F544

C907
C906
B089
A100
HD-OBD
B088
E593
CAN
network
CF75 IV
CF85 IV
XF105
System and component information
ZF intarder EST 42

200634 DW
200634 DAF Trucks N.V., Eindhoven, The
Netherlands.
In the interest of continuing product development,
DAF reserves the right to change specifications
or products at any time without prior notice.
No part of this publication may be reproduced
and/or published by printing, by photocopying, on
microfilm or in any way whatsoever without the
prior consent in writing of DAF Trucks N.V.
STRUCTURE

200634
75 /85 , 105 series
0
1
Structure
TECHNICAL DATA
ZF INTARDER EST 42

200634 1
Contents
TECHNICAL DATA
75 /85 , 105 series
0
Technical data
CONTENTS
Page Date
1. ZF INTARDER EST 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. . . . . 200634
1.1 Power supply and earth of electronic unit . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. . . . . 200634
1.2 CAN connections electronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. . . . . 200634
1.3 K-line electronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. . . . . 200634
1.4 Steering column switch / Steering wheel switches . . . . . . . . . . . . . . . . . . 1-4. . . . . 200634
1.5 Coolant temperature sensor, intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. . . . . 200634
1.6 Neutral position switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8. . . . . 200634
1.7 Intarder proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9. . . . . 200634
1.8 Intarder air supply valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11. . . . 200634
2

200634
TECHNICAL DATA
Contents 75 /85 , 105 series
0

200634 1-1
ZF intarder EST 42
TECHNICAL DATA
75 /85 , 105 series
0
1. ZF INTARDER EST 42
1.1 POWER SUPPLY AND EARTH OF ELECTRONIC UNIT
55 54 53 49 44 42 37 34 31 30 29 52
28 27 22 20 18 16 15 9 1
V300601
2 3 4 14
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat =battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F 'X' mark indicates that additional information is available in 'Technical data'
A B C D E F
20 Earth
(In combination with manual gearbox in-
put signal neutral position switch E593)
<0,5 V DC Voltage loss measurement with as
many consumers as possible
switched on.
27 Earth <0,5 V DC Voltage loss measurement with as
many consumers as possible
switched on.
28 Earth <0,5 V DC Voltage loss measurement with as
many consumers as possible
switched on.
31 Power supply after contact Ubat V DC Ignition on
53 Power supply after contact Ubat V DC Ignition on
54 Power supply before ignition Ubat V DC
55 Power supply before ignition Ubat V DC
1-2

200634
TECHNICAL DATA
ZF intarder EST 42 75 /85 , 105 series
0
1.2 CAN CONNECTIONS ELECTRONIC UNIT
55 54 53 49 44 42 37 34 31 30 29 52
28 27 22 20 18 16 15 9 1
V300601
2 3 4 14
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat =battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F 'X' mark indicates that additional information is available in 'Technical data'
A B C D E F
22 V-CAN2-H According to ISO 11898
49 V-CAN2-L According to ISO 11898

200634 1-3
ZF intarder EST 42
TECHNICAL DATA
75 /85 , 105 series
0
1.3 K-LINE ELECTRONIC UNIT
55 54 53 49 44 42 37 34 31 30 29 52
28 27 22 20 18 16 15 9 1
V300601
2 3 4 14
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat =battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F 'X' mark indicates that additional information is available in 'Technical data'
A B C D E F
14 HD-OBD diagnostic connector (A100)
1-4

200634
TECHNICAL DATA
ZF intarder EST 42 75 /85 , 105 series
0
1.4 STEERING COLUMN SWITCH / STEERING WHEEL SWITCHES
55 54 53 49 44 42 37 34 31 30 29 52
28 27 22 20 18 16 15 9 1
V300601
2 3 4 14
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat =battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F 'X' mark indicates that additional information is available in 'Technical data'
A B C D E F
15 Steering column switch position 1 input
signal
0 VDC If switch not operated
Ubat VDC If switch is in position 1
Ubat VDC If switch is in position 2
Ubat VDC If switch is in position 3
16 Steering column switch position 3 input
signal
0 VDC If switch not operated
0 VDC If switch is in position 1
0 VDC If switch is in position 2
Ubat VDC If switch is in position 3
42 Steering column switch position 2 input
signal
0 VDC If switch not operated
0 VDC If switch is in position 1
Ubat VDC If switch is in position 2
Ubat VDC If switch is in position 3

200634 1-5
ZF intarder EST 42
TECHNICAL DATA
75 /85 , 105 series
0
Downhill Speed Control function
V301054
100%
66%
33%
0%
Position - 0 intarder off
Position - 1 33% braking power
Position - 2 66% braking power
Position - 3 100% braking power
K102020
1 3 5
2 4 6
Downhill Speed Control 0% - 100% braking power
1-6

200634
TECHNICAL DATA
ZF intarder EST 42 75 /85 , 105 series
0
1.5 COOLANT TEMPERATURE SENSOR, INTARDER
55 54 53 49 44 42 37 34 31 30 29 52
28 27 22 20 18 16 15 9 1
V300601
2 3 4 14
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat =battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F 'X' mark indicates that additional information is available in 'Technical data'
A B C D E F
9 Input signal, coolant temperature (F544) 5 V DC Open voltage, with detached connec-
tor
X
37 Earth, coolant temperature sensor
(F544)
<0,5 V DC

