Est-42 71453

System and component information
ZF intarder EST 42
E593
CF75 IV
CF85 IV
XF105
F544
C906
C907
CAN
network
HD-OBD
A100
B089
B088
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.
200634
DW
STRUCTURE
75 /85 , 105 series
TECHNICAL DATA
Structure
ZF INTARDER EST 42
200634
0
1
TECHNICAL DATA
75 /85 , 105 series
Contents
CONTENTS
Technical data
Page
1.
ZF INTARDER EST 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Power supply and earth of electronic unit . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 CAN connections electronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 K-line electronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Steering column switch / Steering wheel switches . . . . . . . . . . . . . . . . . .
1.5 Coolant temperature sensor, intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Neutral position switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 Intarder proportional valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 Intarder air supply valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
200634
1-1 . . . . .
1-1 . . . . .
1-2 . . . . .
1-3 . . . . .
1-4 . . . . .
1-6 . . . . .
1-8 . . . . .
1-9 . . . . .
1-11 . . . .
Date
200634
200634
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200634
TECHNICAL DATA
Contents
75 /85 , 105 series
200634
TECHNICAL DATA
75 /85 , 105 series
ZF intarder EST 42
1. ZF INTARDER EST 42
1.1 POWER SUPPLY AND EARTH OF ELECTRONIC UNIT
55 54 53 52 49
28 27
44 42
37 34
22 20 18 16 15 14
31 30 29
4 3 21
V300601
Electronic unit connection point
Description of connection point
Reading at connection point (Ubat = battery voltage)
Measuring unit
Explanatory notes (if applicable)
'X' mark indicates that additional information is available in 'Technical data'
20
Earth
(In combination with manual gearbox input 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

switched on.
28
Earth
< 0,5
V DC

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
200634
1-1
TECHNICAL DATA
75 /85 , 105 series
ZF intarder EST 42
1.2 CAN CONNECTIONS ELECTRONIC UNIT
55 54 53 52 49
28 27
44 42
37 34
22 20 18 16 15 14
31 30 29
4 3 21
V300601
Measuring unit
22
V-CAN2-H
According to ISO 11898
49
V-CAN2-L
According to ISO 11898
1-2
200634
TECHNICAL DATA
75 /85 , 105 series
ZF intarder EST 42
1.3 K-LINE ELECTRONIC UNIT
55 54 53 52 49
28 27
44 42
37 34
22 20 18 16 15 14
31 30 29
4 3 21
V300601
Measuring unit
14
HD-OBD diagnostic connector (A100)
200634
1-3
TECHNICAL DATA
75 /85 , 105 series
ZF intarder EST 42
1.4 STEERING COLUMN SWITCH / STEERING WHEEL SWITCHES
55 54 53 52 49
28 27
44 42
37 34
22 20 18 16 15 14
31 30 29
4 3 21
V300601
Measuring unit
15
Steering column switch position 1 input

signal
VDC
If switch not operated
Ubat
VDC
If switch is in position 1
Ubat
VDC
Ubat
VDC
VDC
VDC
VDC
Ubat
VDC
VDC
VDC
Ubat
VDC
Ubat
VDC
16
42
1-4

signal

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

Downhill Speed Control
200634
0% - 100% braking power
1-5
TECHNICAL DATA
75 /85 , 105 series
ZF intarder EST 42
1.5 COOLANT TEMPERATURE SENSOR, INTARDER
55 54 53 52 49
28 27
44 42
37 34
22 20 18 16 15 14
31 30 29
4 3 21
V300601
Measuring unit
Input signal, coolant temperature (F544)
V DC
Open voltage, with detached connec- X

tor
37
Earth, coolant temperature sensor

(F544)
< 0,5
V DC
1-6
200634
TECHNICAL DATA
75 /85 , 105 series
Model
ZF intarder EST 42
NTC
V300589
Resistance in relation to measured temperature

Temperature ( C)
200634
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
1-7
TECHNICAL DATA
75 /85 , 105 series
ZF intarder EST 42
1.6 NEUTRAL POSITION SWITCH
55 54 53 52 49
28 27
44 42
37 34
22 20 18 16 15 14
31 30 29
4 3 21
V300601
Measuring unit
20
Input signal neutral position switch

