ZF intarder EST 42

©452009 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.

© 452009 DAVIE
 STRUCTURE
series
Structure

0
ZF INTARDER EST 42 CF75, CF85, XF95
1
ZF INTARDER EST 42 CF75IV, CF85IV, XF105
2

© 452009
 ZF INTARDER EST 42 CF75, CF85, XF95
series Contents

CONTENTS
ZF intarder EST 42 CF75, CF85, XF95

Page Date

1. DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 452009

1.1 Hydraulics diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1 . . . . .
1-2 . . . . .
452009
452009 1
1.3 Key to block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 . . . . . 452009

2. LOCATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 452009

2.1 Location of electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 452009
2.2 Location of hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 . . . . . 452009

© 452009 1
 ZF INTARDER EST 42 CF75, CF85, XF95
Contents series

2 © 452009
 ZF INTARDER EST 42 CF75, CF85, XF95
series Diagrams

1. DIAGRAMS
1.1 HYDRAULICS DIAGRAM

1
8 1 2
1
2
12 19

9 11

13
6 5
10 16 18
17
3 7
14 2
Q
1
1 15
4
2

V300582

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

© 452009 1-1
 ZF INTARDER EST 42 CF75, CF85, XF95
Diagrams series

1.2 BLOCK DIAGRAM

Block diagram V300811 applies to:

- Model CF75/85, production date <2002-41
1 Explanation of block diagram
A: Operation of stop lights if intarder is acti-
vated, not connected as standard

000 1010 steering colomn switch

1010
C831

E199 E029 function error retarder

indication warning diagnosis
E0
2 neutral VIC/DIP Connector
CAN
switch D900/D899 network A021
1 E569 D25 D24 11 2 1
B11 B9 B8 B7 B5 B6

9107

1229
5148 V-constant OFF
5147 V-constant SET
4714 supply +

3701J CAN-H

3700J CAN-L
4713 pos. 3

4712 pos. 2

4711 pos. 1
1197

1230

4690

3420

3417

4883
54 55 31 53 30 16 42 15 18 44 20 29 52 22 49 14

ECU, ZF Intarder EST 42 D902

28 27 2 37 9 1 34 3 4
4888

4887
3516
3515

4878

4960

87
1 1
2 1
T 2 2
R
G036 F544 B089 B088
relay coolant temperature supply proportional
stop light sensor valve valve
A
V300811

Block diagram V300805 applies to:

- Model CF75/85, production date 2002-41
and <2003-21
Modifications to CF75/85, production date 2002-
41 and <2003-21:
- Switching of power supply after ignition on
connection points 31 and 53 modified
Explanation of block diagram
A: Operation of stop lights if intarder is acti-
vated, not connected as standard

1-2 © 452009
 ZF INTARDER EST 42 CF75, CF85, XF95
series Diagrams

000 1010 steering colomn switch

1010
C831
G426 function error retarder
indication warning diagnosis
E0
87
2 neutral
switch
D25
VIC/DIP
D900/D899
D24
CAN
network
11
Connector
A021
2 1
1
1 E593
1234

B11 B9 B8 B7 B5 B6

9107

1229
5148 V-constant OFF
5147 V-constant SET

E199 E351
4714 supply +

3701J CAN-H

3700J CAN-L
4713 pos. 3

4712 pos. 2

4711 pos. 1
1197

1381

4690

3420

3417

4883
54 55 31 53 30 16 42 15 18 44 20 29 52 22 49 14

ECU, ZF Intarder EST 42 D902

28 27 2 37 9 1 34 3 4

4888

4887
3516
3515

4878

4960
87
1 1
2 1
T 2 2
R
G036 F544 B089 B088
relay coolant temperature supply proportional
stop light sensor valve valve
A
V30080

Block diagram V300812 applies to:

- Version XF95
- Model CF75/85, production date 2003-21
Changes to CF75/85, production date >2003-21:
- If AS Tronic is used, connection point 20 is
connected directly to an earth point
Explanation of block diagram
A: Operation of stop lights if intarder is acti-
vated, not connected as standard
B: Used with manual gearbox
C: Used with AS Tronic gearbox

© 452009 1-3
 ZF INTARDER EST 42 CF75, CF85, XF95
Diagrams series

000 1010 steering colomn switch

10
C831
G426 B C
function error retarder E053
indication warning diagnosis

1 87
2 neutral
switch
D25
VIC/DIP
D900/D899
D24
CAN
network
11
Connector
A021
2 1
1 E593
1234

B11 B9 B8 B7 B5 B6

9107
5148 V-constant OFF
5147 V-constant SET

E199 E351
4714 supply +

3701J CAN-H

3700J CAN-L
4713 pos. 3

4712 pos. 2

4711 pos. 1
1197

1381

4690

4690

3420

3417

4883
54 55 31 53 30 16 42 15 18 44 20 20 29 52 22 49 14

ECU, ZF Intarder EST 42 D902

28 27 2 37 9 1 34 3 4

4888

4887
9131

3516
3515

4878

4960
87
1 1
2 1
T 2 2
R
G036 F544 B089 B088
relay coolant temperature supply proportional
stop light sensor valve valve
A
V3008

1-4 © 452009
 ZF INTARDER EST 42 CF75, CF85, XF95
series Diagrams

1.3 KEY TO BLOCK DIAGRAM

Basic code Description

number
A021 Diagnostic socket (16-pin) 1
B088 Intarder proportional valve
B089 Intarder air supply valve
C831 Cruise control/engine speed control/intarder steering column switch
D900/899 VIC/DIP electronic unit
D902 Electronic unit ZF intarder EST42
E029 Fuse, intarders/engine brake
E053 Fuse for diagnostic connector (16-pin)/LED unit/alarm system
E199 Fuse, ZF intarder
E569 Neutral position switch
F544 Coolant temperature sensor for secondary intarder
G036 Relay, stop light
G426 Contact relay

© 452009 1-5
 ZF INTARDER EST 42 CF75, CF85, XF95
Diagrams series

1-6 © 452009
 ZF INTARDER EST 42 CF75, CF85, XF95
series Location information

2. LOCATION INFORMATION

© 452009 2-1
 ZF INTARDER EST 42 CF75, CF85, XF95
Location information series

2.1 LOCATION OF ELECTRICAL COMPONENTS

CF 75/85

2-2 © 452009
 ZF INTARDER EST 42 CF75, CF85, XF95
series Location information

C831

D902

E569

F544
B089

B088

© 452009 2-3
 ZF INTARDER EST 42 CF75, CF85, XF95
Location information series

Basic code Description Location Note

B088 Proportional solenoid Below coolant pipe on left side of intarder
valve
1 B089 Air supply solenoid valve On top of intarder air supply accumulator
C831 Steering column switch On right side of steering column
D902 Electronic unit EST42 In central box below printed circuit board
E569 Neutral switch Back of gearbox gearshift cover
F544 Coolant temperature Outgoing coolant pipe of intarder heat ex-
sensor changer

2-4 © 452009
 ZF INTARDER EST 42 CF75, CF85, XF95
series Location information

XF95

© 452009 2-5
 ZF INTARDER EST 42 CF75, CF85, XF95
Location information series

D902

E593

E593
F544

B089

B088

V300813

2-6 © 452009
 ZF INTARDER EST 42 CF75, CF85, XF95
series Location information

Basic code Description Location Note

B088 Proportional solenoid Below coolant pipe on left side of intarder
valve
B089 Air supply solenoid valve On top of intarder air supply accumulator 1
C831 Steering column switch On right side of steering column
D902 Electronic unit EST42 In central box below printed circuit board
E593 Neutral switch Back of gearbox gearshift cover
F544 Coolant temperature Outgoing coolant pipe of intarder heat ex-
sensor changer