200634 1-7
ZF intarder EST 42
TECHNICAL DATA
75 /85 , 105 series
0
Resistance in relation to measured temperature
V300589
Model NTC
Temperature (C) Resistance ()
Minimum Maximum
20 - 25 33000 47000
80 3300 3700
90 2400 2600
100 1650 1750
110 1250 1350
120 950 1050
130 700 800
140 550 590
1-8

200634
TECHNICAL DATA
ZF intarder EST 42 75 /85 , 105 series
0
1.6 NEUTRAL POSITION SWITCH
55 54 53 49 44 42 37 34 31 30 29 52
28 27 22 20 18 16 15 9 1
V300601
2 3 4 14
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat =battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F 'X' mark indicates that additional information is available in 'Technical data'
A B C D E F
20 Input signal neutral position switch
(E593)
Ubat V DC Gearbox in neutral
<0,5 V DC Gear box in gear
Model Normally Open

200634 1-9
ZF intarder EST 42
TECHNICAL DATA
75 /85 , 105 series
0
1.7 INTARDER PROPORTIONAL VALVE
55 54 53 49 44 42 37 34 31 30 29 52
28 27 22 20 18 16 15 9 1
V300601
2 3 4 14
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat =battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F 'X' mark indicates that additional information is available in 'Technical data'
A B C D E F
3 Earth, proportional valve (B088) <0,5 V DC X
4 Output signal, proportional valve (B088) - % (I) Duty cycle (control current) depends
on the switch position selected
X
1-10

200634
TECHNICAL DATA
ZF intarder EST 42 75 /85 , 105 series
0
Readings
V300603
Resistance of intard-
er proportional valve
at 20 to 25C 23 - 27
The following table lists the proportional valve
control currents and the accompanying pressures
in the intarder.
Control current with defective coolant tempera-
ture sensor or with temperature >120C 250 15 mA
Switch position Control current Control pressure Intarder pressure Pump pressure
0 0 - 15 mA 0 bar 1.5 bar 1.5 bar
Downhill Speed
Control
0 - 425 15 mA 0 - 5.5 1 bar 1.5 - 10.25 1 bar 10.5 1 bar
1 255 15 mA 2.0 1 bar 3.0 1 bar 10.5 1 bar
2 320 15 mA 3.0 1 bar 5.5 1 bar 10.5 1 bar
3 430 15 mA 5.0 1 bar 10.0 1 bar 10.5 1 bar

200634 1-11
ZF intarder EST 42
TECHNICAL DATA
75 /85 , 105 series
0
1.8 INTARDER AIR SUPPLY VALVE
55 54 53 49 44 42 37 34 31 30 29 52
28 27 22 20 18 16 15 9 1
V300601
2 3 4 14
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat =battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F 'X' mark indicates that additional information is available in 'Technical data'
A B C D E F
1 Output signal air supply valve (B089) Ubat V DC Valve activated
34 Earth air supply valve (B089) <0,5 V DC
1-12

200634
TECHNICAL DATA
ZF intarder EST 42 75 /85 , 105 series
0
V300446
Resistance of intard-
er air supply valve at
20 to 25C 125 - 145
Required air pres-
sure 6.3 - 10 bar

200634 1
Contents
ZF INTARDER EST 42
75 /85 , 105 series
1
ZF intarder EST 42
CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. . . . . 200634
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. . . . . 200634
2. SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. . . . . 200634
2.1 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. . . . . 200634
2.2 Hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. . . . . 200634
2.3 Intarder switched off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6. . . . . 200634
2.4 Switching the intarder on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7. . . . . 200634
2.5 Intarder switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9. . . . . 200634
2.6 Switching the intarder off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11. . . . 200634
3. DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. . . . . 200634
3.1 Control switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. . . . . 200634
3.2 Coolant temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. . . . . 200634
3.3 Neutral position switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. . . . . 200634
3.4 Intarder proportional valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. . . . . 200634
3.5 Intarder air supply valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. . . . . 200634
3.6 Volume control valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8. . . . . 200634
3.7 Freewheeling torque reducing system. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9. . . . . 200634
4. CONTROL FUNCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. . . . . 200634
4.1 Limitation of power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. . . . . 200634
4.2 Downhill Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. . . . . 200634
4.3 Temperature adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. . . . . 200634
4.4 Control with activated ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. . . . . 200634
4.5 Control via CAN network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10. . . . 200634
5. DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. . . . . 200634
5.1 Hydraulics diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. . . . . 200634
5.2 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. . . . . 200634
2

200634
ZF INTARDER EST 42
Contents 75 /85 , 105 series
1

200634 1-1
General
ZF INTARDER EST 42
75 /85 , 105 series
1
1. GENERAL
1.1 INTRODUCTION
This system manual describes the layout,
operation and control of the ZF intarder EST42.
The intarder is a wear-resistant, hydraulic
continuous brake. It is primarily intended for use
in prolonged braking, for example when
decelerating from high speed on a level road or
when driving downhill. This reduces service
brake wear. The intarder can be switched on with
the right-hand steering column switch.
The main functions of the ZF intarder EST42 are:
1. Continuous operation of a wear-resistant
vehicle brake. When driving on a level road
or when driving downhill, the intarder can be
used to slow down the vehicle without using
the service brake, depending on the selected
level for the (constant) braking moment. This
will relieve the service brake.
2. Downhill Speed Control function The
Downhill Speed Control function of the
intarder can be used to achieve a constant
vehicle speed (within the system limits) when
driving downhill.
3. Communication with other vehicle systems
to guarantee the optimum braking effect.
1-2

