6.1 Sample ZF-Intarder type plate
10_001707_01_de

Fig. 6.2 Sample EST type plate

EN 6093.758.101c - 2014-08 27
Maintenance

6.3 Oil drain ▪ Park vehicle on level ground and turn off the engine.
▪ To drain the oil, unscrew the drain plugs on the trans-
mission (1a+1b) and the drain plug on the Intarder
housing (2).
Risk of burns!
Contact with hot transmission or hot transmission oil may ▪ After draining the oil, the drain plugs (solenoids) must be
result in burns. cleaned and the sealing rings replaced.
 Wear suitable protective clothing, protective gloves, and ▪ Fit new suction filter.
protective goggles/face protection.
▪ Subsequently, screw in drain plugs again.

The Intarder must NOT be actuated shortly before parking Observe the specified tightening torque for the drain plugs
the vehicle to change oil! in the Technical Data; otherwise, transmission damage may
This ensures that the correct oil quantity is reached in the occur!
transmission.

Please consider before changing the oil:

In the case of an oil change, the oil must be drained into
a suitable container and disposed of in an environmentally-
friendly manner.
As a basic principle: Change the oil after a long ride while the
transmission oil is still hot and thin-bodied.

28 EN 6093.758.101c - 2014-08
 Maintenance

6.4 Truck: oil drain, oil overflow, and oil filler plugs

6.4.1 ZF-Ecosplit 4

029495

2 3 1

029408

1 Oil drain location, transmission

2 Oil drain location, Intarder
3 Suction filter 6
4 Screws for mounting the suction filter
5 Oil overflow plug and oil fill after oil change
6 Oil filler plug after repair

Tightening torques (see Chapter 4, Technical Data)

029494

EN 6093.758.101c - 2014-08 29
Maintenance

6.4.2 ZF-AS Tronic

029407
3 029491_1
5
2 1b

1a/1b Oil drain locations, transmission

2 Oil drain location, Intarder
3 Suction filter
4 Screws for mounting the suction filter
5 Oil overflow plug and oil fill after oil change
6 Oil filler plug after repair

Tightening torques (see Chapter 4, Technical Data)

031021_1

1a

30 EN 6093.758.101c - 2014-08
 Maintenance

6.4.3 TraXon
2
36
1

035929_4

5
2 21

1 Oil drain location, transmission

10_001748_01

2 Oil drain location, Intarder

3 Suction filter
4 Screws for mounting the suction filter
5 Oil overflow plug and oil fill after oil change
6 Oil filler plug after repair

Tightening torques (see Chapter 4, Technical Data)

EN 6093.758.101c - 2014-08 31
Maintenance

6.5 Bus: oil drain, oil filler, and oil overflow plugs

6.5.1 ZF-AS Tronic

029491_1
3

2 1b
5

1a/1b Oil drain locations, transmission

029430

2 Oil drain location, Intarder

3 Suction filter
4 Screws for mounting the suction filter
5 Oil overflow plug and oil fill after oil change
6 Oil filler plug after repair
031021_1
Tightening torques (see Chapter 4, Technical Data)
1a

32 EN 6093.758.101c - 2014-08
 Maintenance

6.5.2 ZF-EcoShift
3 4

035544_2

2 1

035549_1

1 Oil drain locations, transmission

2 Oil drain location, Intarder
3 Suction filter 035543_3
4 Screws for mounting the suction filter
5 Oil overflow plug and oil fill after oil change

Tightening torques (see Chapter 4, Technical Data)

5

EN 6093.758.101c - 2014-08 33
Maintenance

6.6 Oil filter change

Drain oil before oil filter change (see Chapter 6.3, Oil drain).

Use new oil filter (order no. 0501.215.163) for each oil change. 3

Risk of burns!
Contact with hot transmission or hot transmission oil may result in 4
burns.
 Wear suitable protective clothing, protective gloves, and protective
goggles/face protection.

