ZF Friedrichshafen AG

Truck Driveline Technology

88038 Friedrichshafen
Germany
Phone +49 7541 77-0
Fax +49 7541 77-908000
www.zf.com/truck-transmission

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DE0000 762
762 - 2008
- 2010
151051

Driveline and Chassis Technology

EN
 Driving the Future

Driveline Technology
In Modern Trucks
 Table of Contents

1 Automatic Transmission Systems Page 4

2 Concept Transmission Page 14

3 Manual Transmissions Page 16

4 Intarder: Safe Braking Page 24

5 ZF Power Take-Offs: Page 26

More Than Just Driving

6 ZF Worldwide Page 30

2
“We are working worldwide on strengthen-
ing our customers’ competitiveness.”
Bernd Stockmann, Vice President of the Truck Driveline Technology business unit

Increased competitive pressure, legal requirements, rising fees and

costs for automotive fluids are always accompanying the drivers,
fleet owners, and shipping agencies in the transportation industry.
It is our constant endeavor to counteract the cost pressure by offer-
ing innovative and reliable products and systems.

ZF driveline technology reduces the consumption of fuel and

automotive fluids. Extended maintenance intervals and longer ser-
vice lives also have a positive impact on the transport company’s
operating profit. Products like the automatic transmissions from
the AS Tronic family or the wear-free Intarder brake set the bench-
mark for comfort, safety, and ecology. And innovations are being
created already: ZF hybrid technology will bring another impetus
to the moving world and with a flexible transmission approach
based on a modular, extensible transmission platform, we are al-
ready prepared to meet the future requirements in truck driveline
technology …

Closer to the local customers – we supply the “new markets” from

our worldwide production network, i.e. our locations in Brazil,
Russia, India, and China with products which have been designed
specifically for these regions.

Therefore, we are working worldwide on strengthening our cus-

tomers‘ competitiveness by offering reliable products and com-
prehensive services from ZF throughout the entire life cycle of a
truck.

Bernd Stockmann

Bernd Stockmann

3
Automatic Transmission Systems
Traffic is getting heavier. More powerful engines and the aspi-
ration for greater efficiency in freight transport - modern traffic
places ever increasing demands on people and materials. ZF
automatic transmissions are today’s answer to changing con-
ditions.

4
bi BauFahrzeuge (2/2009):
“... The AS Tronic transmission turns hectic public transport business into freestyle…”

France Routes (04/11/2009):

“… This transmission, engineered by ZF, is a must because it makes driving so much
easier …”

Whether it’s long-distance haulage, delivery traffic, or a spe-

cial vehicle, whether it’s a light commercial vehicle or a super-
heavy truck, ZF has the right automatic transmission for every
imaginable truck configuration. And you win three times over
with every transmission you purchase: You gain economic ef-
ficiency, safety, and comfort. You spend less on fuel and ser-
vice. Truck drivers’ jobs are made easier so they can devote
their attention to what is happening on the road.

ZF automatic transmissions give you the gift of effortless

driving.

5
AS Tronic: Driveline Tech-
nology for Heavy Trucks

The AS Tronic is the first automatic transmission for trucks. The

no.1 works hard in the “big boys” on our roads. For long-dis-
tance heavy goods transport, delivery traffic, or special vehicles
– trucks drive at the head of the pack with the no.1 automatic
transmission. The AS Tronic is the first choice for thousands of
drivers. In comparative and individual tests the no.1 gets top
grades. All the benefits of this drive concept will help push ZF
customers right to the top!

6
1 2

1 AS Tronic without Intarder

Shifting automatically, driving economically
2 Intarder
3 Power take-off (PTO)
n Automatically efficient thanks to: optimum protec-
tion against external influences, increased service
intervals, fast gearshifts which save fuel, extended
clutch service life, perfect communication between
engine, clutch, and transmission which protects the
entire driveline, and a drive program which always
selects the most economical engine speed.

n Automatically safe thanks to: no shifting – better

concentration, undivided attention in city traffic,
sensitive maneuvering, and, upon request, equipped
with the Intarder – the wear-free brake for even
more safety.

n Automatically relaxed thanks to: no clutch engage-

ment jolts and load change shocks, no clutch pedal,
manual gear selection possible via tip switch, reli-
able in all situations – both for long distances and
in demanding terrain – perfectly harmonized clutch
and shift activities.

n The AS Tronic can be equipped with clutch-

dependent and drive-dependent PTOs.

n More simple, shorter, lighter, and more standardized than

anything else currently offered on the market.
n No “added on” control elements.
n Only few central connections for compressed air and electrics
n Electronic control unit integrated into the shift module
n Space and weight saving design: two countershafts and
2-speed planetary gear set

For further information visit: www.zf.com/products/astronic

7
AS Tronic mid: Driveline Tech-
nology for Medium Trucks

We developed the AS Tronic mid automatic transmission

system so that also medium truck operators can enjoy
increased safety, economy, and comfort. Be it in long-
distance, delivery, or city traffic requiring numerous gear
changes: reduced fuel consumption and – important in the
case of frequent driver changes – simple operation speak
in favor of the transmission system. Featuring twelve gears,
the AS Tronic mid ensures that vehicles with a gross weight
between 12 and 36 tons make headway.