200634
ZF INTARDER EST 42
General 75 /85 , 105 series
1

200634 2-1
System description
ZF INTARDER EST 42
75 /85 , 105 series
1
2. SYSTEM DESCRIPTION
2.1 ELECTRICAL SYSTEM
The electrical section of the intarder consists of
the electronic unit EST 42 and a number of
components which provide input signals and a
number of components which are controlled
depending on the input signals.
A number of control functions have been
programmed in the electronic unit. For example:
1. Limitation of power
2. temperature control
3. Control with activated ABS
4. Downhill Speed Control
5. Control via CAN
In order to be able to perform the control
functions, the electronic unit EST 42 requires
various input signals and the electronic unit will
control various components.
V301052
F544
C907
C906
B089
A100
HD-OBD
B088
E593
CAN
network
2-2

200634
ZF INTARDER EST 42
System description 75 /85 , 105 series
1
Input signals
- Intarder steering column switch positions
(C906/C907)
- Gearbox neutral position (E593)
- Downhill Speed Control (via V-CAN2)
- Coolant temperature intarder (F544)
Output signals
- Intarder air supply valve (B089):
- Proportional valve (B088)
EST 42 communicates via V-CAN2 with various
other vehicle systems.
EST 42 is diagnosed using DAVIE XD via a K-
line.

200634 2-3
System description
ZF INTARDER EST 42
75 /85 , 105 series
1
2.2 HYDRAULIC SYSTEM
The hydraulic section of the intarder consists of a
housing which is mounted behind the gearbox.
The hydraulic system is controlled and regulated
by the electrical system.
2-4

200634
ZF INTARDER EST 42
System description 75 /85 , 105 series
1
8
2
V300602
1
4
3
5
7
6
9
10
1 Oil pump pressure control valve
2 Selector valve spring sealing plug

200634 2-5
System description
ZF INTARDER EST 42
75 /85 , 105 series
1
3 Accumulator
4 Heat exchanger
5 Control plunger for proportional solenoid
valve
6 Stator and rotor
7 Oil pump gear wheels
8 Freewheeling torque reduction ring
segment
9 Freewheeling torque reduction control
plunger
10 Residual pressure valve
2-6

200634
ZF INTARDER EST 42
System description 75 /85 , 105 series
1
2.3 INTARDER SWITCHED OFF
When the intarder is switched off, the steering
column switch is in position 0 (zero position).
The proportional valve (8) is not energised by the
electronic unit; the pressure in the intarder circuit
is 0 bar (there is no oil in the intarder circuit). This
means that the pressure between the control
plungers of the freewheeling torque reducing
system (10) is also 0 bar. The ring segments of
the freewheeling torque reducing system are now
situated between the stator and rotor and thus
reduce the friction in the drive line.
The intarder oil pump (3) pumps the oil via the
selector valve (13) to the heat exchanger (16)
and into the accumulator (11). The accumulator is
filled with oil until a maximum pressure of 1.5 bar
is reached, this pressure being limited by the
residual pressure valve (14). The output of the oil
pump (3) depends on the vehicle speed. After the
intarder has been switched off, the accumulator
(11) will be completely full when approximately
500 metres have been covered.
Any excess oil goes back to the gearbox oil
reservoir. When the accumulator (11) is full, the
gearbox oil is pumped through the heat
exchanger (16). In this way the gearbox oil is
continuously cooled.
1
2
3
4
5
6
7
8
9
11
12
13
10
14
15
16
17
18
19
1 2
Q
1
2
1 2
V300582

200634 2-7
System description
ZF INTARDER EST 42
75 /85 , 105 series
1
2.4 SWITCHING THE INTARDER ON
The steering column switch can be used to switch
the intarder on and to select the desired braking
moment. The electronic unit then activates the
following components:
- the proportional valve (8). The current
supplied by the electronic unit depends on
the desired braking moment. The control
pressure is set by means of the proportional
valve.
- the intarder air supply valve (12). The air
pressure (max. 10 bar) pumps the oil out of
the accumulator into the intarder circuit.
Further control is completely hydraulic.
The proportional valve (8) sets a control pressure
that depends on the current supplied by the
electronic unit. Two valves are actuated on the
basis of this control pressure, viz.:
1
2
3
4
5
6
7
8
9
11
12
13
14
15
16
17
18
19
1 2
Q
1
2
1 2
V300596
10
2-8

200634
ZF INTARDER EST 42
System description 75 /85 , 105 series
1
1. the selector valve (13). The control pressure
switches the selector valve (13) directly. This
valve being switched results in a so-called
intarder circuit. Now the oil runs from the
rotor/stator via the selector valve (13) to the
heat exchanger and then back again to the
rotor/stator via the selector valve (13).
2. the volume control valve (9). The control
pressure determines the position of the
valve. This position ensures that the oil pump
can actually pump oil into the intarder circuit.
In the intarder circuit a pressure is built up
and this intarder pressure, the control
pressure and a preset spring pressure
determine the position of the valve.