© 452009 2-7
 ZF INTARDER EST 42 CF75, CF85, XF95
Location information series

2.2 LOCATION OF HYDRAULIC COMPONENTS

1 2

10 4

8 6 5

V300602

2-8 © 452009
 ZF INTARDER EST 42 CF75, CF85, XF95
series Location information

Description Location Note

1 Oil pump pressure con- On right side of intarder
trol valve
2 Selector valve spring
sealing plug
On right side of intarder 1
3 Accumulator On back of intarder
4 Heat exchanger On back of intarder
5 Control plunger for pro- On left side of intarder
portional solenoid valve
6 Stator and rotor On left side of intarder
7 Oil pump gear wheels On left side of intarder
8 Freewheeling torque re- On left side of intarder between stator and
duction ring segment rotor
9 Freewheeling torque re- On left side of intarder below ring segments
duction control plunger
10 Residual pressure valve Centre underside of intarder

© 452009 2-9
 ZF INTARDER EST 42 CF75, CF85, XF95
Location information series

2-10 © 452009
 ZF INTARDER EST 42 CF75IV, CF85IV, XF105
series Contents

CONTENTS
ZF intarder EST 42 CF75IV, CF85IV, XF105

Page Date

1. DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 452009

1.1 Hydraulics diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 452009
1.2 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 452009

2. LOCATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 452009

2.1 Location information, ZF intarder, EST-42 . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 452009 2

© 452009 1
 ZF INTARDER EST 42 CF75IV, CF85IV, XF105
Contents series

2 © 452009
 ZF INTARDER EST 42 CF75IV, CF85IV, XF105
series Diagrams

1. DIAGRAMS
1.1 HYDRAULICS DIAGRAM

1
8 1 2

2
12 19

9 11 2

13
6 5
10 16 18
17
3 7
14 2
Q
1
1 15
4
2

V300582

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

© 452009 1-1
 ZF INTARDER EST 42 CF75IV, CF85IV, XF105
Diagrams series

1.2 BLOCK DIAGRAM

Block diagram V301042 applies to:

- XF105
- CF85 IV
- CF75 IV
Explanation of block diagram

2 A Version with manual gearbox

B Version with AS Tronic

1-2 © 452009
 ©
series

452009
kl. 30 kl. 15 kl. 15 Steering colomn switch Diagnosis connector
C906 / C907 A100
G426 A B
11
Vehicle Vehicle
87 2 neutral CAN2-high CAN2-low
switch
1 E593
12 10 9 8

E199 E351 E035

Pos. 3
Pos. 2
Pos. 1
CAN2-H
CAN2-L

54 55 31 53 16 42 15 20 20 22 49 14
ECU, ZF Intarder EST 42 D902
28 27 37 9 1 34 3 4

1 3
2 1
T 4 2
R
F544 B089 B088
Coolant temperature Supply Proportional
sensor valve valve

V301042
ZF INTARDER EST 42 CF75IV, CF85IV, XF105

1-3
Diagrams

2
 ZF INTARDER EST 42 CF75IV, CF85IV, XF105
Diagrams series

Block diagram legend

Basic code Description
A100 Connector, HD-OBD diagnostics
B088 Valve, proportional
B089 Valve, supply
C906 steering column AGC /steering column AS Tronic (wk 49)

2 C907
D902
Steering column MGS/ AGC
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

1-4 © 452009
 ZF INTARDER EST 42 CF75IV, CF85IV, XF105
series Location information

2. LOCATION INFORMATION

© 452009 2-1
 ZF INTARDER EST 42 CF75IV, CF85IV, XF105
Location information series

2.1 LOCATION INFORMATION, ZF INTARDER, EST-42

2
E593
E592

E595

D902

F120

F544

B089

C906

C907
B088

E503367

2-2 © 452009
English
Printed in the Netherlands DAVIE