8
1 2

1 AS Tronic mid

Fast gear changes save fuel
2 Power take-off (PTO)

n Smooth gear changes protect the clutch and the

downstream driveline. If drivers want to inter-
vene and change gears manually, all they have to
do is operate the switch. The following applies to
both the automatic and the manual mode: Incor-
rect shifting is excluded thanks to the electronic
control unit. It is also responsible for extending
the clutch service life and reducing fuel con-
sumption. The electro-pneumatically shifted
transmission systems of the AS Tronic mid range
are available as modular systems with an instal-
lation length of 840 and 900 millimeters (33 and
35.4 inches).

n The AS Tronic mid can be equipped with clutch-

dependent and drive-dependent PTOs.

n Optional: manual or automatic shifting

n Reliable and service-friendly thanks to modular
design
n Reduced operating costs: fuel consumption,
clutch wear

For further information visit: www.zf.com/products/astronicmid

9
AS Tronic lite: Driveline Tech-
nology for Light Trucks

The city is a natural territory for light trucks.

The city is a demanding place. It demands a
lot from the drivers who have to arrive safely
and on time at their destinations despite
heavy traffic. And it demands just as much
from the vehicle: stop and go and constant
speed changes stretch the driveline to its
limit.

10
1

1 AS Tronic lite

For undivided attention in city
traffic

n The AS Tronic lite automatic transmission system

fights both driver and material fatigue. Integrated
electronics perfectly control clutch engagement and
shifting processes – incorrect shifting is impossible,
even when inexperienced drivers are at the wheel.
Quick shifting times ensure the necessary dynamic
performance. Particularly in the city, fast accelera-
tion is worth a lot.

n The AS Tronic lite also goes easy on the budget.

The increased clutch life and reduced fuel con-
sumption help reduce costs. With its space-saving,
low installation height, the electro-hydraulically
operating transmission system is predestined for
light and medium trucks. It weighs no more than
an appropriate manual transmission.

n The AS Tronic lite can be equipped with clutch-

dependent PTOs.

n Optional: manual or automatic shifting

n Reliable and service-friendly thanks to modular
design
n Reduced operating costs: fuel consumption,
clutch wear

For further information visit: www.zf.com/products/astroniclite

11
TC Tronic: Driveline Technology
for Heavy Tractors
Heavy tractors in action. The mere sight of them and listening to the
roar of their engines is enough to give you an idea of their power.
Large, ultra-heavy loads are moved from one place to another by
using high-torque drives. To make sure that the enormous forces
of the electronically controlled diesel engines are transmitted with
precision, the TC Tronic automatic transmission system is available
with a torque converter clutch. This allows heavy tractors to drive off
smoothly.

n Comfort also for drivers of special vehicles: Wherever

extended and frequent maneuvering is required, wher- n The TC Tronic can be equipped with power
ever difficult terrain is found to be the working envi- take-offs for various applications.
ronment, the TC Tronic ensures precise and perfectly
measured movements. The TC Tronic combines the Suitable for:
advantages of an automatic transmission with those of n Heavy tractors
a hydrodynamic torque converter clutch. Thanks to the n Mobile cranes
torque converter, starting and maneuvering are wear- n Off-road commercial vehicles
free.
For further information visit:
n With the TC Tronic, the driver can choose between www.zf.com/products/tctronic
automatic or manual shifting by means of a tip switch.
The electronic controls prevent incorrect shifting, even
in manual mode. Clutch operation is automatic. The
twelve forwards and two reverse gears are perfectly
tuned to allow drivers to master even the most chal-
lenging driving situations. A primary retarder ensures 1 TC Tronic
perfect deceleration. Torque converter clutch for smooth starting

12
Ecomat: Safe, Economical, and
Comfort-Enhancing
Be it fire trucks or municipal vehicles: The Ecomat 6-speed auto-
matic transmission is the ideal supplement at the driveline end.
In comparison to the 5-speed transmission, it has two important
advantages: better tractive power and maximum driving speed at
lower engine speeds and use of the torque converter.