200634 2-9
System description
ZF INTARDER EST 42
75 /85 , 105 series
1
2.5 INTARDER SWITCHED ON
If the intarder is switched on, the electronic unit
supplies a constant current to the proportional
valve (8). As a result, this valve also supplies a
constant control pressure to the selector valve
(13). Owing to this control pressure, the pump
pressure, the spring pressure and the pressure in
the intarder circuit, the volume control valve (9)
reaches a state of balance.
The pressure in the intarder circuit determines
the braking power supplied by the intarder. This
pressure depends on the degree of filling and the
rpm, so that the volume control valve (9) will
constantly search a state of balance via the
speed range. If the intarder is switched on, only
part of the total quantity of oil in the gearbox is
pumped through the heat exchanger (16).
The pressure in the intarder circuit also exists in
the freewheeling torque reducing system (10).
The ring segments between the stator and rotor
are now pushed out, so that they no longer affect
the braking effect of the intarder.
1
2
3
4
5
6
7
8
9
11
12
13
14
15
16 10
17
18
19
1 2
Q
1
2
1 2
V300597
2-10

200634
ZF INTARDER EST 42
System description 75 /85 , 105 series
1
Changing to another brake position
If another braking moment is desired via the
operating handle, the electronic unit will vary the
current to the proportional valve (8). As a result,
the proportional valve (8) supplies an altered
control pressure, so that the volume control valve
(9) takes on a new balanced position. This will
change the oil pressure in the intarder circuit,
resulting in the desired braking moment.
While the intarder is in use, the intarder air supply
valve (12) stays activated so that there is still air
pressure on the accumulator (11).
As long as there is oil pressure in the stator/rotor
circuit, the ring segments of the freewheeling
torque reducing system are not positioned
between the stator and rotor.

200634 2-11
System description
ZF INTARDER EST 42
75 /85 , 105 series
1
2.6 SWITCHING THE INTARDER OFF
When the intarder is switched off, the air supply
valve (12) is no longer energised. As a result, the
accumulator (11) is bled and once again
completely filled with oil.
The proportional valve (8) is no longer controlled
by the electronic unit, so that there is no control
pressure on the selector valve (13). The selector
valve (13) becomes pressureless and is pressed
in such a position by the pre-tensioned spring that
no more oil is pumped into the intarder circuit.
The remaining oil leaves the intarder circuit via
the volume control valve (9). The oil is then only
pumped through the heat exchanger (16). Air is
all that is left in the intarder circuit.
The oil pressure in the freewheeling torque
reducing system (10) falls away as well.
The spring tension causes the control plungers
and therefore also the ring segments to move in
between the stator and rotor. The air flow
between the stator and rotor is blocked, which
reduces the friction loss moment.
1
2
3
4
5
6
7
8
9
11
12
13
10
14
15
16
17
18
19
1 2
Q
1
2
1 2
V300582
2-12

200634
ZF INTARDER EST 42
System description 75 /85 , 105 series
1

200634 3-1
Description of components
ZF INTARDER EST 42
75 /85 , 105 series
1
3. DESCRIPTION OF COMPONENTS
3.1 CONTROL SWITCHES
When the vehicle is equipped with an intarder,
then the vehicle is always fitted with one of the
two steering column switches illustrated in
combination with steering wheel switches.
Switching the intarder on
The intarder is switched on by moving the right-
hand steering column switch downwards from the
rest position (OFF). The intarder has three
positions (1, 2 and 3). The Downhill Speed
Control must be activated via a steering wheel
switch.
The division of the maximum braking effect of the
intarder is as follows:
V301043
1
2
3
V301044
1
2
3
K102020
1 3 5
2 4 6
Rest position
(OFF)
Intarder not
active
Brake position
1:
approx. 33% of
the maximum
braking effect.
Brake position
2:
approx. 66% of
the maximum
braking effect.
Brake position
3:
the maximum
braking effect
(with the as-
sistance of the
engine brake).
Downhill
Speed Control
0 to 100%
braking effect.
3-2

200634
ZF INTARDER EST 42
Description of components 75 /85 , 105 series
1
Note:
If the warning indicator '"(( ))" on the instrument
panel lights up, the intarder is activated.
Switching the intarder off
The intarder is switched off by moving the
steering column switch upwards into its rest
position (OFF).
Engaging Downhill speed control
The Downhill Speed Control is activated by
pressing the spring-operated switch (5) on the
left-hand steering column switch. When the
intarder is switched on in the Downhill Speed
Control, the intarder will not allow the vehicle to
go faster than the speed it was doing when it was
switched on.
Disengaging Downhill speed control
Press steering wheel switch (6) to deactivate
Downhill Speed Control.
V300611
R
K102020
1 3 5
2 4 6

200634 3-3
Description of components
ZF INTARDER EST 42
75 /85 , 105 series
1
3.2 COOLANT TEMPERATURE SENSOR
The coolant temperature sensor is an NTC
resistor. The resistance decreases as the
temperature increases. The coolant temperature
at the output side of the cooler is monitored with
the aid of this sensor. If the coolant temperature
is too high the maximum available intarder
braking moment is adjusted. See "Technical
data". A special control in the electronic unit of the
intarder is put into operation before the maximum
permissible temperature is reached so that the
braking moment is adjusted.
V300589
3-4

