ZF-Intarder The Powerful

Continuous Brake for Medium and Heavy Trucks

H. Kato
TT
ZF Friedrichshafen AG

2015-09-18

TT, Intarder Training, Public

ZF Friedrichshafen AG, 2014

Development
Retarder Systems for Commercial Vehicles
System

ZF-Retarder
Hydrodynamic
auxiliary brake

ZF-Intarder
First
generation

ZF-Intarder
Second
generation

ZF-Intarder
Third
generation

Heavy truck
Medium truck

Heavy truck
Medium truck

Heavy truck
Medium truck

Heavy truck
Medium truck

Coach

Coach
Intercity bus

Coach
Intercity bus

Coach
Intercity bus

Principle

Dual flow

Single flow

Single flow

Single flow

Operating modes

Manual, 1 automatic

Manual, 3 automatic

Manual, 3 automatic

Manual, 3 automatic

Max. brake torque [Nm]

2 500

3 200

3 200

4 000

Max. braking performance [kW]

300

420

500

600

1987

1993

2000

2006

Application

2015-09-18

TT, Intarder Training, Public

ZF Friedrichshafen AG, 2014

Product Data

Operating Modes

Bremsomat Bremsomatic Bremsomatic + Tempomat

(cruise control)

Braking stages

Brake torque [Nm]

AS Tronic:
4 000 (Power) or 3 300 (Eco)
Ecosplit (4th generation): 3 500

Brake power [kW]

Max. 600 (short-time)

Idle speed performance (1 500rpm)

1.4 kW (Power); 1.1 kW (Eco)

Noise [db(A)]

80

Weight of Intarder unit [kg]

Approx. 70 (depending on version)

Operating principle

Hydrodynamic hydraulic brake

Control unit

Electronic (CAN communication)

Oil supply

Together with the transmission

Cooling and heating function

Via the vehicle cooler for the transmission and the Intarder

Compatibility

With ABS systems, EBS

Release

According to the Directive on the Transportation of

Hazardous Goods (GGV)

2015-09-18

TT, Intarder Training, Public

ZF Friedrichshafen AG, 2014

Installation Dimensions
Ecosplit With ZF-Intarder
A

305

484

SAE 1

301

2015-09-18

300

TT, Intarder Training, Public

ZF Friedrichshafen AG, 2014

Brake Torque Chart

Ecosplit With ZF-Intarder
4 500
4 000

Max. brake torque

600 kW

3 500

Brake torque TOutput [Nm]

3 000
2 500
2 000
1 500
1 000
500
0
0

2015-09-18

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40

60
80
Velocity v [km/h]

100

120

ZF Friedrichshafen AG, 2014

The Highlights
ZF-Intarder for the modern truck
Integrated retarder system
Optimal scope of effect
Fading and wear-free braking
Integration in brake management
Up to 90 percent of all braking with Intarder.
No interruption of brake power when changing
gears
Quiet operation!

2015-09-18

TT, Intarder Training, Public

ZF Friedrichshafen AG, 2014

System Comparison

Primary braking and retarder systems

Secondary retarder systems

All types of engine brakes

All electric or hydraulic retarders

between transmission and axle

All engine-side retarders

Pritarder (MAN)

Telma
Voith R133 / R115
Water retarder (Voith)
ZF-Intarder

Features

Features

No braking action when changing gears

No interruption of the brake power

Braking performance depends upon the engine speed

Braking performance depends on the propshaft speed

Quiet operation

2015-09-18

TT, Intarder Training, Public

ZF Friedrichshafen AG, 2014

System Comparison
Brake Power

Brake power [N]

ZF-Intarder

Primary systems

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

Vehicle speed [km/h]

8

2015-09-18

TT, Intarder Training, Public

ZF Friedrichshafen AG, 2014

A View Into the Retarder System

ZF-Intarder unit
Heat exchanger

Propshaft

Display
Basic transmission
(here: AS Tronic)
9

2015-09-18

TT, Intarder Training, Public

Brake step selector lever

(Steering-column switch)