n The latest transmission generation does not only con-
tribute to the optimization of driving characteristics
and efficiency but also to considerable fuel savings and
reduced pollutant emissions.
n The Ecomat transmission has been designed for Euro 4
engines and, with its six gears, it is perfectly adapted
to frequent starting processes in inner city traffic. A
true relief for the driver. A special torsional damper not
only ensures further fuel savings but also preserves the
driveline. This way, the service life of the entire trans-
mission is extended. Furthermore, the torsional damper
contributes to minimizing vibrations. In addition, the
use of Ecofluid A plus, ZF’s transmission oil which has
been adjusted to special temperature requirements,
additionally extends the maintenance intervals.
n Ecomat can be equipped with power take-offs
for different applications.
n Preservation of the driveline thanks to smooth
gearshifts
n Programmable according to route topography
n Good road safety thanks to integrated retarder
n For municipal and construction vehicles
For further information visit:
www.zf.com/products/ecomattruck
2 Ecomat
Driving automatically, without torque interruption

13
Concept Transmission
For decades, transmission systems from ZF have been setting the stan-
dard in driveline technology for modern commercial vehicles. The require-
ments always emerge from the markets. The innovations are created with
the determination of finding optimal solutions. The next step to optimize
goods transport is called ‘Concept Transmission’.

With Concept Transmission, ZF is presenting a trendsetting modular

transmission system. After all, ZF has a powerful argument in response
to the ever more complex requirements: reducing system complexity.
The approach: one basic transmission which is combined with different
starting elements and optimized at the software end for the respective
application. The result: an innovative transmission system which is more
powerful and at the same time more economical, accounting for the in-
creasingly stringent environmental requirements, offering more comfort
and even more reliability.

14
 1 2
Four starting modules multiply the basic transmission's
possible applications:
The transmission can be combined with a ZF-Intarder
in any combination.
1 Dual-clutch module
• Powershift without torque interruption
• Reduced fuel consumption and emissions
by lower engine speeds combined with long
axles
2 WSK torque converter clutch
• Driving with high loads under tough
conditions (example: construction site traffic
or heavy transport)
• Wear-free, smooth, and comfortable starting
with the torque converter
3 Single- or double-disk clutch
• Depending on the vehicle weight
3 4
4 Hybrid module*
• Recuperation (generator function of the electric
motor during braking: charging the battery)
• Electric driving (driving without engine opera-
tion)
• Boosting (stored electrical energy for increased
performance of the diesel engine)
• Start-stop function (starting the engine and
driving off with the electric motor)
• Additional functionality (electric operation of
PTO or cooling units)
*Development promoted by:
15
Manual Transmissions
We continuously improve tried-and-trusted systems. ZF manual
transmissions represent custom-made truck driving: With five, six,
nine, twelve or sixteen gears, they are perfectly adjusted to the
performance range of modern commercial vehicles. Hills and val-
leys, stop and go, acceleration – they transmit the right torque for
every situation in all kinds of trucks. These robust transmissions
are characterized by extremely quiet running and optimal gear
spacing. They have long since proven their economic viability. Low
fuel consumption and minimal maintenance guarantee efficient
operation.

16
The constant further development of all manual transmission ranges
and the use of improved materials and processing technologies en-
sure that ZF’s manual transmissions are always state-of-the-art. They
live up to the challenges of powerful engines and heavy vehicles. At
the same time, efficiency and ecology are equally important criteria
for product development at ZF. Automotive manufacturers are equally
interested in weight reduction and compact dimensions as they are
in simple installation of the transmissions.

17
Ecosplit: Driveline Technology for
Heavy Trucks
Transporting heavy loads to their destination quickly, safely, and
economically. Doing a good job also in difficult terrain, off the
road. To achieve this, commercial vehicles need a powerful engine
and a transmission which transfers power with precision: Ecosplit.
With the light transmission version featuring twelve gear steps,
long-distance truck drivers are able to always achieve the optimum
output with all engines – when starting, accelerating, and making
headway. With sixteen gear steps, the Ecosplit manual transmission
shows its strength also in off-road applications. The gear spreading
is specifically adjusted to construction and special vehicle require-
ments.

n Thanks to its wide torque range, the Ecosplit

synchromesh transmission gets by with twelve
or sixteen gear steps. A light-metal housing
saves unnecessary weight, and the helical
gears allow for quiet running. Short-travel
and double-cone synchronizers as well as the
Servoshift unit reduce shift forces and paths.
The Ecosplit transmission range, which is
equipped with an integrated bell housing, is
available with a wide range of features for all
truck applications up to 44 tons total weight.

n The electronic control unit prevents accidental

changing over from higher gears to the gears
of the lower range change group. Further-
1
more, a gate lock in the lower range change
group prevents accidental down-shifting.

n Ecosplit can be equipped with clutch-

dependent and drive-dependent power
take-offs.