200634
ZF INTARDER EST 42
Description of components 75 /85 , 105 series
1
3.3 NEUTRAL POSITION SWITCH
The neutral position switch (E593) is fitted on the
gearbox gearshift cover.
If a gear is engaged, the selector shaft (5) is in
such a position that pin 4, its contact surface
against the pressure of spring 3, links
connections 1 and 2. The neutral position switch
is now closed and an earth signal is therefore
sent. This signal can be used for various vehicle
systems or functions (intarder, engine
management, cruise control, engine speed
control).
The table below lists the statuses of the neutral
position switch.
V300612
2
4
3
1
5
Gearbox Neutral position switch
Neutral Open
Gear engaged Closed

200634 3-5
Description of components
ZF INTARDER EST 42
75 /85 , 105 series
1
3.4 INTARDER PROPORTIONAL VALVE
This valve converts the control current supplied
by the electronic unit into a control pressure in the
intarder housing. The proportional valve consists
of two parts: a solenoid valve and a control
plunger.
The solenoid valve is located on the outside of the
intarder housing.
The control plunger is located inside the intarder
housing.
The solenoid valve is a duty-cycle controlled
valve. This means that the control current gets
higher as the duty cycle increases.
Inside the solenoid valve there is a core.
The force with which the core is pressed out of
the coil depends on the duty-cycle value (control
current).
The core pushes against the control plunger of
the proportional valve.
V300603
V300604
3-6

200634
ZF INTARDER EST 42
Description of components 75 /85 , 105 series
1
Operation of control plunger
The control plunger (7) of the proportional valve is
located inside the intarder housing.
When the proportional valve is not in operation,
the control plunger (7) is in its extreme right
position.
The pump pressure side (1) is cut off from the
control pressure side (2) and the return side (3) is
connected to the control pressure side (2).
When the solenoid valve (5) presses the core (6)
to the left, the core in its turn will press the control
plunger (7) to the left.
The pump pressure side (1) is connected to the
control pressure side (2) and the return side (3) is
cut off. The control pressure increases.
The pressure in the control pressure side (2) can
reach the enclosed space (8) to the left of the
control plunger (7) via a bore (4) in the control
plunger (7).
The control pressure on the left-hand side of the
control plunger (7) and the force exerted by the
core (6) on the right-hand side of the control
plunger (7) create a state of balance so that the
control pressure is adjusted.
1 2 3
7
5
4 8
6
V300251

200634 3-7
Description of components
ZF INTARDER EST 42
75 /85 , 105 series
1
3.5 INTARDER AIR SUPPLY VALVE
This valve is an electropneumatic 3/2-way valve.
This valve is used to pass on the air pressure
from the air supply system to the accumulator.
As a result, the intarder responds more quickly so
that braking power is available to the driver right
away.
When the intarder is switched on, the electronic
unit energises the air supply valve.
The air pressure sets the piston in the
accumulator in motion. The piston presses the oil
out of the accumulator and forces it into the
intarder circuit.
When the intarder is switched off the air supply
valve is no longer energised.
The oil pressure will cause the piston to move
upward.
The air above the piston can escape into the air
supply valve via a bore.
V300446
3-8

200634
ZF INTARDER EST 42
Description of components 75 /85 , 105 series
1
3.6 VOLUME CONTROL VALVE
The volume control valve consists of a plunger (8)
and a control plunger (9).
In rest position, the spring (7) presses the control
plunger (9) in its extreme left position. The return
side (1) is connected to the intarder pressure side
(2).
The pump pressure side (3) is cut off from the
intarder pressure side (2). In this way the intarder
pressure side (2) is pressureless.
When there is a control pressure on the left-hand
side of the control plunger (9), the control plunger
(9) is pushed to the right, against the spring
pressure. The pump pressure side (3) is now
connected to the intarder pressure side (2) and
the return side (1) is cut off.
This causes the pressure on the intarder
pressure side (2) to increase. The intarder
pressure (2) can get into the control plunger (9)
via bore 6 in the control plunger (9). The pressure
in the control plunger (9) and the force exerted by
spring 7 cause the control plunger (9) to move to
the left against the control pressure, until it
reaches a state of balance.
In this way it is possible to control the intarder
pressure and the resulting braking moment.
1 2
7 4 9 8 6
3 1 5
V300252

200634 3-9
Description of components
ZF INTARDER EST 42
75 /85 , 105 series
1
3.7 FREEWHEELING TORQUE REDUCING SYSTEM
The freewheeling torque reducing system
consists of a double control plunger (4) with
spring (1) and two ring segments (5) that hinge on
pivot points (2). The pivot points (2) are located
inside the intarder housing (12).
5
2
5
2
8
9
1 4 4 1 7
12
V300609
3-10

200634
ZF INTARDER EST 42
Description of components 75 /85 , 105 series
1
Both ring segments (5) are located between the
stator (9) and the rotor (8). When the intarder is
switched on and off, the oil pressure moves the
ring segments (5) parallel to the stator and the
rotor. The ring segments (5) are mechanically
connected to the control plungers (4).
V300608
10
8
11
2
3 6
5
4
9