(E593)
Ubat
V DC
Gearbox in neutral
< 0,5
V DC
Gear box in gear
Model
1-8
Normally Open
200634
TECHNICAL DATA
75 /85 , 105 series
ZF intarder EST 42
1.7 INTARDER PROPORTIONAL VALVE
55 54 53 52 49
28 27
44 42
37 34
22 20 18 16 15 14
31 30 29
4 3 21
V300601
Measuring unit
Earth, proportional valve (B088)
< 0,5
V DC
Output signal, proportional valve (B088)
% (I)
200634
F
X
Duty cycle (control current) depends

on the switch position selected
1-9
TECHNICAL DATA
75 /85 , 105 series
ZF intarder EST 42
Resistance of intarder proportional valve

at 20 to 25 C
23 - 27
V300603
Readings
The following table lists the proportional valve
control currents and the accompanying pressures
in the intarder.
Control current with defective coolant temperature sensor or with temperature > 120 C
Switch position
Control current
250 15 mA
Control pressure Intarder pressure
Pump pressure
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
255 15 mA
2.0 1 bar
3.0 1 bar
10.5 1 bar
320 15 mA
3.0 1 bar
5.5 1 bar
10.5 1 bar
430 15 mA
5.0 1 bar
10.0 1 bar
10.5 1 bar
1-10
200634
TECHNICAL DATA
75 /85 , 105 series
ZF intarder EST 42
1.8 INTARDER AIR SUPPLY VALVE
55 54 53 52 49
28 27
44 42
37 34
22 20 18 16 15 14
31 30 29
4 3 21
V300601
Measuring unit
Output signal air supply valve (B089)
Ubat
V DC
Valve activated
34
Earth air supply valve (B089)
< 0,5
V DC
200634
1-11
TECHNICAL DATA
75 /85 , 105 series
ZF intarder EST 42
Resistance of intarder air supply valve at

20 to 25 C
Required air pressure
125 - 145
6.3 - 10 bar
V300446
1-12
200634
ZF INTARDER EST 42
75 /85 , 105 series
Contents
CONTENTS
ZF intarder EST 42
Page
Date
1.
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200634

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

5.1 Hydraulics diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200634
5.2 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 200634
200634
ZF INTARDER EST 42
Contents
75 /85 , 105 series
200634
ZF INTARDER EST 42
75 /85 , 105 series
General
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.
2.
3.
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.
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.
Communication with other vehicle systems
to guarantee the optimum braking effect.
200634
1-1
ZF INTARDER EST 42
General
75 /85 , 105 series
1-2
200634
ZF INTARDER EST 42
75 /85 , 105 series
System description
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.
2.
3.
4.
5.
Limitation of power
temperature control
Control with activated ABS
Downhill Speed Control
Control via CAN
E593
F544
C906
C907
CAN
network
HD-OBD
A100
B089
B088
V301052
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.
200634
2-1
ZF INTARDER EST 42
System description
75 /85 , 105 series
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 Kline.
2-2
200634
ZF INTARDER EST 42
75 /85 , 105 series
System description
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.
200634
2-3
ZF INTARDER EST 42
75 /85 , 105 series
System description
3
9
10
V300602
1
2
2-4
Oil pump pressure control valve

Selector valve spring sealing plug
200634
ZF INTARDER EST 42
75 /85 , 105 series
3
4
5
6
7
8
9
10
System description
Accumulator
Heat exchanger
Control plunger for proportional solenoid
valve
Stator and rotor
Oil pump gear wheels
Freewheeling torque reduction ring
segment
Freewheeling torque reduction control
plunger
Residual pressure valve
200634
2-5
ZF INTARDER EST 42
75 /85 , 105 series
System description
2.3 INTARDER SWITCHED OFF
19
12
9
11
13
6 5
18
16
10
17
3
1
7
4
14
Q
1
15
V300582
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.
2-6
200634
ZF INTARDER EST 42
75 /85 , 105 series
System description
2.4 SWITCHING THE INTARDER ON
1 2
1
2
19
12
9
11
13
6 5
18
16
10
17
3
1
7
4
14
Q
1
15
V300596
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.:
200634
2-7
ZF INTARDER EST 42
System description
1.
1
2.
2-8
75 /85 , 105 series
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).
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
ZF INTARDER EST 42
75 /85 , 105 series
System description
2.5 INTARDER SWITCHED ON
1 2
1
2
19
12
9
11
13
6 5
10
18
16
17
3
1
7
4
14
Q
1
15
V300597
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.
200634
2-9
ZF INTARDER EST 42
System description
75 /85 , 105 series
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.
2-10
200634
ZF INTARDER EST 42
75 /85 , 105 series
System description
2.6 SWITCHING THE INTARDER OFF
19
12
11
13
6 5
18
16
10
17
3
1
7
4
14
Q
1
15
V300582
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.
200634
2-11
ZF INTARDER EST 42
System description
75 /85 , 105 series
2-12
200634
ZF INTARDER EST 42
75 /85 , 105 series
Description of components
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 righthand 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:
Rest position
(OFF)
Intarder not
active
Brake position approx. 33% of