Ecosplit/AS Tronic/TraXon/EcoShift

▪ Unscrew screw(s) (4) from suction filter (3). 3

There is residual oil in the Intarder housing!

▪ Remove suction filter (3) from the Intarder housing.

3.1

▪ Grease O-rings (3.1) on the new suction filter (3).

▪ Insert new suction filter (3) into the housing.
▪ Fasten suction filter (3) with screws (4).
Tightening torques (see Chapter 4, Technical Data) 029490_1/029493

34 EN 6093.758.101c - 2014-08
 Maintenance

6.7 Oil fill

6.7.1 Oil fill after oil change

▪ Perform oil fill and oil level check on transmission and ▪ In addition, oil quantities for attached PTOs must be
Intarder only when the vehicle is parked on level ground considered.
and the engine is switched off.
▪ In the case of transmissions with a separately installed
▪ With a transverse installation angle it needs to be ensured Intarder heat exchanger, also consider the connecting
that the transmission is aligned in a position with a 0° pipes’ filling quantity.
transversal angle because, otherwise, the filling quantity
will not be correct.
▪ Use a new oil filter for each oil change.
Too little oil in the transmission will cause damage to the
▪ For oil grade and oil change intervals, refer to ZF List of transmission.
Lubricants TE-ML according to transmission type plate (see
Chapter 4, Technical Data).
▪ The specified oil quantities are reference values and may
vary depending on the installation angle and the trans- Risk of accident!
mission model. Too little oil in the transmission may lead to Intarder
failure.
▪ Oil quantity and tightening torques (see Chapter 4, Reduced or no braking action of the Intarder.
Technical Data).  Apply service brake.
 Continuation of travel with increased caution by using the
service brake.
 Repair transmission.

EN 6093.758.101c - 2014-08 35
Maintenance

▪ Open oil overflow plug (5) (also refer to Chapter 6.4 and
6.5).
▪ Fill transmission at pos. 5 until overflow. Correct performance of the oil fill process and oil level check
after the test run are crucial for ensuring the precise oil
▪ Screw in oil overflow plug (5) with sealing ring. volume.
▪ Perform a test drive (for at least 1 minute at a minimum With a separately installed heat exchanger, perform oil level
speed of 10 km/h). check within 5 minutes after the test run; otherwise, there is
At the start, briefly activate the Intarder (highest braking a risk of the heat exchanger running empty.
stage) and deactivate it again (position 0).
▪ Switch off the engine.
▪ Open oil overflow plug (5).
▪ Check oil level and, if necessary, fill up oil until overflow.
– Perform oil level check while transmission is hand-hot
(< 40 °C).
– The oil level is correct if the filling level reaches bottom
edge of overflow bore or when oil flows out of overflow
bore.
▪ Screw in oil overflow plug (5) with new sealing ring.

36 EN 6093.758.101c - 2014-08
 Maintenance

6.7.2 Oil fill after repairs ▪ In the case of transmissions with a separately installed
Intarder heat exchanger, also consider the connecting
▪ Perform oil fill and oil level check on transmission and pipes’ filling quantity.
Intarder only when the vehicle is parked on level ground
and the engine is switched off.
▪ With a transverse installation angle it needs to be ensured
that the transmission is aligned in a position with a 0° Too little oil in the transmission will cause damage to the
transversal angle because, otherwise, the filling quantity transmission.
will not be correct.
▪ For oil grade and oil change intervals, refer to ZF List of
Lubricants TE-ML according to transmission type plate (see
Chapter 4, Technical Data). Risk of accident!
Too little oil in the transmission may lead to Intarder
▪ The specified oil quantities are reference values and may
failure.
vary depending on the installation angle and the trans-
Reduced or no braking action of the Intarder.
mission model.
 Apply service brake.
▪ Oil quantity and tightening torques (see Chapter 4, Tech-  Continuation of travel with increased caution by using the
nical Data). service brake.
 Repair transmission.
▪ In addition, oil quantities for attached PTOs must be
considered.