200634 3-11
Description of components
ZF INTARDER EST 42
75 /85 , 105 series
1
Intarder not switched on
If the intarder is not switched on, all the oil has
disappeared from the intarder circuit and the
intarder circuit is pressureless. The pressure
exerted by the springs (1) causes the control
plungers (4) of the freewheeling torque reducing
system to move inwards.
The ring segments (5) have a cam on the
underside, which falls into a recess in the plunger
(4). In this way the moving plunger carries the ring
segment along.
The ring segments move between the stator and
rotor, impeding the air flow between the rotor and
stator. The friction between the stator and rotor
decreases, reducing the friction losses in the
drive.
Intarder switched on
When the intarder is switched on, oil pressure
builds up in the intarder circuit.
The oil pressure reaches the intarder housing via
the rotor (11) outlet and bores 3 and 6 between
the two control plungers. The oil pressure
presses both control plungers outward against
the pressure of both springs (1). The ring
segments are mechanically connected to the
control plungers and are consequently moved
away from their position in between the stator and
rotor. The ring segments do not hinder the oil flow
between the rotor and stator, so that the intarder
can use maximum braking force.
V300618
2 5 5
6 3 4 4 1 1 7
V300619
2 5 5
6 3 4 4 1 1 7
3-12

200634
ZF INTARDER EST 42
Description of components 75 /85 , 105 series
1

200634 4-1
Control functions
ZF INTARDER EST 42
75 /85 , 105 series
1
4. CONTROL FUNCTIONS
4.1 LIMITATION OF POWER
Limitation of power
The electronic unit uses the braking moment
(control current to proportional valve) and the
speed of the output shaft to calculate the braking
power that has been built up. When the
calculated braking power has reached the
maximum value, the electronic unit reduces the
current to the proportional valve. This will
decrease the control pressure in the intarder unit
and the volume control valve reduces the intarder
pressure. In this way the braking power is limited
to a maximum.
Power limitation in constant brake position
One of the constant brake positions can be
selected using the steering column switch. If the
vehicle speed varies somewhat while driving
downhill while the brake is in a constant position,
the electronic unit of the intarder automatically
adjusts the current to the proportional valve.
Should the vehicle speed increase a little, the
current through the proportional valve will slightly
decrease. The braking moment will become
lower, yet the braking power remains constant.
Power limitation during acceleration
If the accelerator pedal is operated while one of
the constant brake positions has been selected,
the current maximum available braking power is
reduced by 100 kW. If the desired braking power
is below the current maximum available braking
power, the reduction will be less as well. A
situation may occur in which there is no reduction
at all.
If the Downhill Speed Control function is active
then there is no reduction during acceleration but
the Downhill Speed Control function is switched
off.
3500
3000
2500
2000
1500
1000
500
0
100 300 700 1100 1500 1900 2300 [min-1]
[Nm]
420 kW
V300583
I [A]
V [km/h]
V300584
4-2

200634
ZF INTARDER EST 42
Control functions 75 /85 , 105 series
1
Power limitation at low engine speed
When the intarder is activated, the electronic unit
of the intarder checks the engine speed.
If too low an engine speed is detected, the
maximum braking power of the intarder is
restricted.
When the engine speed is low and consequently
the coolant pump output is low, the through-flow
of the cooling system will be low as well. If the
coolant flows slowly through the cooling system,
the oil in the intarder cannot be sufficiently cooled
and the coolant temperature becomes too high.
This situation may occur when the intarder is
activated while driving downhill and a high gear
(too high) has been chosen.
350
300
250
200
150
100
50
0
0 1000 2000 500 1500 2500 3000 3500
450
[kW]
400
V300588
[min-1]

200634 4-3
Control functions
ZF INTARDER EST 42
75 /85 , 105 series
1
4.2 DOWNHILL SPEED CONTROL
This control keeps the desired vehicle speed at a
constant level during descents.
Downhill Speed Control can be activated with the
steering wheel switch (5).
The current vehicle speed is stored in the
electronic unit.
The intarder is switched on when the vehicle
speed increases:
- the warning indicator on the instrument panel
is activated.
- the proportional valve and the air supply
valve are activated.
If the vehicle speed keeps increasing, the
electronic unit generates a higher control current,
so that the braking moment of the intarder
increases. The intarder is switched off once the
vehicle speed has been reduced to the stored
value.
V300592
K102020
1 3 5
2 4 6
V300611
R
4-4

200634
ZF INTARDER EST 42
Control functions 75 /85 , 105 series
1
When the intarder is switched off via the steering
column switch (OFF) or the ignition lock or when
it is switched to position 1, 2 or 3, the Downhill
Speed Control value stored in the electronic unit
is erased.
Note:
During Downhill Speed Control, the maximum
braking moment is also possible under certain
conditions, for instance on long descents!
Selection of Downhill Speed Control during a
constant brake position
Downhill Speed Control can still be activated
during descents with a selected constant brake
position (1, 2 or 3).
This means that the electronic unit automatically
activates the function that requires the highest
braking moment.
Suppose brake position two has been selected
and the vehicle speed during a descent keeps
increasing, the Downhill Speed Control function
can be selected as well to stop the speed from
increasing further.
The electronic unit automatically adjusts the
control current through the proportional valve, so
that the intarder supplies the desired braking
moment to keep the vehicle speed at a constant
level.
The Downhill Speed Control function is switched
off once the vehicle speed again equals the
speed that was stored in the electronic unit when
the Downhill Speed Control function was
selected. Brake position two, which was selected
as well, takes over again.
V301043
1
2
3