ZF Friedrichshafen AG, 2014

Communication in the Driveline

Connection to the truck's CAN system with conventional setup

Engine control
(EDC)

Transmission, e.g.
AS Tronic

Intarder
control

Brake control
ABS/EBS

Vehicle CAN

10

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ZF Friedrichshafen AG, 2014

Structure

Hydraulic control unit

Solenoid valves

On-site electronics
Stainless steel heat exchanger

Stator
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Rotor

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Step-up gear

Hydraulic pump
ZF Friedrichshafen AG, 2014

Mode of Operation - Intarder

The Intarder's drive

Step-up gear
Output shaft

Output shaft
Stator
Oil flow
Rotor

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Cooling Circuit

Cooling water circuit between the Intarder and the engine

Engine heat exchanger

Oil circuit between the

Intarder and the transmission
Intarder heat exchanger

Intarder heat exchanger

13

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The "Heating Circuit"

Cooling water circuit between the Intarder and the engine

Engine heat exchanger

Oil circuit between the

Intarder and the transmission
Intarder heat exchanger

Intarder heat exchanger

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Mode of Operation - Control Unit

2
4
5

3
1

15

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ZF Friedrichshafen AG, 2014

Hydraulic diagram

16

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TT, Intarder Training, Public

ZF Friedrichshafen AG, 2014

Hydraulic diagram

17

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ZF Friedrichshafen AG, 2014

Position of components

18

2015-09-18

TT, Intarder Training, Public

ZF Friedrichshafen AG, 2014

ZF-Intarder
ZF-Ecofluid M
The plus thanks to ZF-Ecofluid M:
Extended oil change intervals
Reduced oil consumption
Reduced costs for lubrication

19

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TT, Intarder Training, Public

ZF Friedrichshafen AG, 2014

Diagnosis
Actions:
Basic diagnosis with TESTMAN via OBD2-plug inside cabin:
Fill out Intarder check list
Read out and save statistic data of Intarder
Read out error memory and delete afterwards
ECU identification (Check Intarder SN with Type plate and EST52 Type plate and check software)
To order EST52, Intarder SN is necessary.

*SN = Serial Number

20

2015-09-18

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ZF Friedrichshafen AG, 2014

Brake power limitation

The maximum brake torque is limited by several influencing factors such as;
Coolant Temperature (Permitted temperature is 105)
ECU Temperature (The limitation starts at 132 ECU temperature)
Oil Temperature (By reaching oil temperature or 170 the available brake power will be reduced.)
Too wide Difference between Oil and Coolant temperature
(If the temperature difference exceeds 108 the brake power will be reduced.)
Too high Output Shaft Speed (A reduction starts at 2600 rpm output shaft speed.)
Engine idle protection (Below 860 rpm engine speed the maximum brake power is limited.)
Engine load (If the acceleration is applied, the maximum available brake power is reduced.)

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ZF Friedrichshafen AG, 2014

Brake power limitation

Operation mode (Brake torque requests are only executed in normal operation mode.)
Error reaction (If a severe error occurs, the brake torque is limited to 0 Nm.)
TSC1 ABS/EBS Limitation
Small Brake Torques (Brake torque requests below 200Nm cannot be executed.)
Small output shaft speed
(The control current is limited for output shaft speeds close to the vehicle standstill.)

22

2015-09-18

TT, Intarder Training, Public

ZF Friedrichshafen AG, 2014

Thank you fr your attention

ZF Friedrichshafen AG behlt sich smtliche Rechte an den gezeigten technischen Informationen einschlielich der Rechte zur Hinterlegung von Schutzrechtsanmeldungen und an daraus entstehenden Schutzrechten im In- und Ausland vor.
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ZF Friedrichshafen AG reserves all rights regarding the shown technical information including the right to file industrial property right applications and the industrial property rights resulting from these in Germany and abroad.

2014