1:
the maximum
braking effect.
V301043
Brake position approx. 66% of

2:
the maximum
braking effect.
Brake position the maximum
3:
braking effect
(with the assistance of the
engine brake).
1
2
Downhill
0 to 100%
Speed Control braking effect.
3
V301044
K102020
200634
3-1
ZF INTARDER EST 42
75 /85 , 105 series
Note:
If the warning indicator '"(( ))" on the instrument
panel lights up, the intarder is activated.
1
R
V300611
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.
K102020
Disengaging Downhill speed control

Press steering wheel switch (6) to deactivate
Downhill Speed Control.
3-2
200634
ZF INTARDER EST 42
75 /85 , 105 series
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
200634
3-3
ZF INTARDER EST 42
75 /85 , 105 series
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
3-4
Gearbox
Neutral position switch
Neutral
Open
Gear engaged
Closed
200634
ZF INTARDER EST 42
75 /85 , 105 series
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.
V300603
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.
V300604
200634
3-5
ZF INTARDER EST 42
75 /85 , 105 series
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).
V300251
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.
3-6
200634
ZF INTARDER EST 42
75 /85 , 105 series
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
200634
3-7
ZF INTARDER EST 42
75 /85 , 105 series
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.
3-8
7 6
5
V300252
200634
ZF INTARDER EST 42
75 /85 , 105 series
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).
1
8
12
5
5
9
7
V300609
200634
3-9
ZF INTARDER EST 42
75 /85 , 105 series
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).
10
11
4
V300608
3-10
200634
ZF INTARDER EST 42
75 /85 , 105 series
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.
3 6
7
V300618
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.
3 6
7
V300619
200634
3-11
ZF INTARDER EST 42
75 /85 , 105 series
3-12
200634
ZF INTARDER EST 42
75 /85 , 105 series
Control functions
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.
[Nm]
420 kW
3500
3000
2500
2000
1500
1000
500
0
100 300
700
1100
1500
1900
2300 [min-1]
V300583
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.
I [A]
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.
V [km/h]
V300584
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.
200634
4-1
ZF INTARDER EST 42
75 /85 , 105 series
Control functions
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.
4-2
[kW]
450
400
350
300
250
200
150
100
50
0
0
500
1000
1500
2000
2500
3000 3500
[min-1]
V300588
200634
ZF INTARDER EST 42
75 /85 , 105 series
Control functions
4.2 DOWNHILL SPEED CONTROL
V300592
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.
K102020
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.
R
V300611
200634
4-3
ZF INTARDER EST 42
Control functions
75 /85 , 105 series
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!
1
2
3
V301043
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.
4-4
200634
ZF INTARDER EST 42
75 /85 , 105 series
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.
Control functions
1
2
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).
K102020
K102021
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.
200634
4-5
ZF INTARDER EST 42
Control functions
75 /85 , 105 series
V300590
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.
K101943
4-6
200634
ZF INTARDER EST 42
75 /85 , 105 series
Control functions
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.
[kW]
450
400
350
300
250
200
150
100
50
0
0
85
90
95
100
105
110
115 120
125
V300837
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 95 C, the fan clutch is
immediately activated with a delay of 0 seconds.
If the temperature is below 95 C, the fan clutch is
activated with a delay of some seconds,
depending on the exact temperature.
T [S]
90
95
V300585
200634
4-7
ZF INTARDER EST 42
75 /85 , 105 series
Control functions
Fan speed control

The speed of the electronically controlled fan
depends on the coolant temperature. At a coolant
temperature of 78 C, 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 1 C
change in the coolant temperature.
However, the maximum fan speed still depends
on the engine speed.
N [RPM]
2825
160 RPM /
200
78
83
V300839
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
92 C
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.
4-8
200634
ZF INTARDER EST 42
75 /85 , 105 series
Control functions
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.
200634
4-9
ZF INTARDER EST 42
Control functions
75 /85 , 105 series
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:
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 activated, 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 function 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 function when accelerating and gearbox is engaged and clutch pedal is not operated
DMCI
Request to deactivate intarder owing to ABS intervention