200634 4-5
Control functions
ZF INTARDER EST 42
75 /85 , 105 series
1
Downhill Speed Control in combination with
the cruise control function
Downhill Speed Control and cruise control can be
selected at the same time. This means that both
functions can be selected at the same vehicle
speed.
However, in connection with unnecessary
heating of drive line and cooling system and the
extra consumption of fuel, it is not desirable that
both functions are active at the same time.
This is why the electronic unit of the intarder
automatically adjusts the currently stored vehicle
speed of the Downhill Speed Control in relation to
the stored cruise control speed by a minimum
programmed value of 3 km/h.
Example:
If both functions are selected at a vehicle speed
of 60 km/h, the vehicle speed is maintained while
driving on a level road or while driving on an
incline at 60 km/h (cruise control) and during a
descent at about 63 km/h (Downhill Speed
Control).
Downhill Speed Control and neutral switch
If, during a descent, a lower gear is selected while
the intarder is switched on, it may happen that the
engine speed is synchronised with the lower
engaged gear (double-declutching).
If, however, the accelerator pedal is operated
when the Downhill Speed Control is active, the
electronic unit of the intarder deactivates the
Downhill Speed Control function.
Example:
In the situation below it is not desirable that the
intarder of the rearmost vehicle, during Downhill
Speed Control, is switched off during a descent.
K102020
1 3 5
2 4 6
K102021
1 3 5
2 4 6
4-6

200634
ZF INTARDER EST 42
Control functions 75 /85 , 105 series
1
The neutral switch sends a signal to the
electronic unit, indicating that the gearbox is in
neutral.
This prevents the electronic unit from
automatically switching off the Downhill Speed
Control when the accelerator pedal is operated in
the neutral position.
The neutral switch is open in neutral, so that the
electronic unit of the intarder stops receiving an
earth signal.
Furthermore, the clutch is operated when shifting
down. The clutch proximity switch is linked to the
engine management system and will use a CAN
message to indicate that the drive line is
interrupted. This function also prevents the
Downhill Speed Control function from being
deactivated when shifting down.
Display of desired vehicle speed on DIP when
Downhill Speed Control is switched on
If the Downhill Speed Control is switched on at a
certain vehicle speed, this desired vehicle speed
is stored in the EST 42 unit memory. The value of
the desired vehicle speed is also displayed on the
DIP dot matrix when driving downhill.
The symbol for the desired vehicle speed
appears at position 6a of the indication bar (A).
The driver thus has constant feedback regarding
the speed at which the Downhill Speed Control
can become active.
V300590
K101943

200634 4-7
Control functions
ZF INTARDER EST 42
75 /85 , 105 series
1
4.3 TEMPERATURE ADJUSTMENT
Temperature-dependent limitation of braking
moment
When the coolant temperature is too high, the
electronic unit reduces the control current
through the proportional valve in accordance with
a fixed control program.
The temperature at which this reduction is started
depends on the desired braking moment (position
of the steering column switch).
With a desired high braking moment, the
reduction will be started earlier than with a
desired low braking moment.
Electronically controlled fan clutch
Switching on
When using the intarder, the electronically
controlled viscous fan clutch can be activated to
control the fan speed. In this way, a sufficiently
cooling air flow is obtained to keep the
temperature of the cooling system within limits.
If the desired braking power of the intarder is
higher than 10 kW, the electronic unit of the
intarder will actuate the engine management
system via a V-can message, to activate the
electronically-controlled viscous fan clutch.
Delayed activation
Actuation of the fan clutch also depends on the
coolant temperature.
If the temperature exceeds 95C, the fan clutch is
immediately activated with a delay of 0 seconds.
If the temperature is below 95C, the fan clutch is
activated with a delay of some seconds,
depending on the exact temperature.
0
350
300
250
200
150
100
50
0 85 90 95 100 120 115 110 105 125
450
[kW]
400
V300837
90
0
5
95
T [S]
V300585
4-8

200634
ZF INTARDER EST 42
Control functions 75 /85 , 105 series
1
Fan speed control
The speed of the electronically controlled fan
depends on the coolant temperature. At a coolant
temperature of 78C, the fan speed is at least 200
rpm.
The pre-programmed temperature control in the
electronic unit ensures that the speed of the fan
increases or decreases by 160 rpm with each 1C
change in the coolant temperature.
However, the maximum fan speed still depends
on the engine speed.
Activating the exhaust brake
If the intarder is switched on while the Downhill
Speed Control function is activated, the exhaust
brake is automatically activated if the following
conditions are met.
The conditions for activation of the exhaust brake
are:
- intarder coolant temperature higher than
92C
- the desired braking power is higher than 250
kW
The electronic unit of the intarder activates the
exhaust brake via a V-CAN message to the
electronic unit of the engine management
system.
By activating the exhaust brake, the braking
moment calculated by the intarder can be
reduced. This reduces the thermal load on the
cooling system.
Together, the activated exhaust brake and the
intarder (with adapted braking moment) provide
the constant braking moment that is necessary to
maintain a constant vehicle speed during
descents.
The exhaust brake is deactivated again if the
desired braking power of the intarder is below 10
kW.
78
200
2825
83
N [RPM]
160
RPM /
V300839

200634 4-9
Control functions
ZF INTARDER EST 42
75 /85 , 105 series
1
4.4 CONTROL WITH ACTIVATED ABS
The ABS system is activated when one or more
wheels threaten to slip during braking with the
intarder.
The ABS switches the intarder off. At that
moment the electronic unit of the intarder
switches the proportional valve and the air supply
valve off.
The intarder is activated again when the ABS is
no longer active.
With an activated Downhill Speed Control, the
stored vehicle speed is retained after an
intervention of the ABS.
4-10