EN 6093.758.101c - 2014-08 37
Maintenance

▪ Open oil filler plug (6).

▪ Fill transmission at pos. 6 until overflow.
Correct performance of the oil fill process and oil level check
▪ Screw in oil filler plug (6) with new sealing ring. after the test run are crucial for ensuring the precise oil
▪ Perform a test drive (for at least 1 minute at a minimum volume.
speed of 10 km/h). With a separately installed heat exchanger, perform oil level
At the start, briefly activate the Intarder (highest braking check within 5 minutes after the test run; otherwise, there is
stage) and deactivate it again (position 0). a risk of the heat exchanger running empty.

▪ Switch off engine.

▪ Open oil overflow plug (5).
▪ Check oil level and, if necessary, fill up oil until overflow.
– Perform oil level check while transmission is hand-hot
(< 40 °C).
‒ The oil level is correct if the filling level reaches bottom
edge of overflow bore or when oil flows out of overflow
bore.
▪ Screw in oil overflow plug (5) with new sealing ring.

38 EN 6093.758.101c - 2014-08
 Maintenance

6.8 Engine coolant 6.8.1 Monitoring and change intervals

Continuous monitoring of the coolant, at least every six

months, is very important.
▪ When refilling engine coolant, you must observe the What is commonly referred to as a density spindle or a
vehicle manufacturer’s instructions! Otherwise, the refractometer is used to determine the concentration of the
oil/coolant heat exchanger may be damaged! cooling agent in the coolant.
▪ In order to avoid heat exchanger damage, the following
limit values for the oil/coolant heat exchanger at operating Change interval of the engine coolant:
temperature must not be exceeded or fallen below: ▪ Observe change intervals of the vehicle and/or engine
– Maximum permitted coolant overpressure 3.5 bar manufacturer.
– Minimum required coolant overpressure 0.6 bar at
engine idling speed Consider in general:
▪ Since the coolant is subject to an aging process, the
▪ Engine coolant complete coolant quantities must be exchanged according
(mixture of freshwater and antifreeze-anticorrosive agent) to the vehicle manufacturer's specification.
Recommended quantity of antifreeze-anticorrosive agent:
▪ The coolant must be changed immediately in the event of
40 – 50 vol. %
sludge formation or an abrupt drop in concentration.
▪ Antifreeze-anticorrosive agent ▪ Check function of the coolant expansion tank.
Basic fluid: ethylene glycol with corrosion inhibitors (applies
▪ If the coolant expansion tank is opened at operating
in Europe and South Africa, but not worldwide)
temperature, coolant overpressure cannot build up anymore.
▪ Freshwater
pH value 6.5 – 8.5; total hardness < 20 °dH

EN 6093.758.101c - 2014-08 39
Maintenance

6.8.2 Draining residual coolant at heat exchanger

Risk of burns!
Contact with hot coolant may result in burns.
 Wear suitable protective clothing, protective gloves, and
protective goggles/face protection.

The residual coolant can be drained once the temperature

sensor has been removed.

▪ Remove screw (7).

▪ Take out temperature sensor (8).
▪ After draining the residual coolant, insert the temperature
sensor (8) with new O-ring and tighten with screw (7).
Tightening torque (see Chapter 4, Technical Data)
7 8
029492
Fig. 6.3 Temperature sensor on the heat exchanger

40 EN 6093.758.101c - 2014-08
 Maintenance

6.9 Bleeding the ZF-Intarder

Pressure differences are compensated for via the trans-

mission’s bleeder valve.

For this, please consult the respective chapter of the trans-

mission’s operating instructions.

EN 6093.758.101c - 2014-08 41
ZF Friedrichshafen AG

EN 6093.758.101c - 2014-08
88038 Friedrichshafen
Deutschland · Germany
Telefon/Phone +49 7541 77-0
Telefax/Fax +49 7541 77-908000
www.zf.com