Desired braking moment for service brake, request for percentage of intarder
braking power, to assist service brake
Downhill Speed Control function active
ABS/EBS-2
EBS -2
VIC-2
Data sent by the EST 42 unit include:
4-10
200634
ZF INTARDER EST 42
75 /85 , 105 series
Signal
Intarder braking moment reference in Nm
Current intarder braking moment expressed as a percentage of Nm
Control functions
To
ABS/EBS-2/DMCI/AS
Tronic
EBS-2/AS Tronic
Desired intarder braking moment in percent, to activate the electronically controlled 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
200634
4-11
ZF INTARDER EST 42
Control functions
75 /85 , 105 series
4-12
200634
ZF INTARDER EST 42
75 /85 , 105 series
Diagrams
5. DIAGRAMS
5.1 HYDRAULICS DIAGRAM
19
12
9
11
13
6 5
18
16
10
17
3
1
7
4
14
Q
1
15
V300582
Explanatory notes to hydraulics diagram

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Gearbox oil pump

Gearbox oil filter
Intarder oil pump
Intarder oil filter
Rotor
Stator
Pressure-limiting valve
Intarder proportional valve
Volume control valve
Freewheeling torque reducing system
Accumulator
Intarder air supply valve
Intarder circuit selector valve
Residual pressure valve
Coolant temperature sensor
Heat exchanger
Engine
Radiator
Air supply
200634
5-1
ZF INTARDER EST 42
75 /85 , 105 series
Diagrams
5.2 BLOCK DIAGRAM
Block diagram V301042 applies to:

XF105
CF85 IV
CF75 IV
Block diagram legend
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
Explanation of block diagram

A Version with manual gearbox
B Version with AS Tronic
5-2
200634
55
27
54
28
E199
31
53
E351
87
G426
E035
kl. 15
12
16
2
T
37
15
20
A
neutral
switch
E593
20
B089
Supply
valve
B088
Proportional
valve
Vehicle
CAN2-low
49
22
Vehicle
CAN2-high
CAN2-L
34
ECU, ZF Intarder EST 42 D902
F544
Coolant temperature
sensor
42
10
Steering colomn switch

C906 / C907
Pos. 3
kl. 15
Pos. 2
200634
Pos. 1
CAN2-H
kl. 30
14
11
V301042
Diagnosis connector
A100
ZF INTARDER EST 42
75 /85 , 105 series

Diagrams
5-3
ZF INTARDER EST 42
Diagrams
75 /85 , 105 series
5-4
200634
English
Printed in the Netherlands
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System and component information

200634 DAF Trucks N.V., Eindhoven, The

75 /85 , 105 series

1.1 POWER SUPPLY AND EARTH OF ELECTRONIC UNIT

Electronic unit connection point

Description of connection point

Reading at connection point (Ubat = battery voltage)

Explanatory notes (if applicable)

'X' mark indicates that additional information is available in 'Technical data'

Voltage loss measurement with as

Voltage loss measurement with as

Voltage loss measurement with as

Power supply after contact

Power supply after contact

Power supply before ignition

Power supply before ignition

1.2 CAN CONNECTIONS ELECTRONIC UNIT

Electronic unit connection point

Description of connection point

Reading at connection point (Ubat = battery voltage)

Explanatory notes (if applicable)

'X' mark indicates that additional information is available in 'Technical data'

According to ISO 11898

According to ISO 11898

1.3 K-LINE ELECTRONIC UNIT

Electronic unit connection point

Description of connection point

Reading at connection point (Ubat = battery voltage)

Explanatory notes (if applicable)

'X' mark indicates that additional information is available in 'Technical data'

HD-OBD diagnostic connector (A100)

1.4 STEERING COLUMN SWITCH / STEERING WHEEL SWITCHES

Electronic unit connection point

Description of connection point

Reading at connection point (Ubat = battery voltage)

Explanatory notes (if applicable)

'X' mark indicates that additional information is available in 'Technical data'

Steering column switch position 1 input

If switch not operated

If switch not operated

If switch not operated

Steering column switch position 3 input

Steering column switch position 2 input

33% braking power

66% braking power

100% braking power

Downhill Speed Control function

0% - 100% braking power

1.5 COOLANT TEMPERATURE SENSOR, INTARDER

Electronic unit connection point

Description of connection point

Reading at connection point (Ubat = battery voltage)

Explanatory notes (if applicable)

'X' mark indicates that additional information is available in 'Technical data'

Input signal, coolant temperature (F544)

Open voltage, with detached connec- X

Earth, coolant temperature sensor

Resistance in relation to measured temperature

1.6 NEUTRAL POSITION SWITCH