200634
ZF INTARDER EST 42
Control functions 75 /85 , 105 series
1
4.5 CONTROL VIA CAN NETWORK
The electronic unit of the ZF intarder EST 42 is
incorporated in the V-CAN2 network of the
vehicle. The electronic unit communicates with
other electronic vehicle systems via the CAN
connection on points 22 and 49. In this way data
is exchanged, so that other electronic systems
can influence the control functions of the intarder.
The electronic unit of the intarder also needs data
from other systems to optimise the intarder
function. The intarder can also be limited or
switched on and off by other vehicle systems,
such as the EBS-2, ABS-D, tachograph, DMCI
and AS Tronic.
The vehicle speed signal, for instance, is offered
via the tachograph and CAN messages to the
electronic unit of the intarder, among others.
If the speed signal should be missing due to a
failure, the Downhill Speed Control (if active) will
be deactivated. With an activated Downhill Speed
Control function the speed signal is an important
signal for the electronic unit of the intarder.
Also special functions, such as the limitation of
the maximum braking power of the intarder and
actuation of the exhaust brake or the
electronically controlled fan clutch (limitation of
the coolant temperature), go via CAN messages.
Data received by the EST 42 unit includes:
Data sent by the EST 42 unit include:
Signal From
Rpm of gearbox output shaft to calculate the (maximum) braking power Tachograph
Vehicle speed Tachograph
Vehicle speed backup DMCI
Cruise control active signal: when the Downhill Speed Control function is activat-
ed, the stored vehicle speed is automatically 3 km/h higher than the stored cruise
control speed
DMCI
Stored cruise control speed DMCI
Engine speed DMCI
Clutch proximity switch, prevents deactivation of Downhill Speed Control func-
tion when accelerating during descent when drive line is broken
DMCI
Brake pedal switch, extra delay of vehicle by 'freezing' the intarder braking power
in Downhill Speed Control function and use of service brake
DMCI
Accelerator pedal idling switch, to deactivate the Downhill Speed Control func-
tion when accelerating and gearbox is engaged and clutch pedal is not operated
DMCI
Request to deactivate intarder owing to ABS intervention ABS/EBS-2
Desired braking moment for service brake, request for percentage of intarder
braking power, to assist service brake
EBS -2
Downhill Speed Control function active VIC-2

200634 4-11
Control functions
ZF INTARDER EST 42
75 /85 , 105 series
1
Signal To
Intarder braking moment reference in Nm ABS/EBS-2/DMCI/AS
Tronic
Current intarder braking moment expressed as a percentage of Nm EBS-2/AS Tronic
Desired intarder braking moment in percent, to activate the electronically control-
led fan clutch
DMCI
Desired intarder braking moment in percent, depending on the brake position or
Downhill Speed Control function selected via the steering column switch or the
steering wheel switch
EBS-2/VIC-2/AS
Tronic
Selected constant intarder braking moment in percent, to deactivate the cruise
control function when brake position 1, 2 or 3 is selected via the steering column
switch
DMCI/AS Tronic
Maximum available intarder braking moment in percent, for combined action of
EBS/intarder
EBS-2/AS Tronic
Request for activation of exhaust brake DMCI/AS Tronic
Display of desired vehicle speed on DIP when Downhill Speed Control function
is switched on
VIC-2/AS Tronic
4-12

200634
ZF INTARDER EST 42
Control functions 75 /85 , 105 series
1

200634 5-1
Diagrams
ZF INTARDER EST 42
75 /85 , 105 series
1
5. DIAGRAMS
5.1 HYDRAULICS DIAGRAM
Explanatory notes to hydraulics diagram
1. Gearbox oil pump
2. Gearbox oil filter
3. Intarder oil pump
4. Intarder oil filter
5. Rotor
6. Stator
7. Pressure-limiting valve
8. Intarder proportional valve
9. Volume control valve
10. Freewheeling torque reducing system
11. Accumulator
12. Intarder air supply valve
13. Intarder circuit selector valve
14. Residual pressure valve
15. Coolant temperature sensor
16. Heat exchanger
17. Engine
18. Radiator
19. Air supply
1
2
3
4
5
6
7
8
9
11
12
13
10
14
15
16
17
18
19
1 2
Q
1
2
1 2
V300582
5-2

200634
ZF INTARDER EST 42
Diagrams 75 /85 , 105 series
1
5.2 BLOCK DIAGRAM
Block diagram V301042 applies to:
- XF105
- CF85 IV
- CF75 IV
Block diagram legend
Explanation of block diagram
Basic code Name
A100 Connector, HD-OBD diagnosis
B088 Valve, proportional
B089 Valve, supply
C906 Selector switch, Man/Auto
C907 Switch, man. gear up/down
D902 ECU, intarder EST-42
E035 Fuse, steering column
E199 Fuse, ZF intarder
E351 Fuse, electrical systems
E593 Switch, neutral position
F544 Sensor, coolant temp. intarder
A Version with manual gearbox
B Version with AS Tronic

200634 5-3
Diagrams
ZF INTARDER EST 42
75 /85 , 105 series
1
3
4
1
1
2
1
4
T
R
3
7
9
2
8
2
7
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2
C A N 2 - L
4
9
2
0
A
B
8
7
5-4

200634
ZF INTARDER EST 42
Diagrams 75 /85 , 105 series
1
Printed in the Netherlands DW
English