18
2 3
n Twelve or sixteen gear steps
n Compact and light design
n Low installation weight
n Minimized noise emission

1 Ecosplit
Optimum power transmission
2 Intarder For additional information visit:
3 Power take-off (PTO) www.zf.com/products/ecosplit
19
Ecomid: Driveline Technology
for Medium Trucks
Quickly transporting goods to another city, maneuvering in a pe-
destrian zone with heavy load. Collecting garbage in residential
areas. Doing hard work on a construction site, or reliably clearing
snow in the winter. Equipped with the Ecomid manual transmis-
sion system, vehicles have proven successful in long-distance traf-
fic, are used in a various applications as delivery and municipal
vehicles – and work very efficiently in all of these tasks. All around
the globe, medium trucks with Ecomid transmissions show off their
wide range of possibilities.

n The Ecomid makes it child’s play for truck

drivers to change gears while navigating busy
city streets. Nine gears effectively transfer the
engine power to the road - be it when driving
off after red lights, keeping up with the traf-
fic flow, or when driving uphill. Gears can
be engaged without any effort, quietly and
quickly - thanks to the pneumatic Servoshift
shifting assistance. The manual transmis-
sion with integrated clutch bell housing is
the perfect choice for commercial vehicles
with a gross vehicle weight of up to 36 tons.

n Thanks to the new ribbing, gear and housing

geometry, it has been possible to reduce noise
1
emissions. Thus, the Ecomid transmission
meets legal noise protection requirements
even without additional encapsulation. The
new Intarder generation, which can be in-
tegrated into the transmission, works in a
quieter and more environmentally friendly
manner. The wear-free transmission brake
with a 25 percent higher brake force than the
previous model can carry out up to 80 per-
cent of all braking. The consequence: more
safety, reduced brake wear, less brake dust.
1 Ecomid
Shifting made simple and economical
20
n Nine gear steps
n Dashboard-compatible shift system
n Compact and light design
n Low installation weight
n Minimized noise emissions
n Intarder and power take-offs possible

For further information visit: www.zf.com/products/ecomid

21
Ecolite: Driveline Technology
for Light Trucks
It is impossible to imagine our daily lives without them. Light com-
mercial vehicles and light trucks guarantee that we are supplied
with the necessities of life – everything from our breakfast rolls to
newspapers. Their services are irreplaceable particularly in metro-
politan areas where traffic is dense. These environments call for
low-maintenance vehicles which can be used flexibly, are easy to
operate, and feature low operating costs.

n The Ecolite range makes a wide selection of man-

ual transmissions with five or six gears available.
Their low weight, high performance, suitable
gear spreading, and quiet operation guarantee
efficient operation with optimal driving comfort.
And thanks to their robust design, the manual ZF
transmissions have very long service lives.

n Particularly in inner city traffic, legal provisions

to protect both man and the environment have
become stricter. Noise emissions produced by
commercial vehicles have to be reduced. Due to
a new gear and housing geometry the Ecolite’s
transmission noise is significantly below the legal
limit values. It is possible to install the transmis-
1
sion without additional encapsulation which is
also to the benefit of weight and size.

n Transmissions of the Ecolite range can be

equipped with up to two clutch-dependent power
take-offs.

1 Ecolite
Agile driving, dynamic shifting
22
n Five or six gear steps
n Dashboard-compatible shift system
n Compact and light design
n Low installation weight
n Minimized noise emissions

For further information visit: http://www.zf.com/products/ecolite

23
Intarder: Safe Braking
Efficiency and economy count when transporting goods. Engine
and transmission have to be suitable for the job. Safety is equally
important. The brakes have to work just as well as the engine! To
protect the brakes from fading due to long-term stress, secondary
retarders handle much of the work (80 to 90 percent).
This means that the service brakes stay cool and are ready for use
where necessary. In contrast to retarders made by other manufac-
turers, the Intarder is integrated in the transmission. Gentle brake
modulation is made possible by five brake levels. Its compact de-
sign hardly changes the transmission dimensions at all.

24
1 2

1 Intarder
Wear-free braking and increased safety
2 Power take-offs
Also possible for transmissions with Intarders

The latest version of the ZF transmission brake is

n 
lighter, and it has been possible to reduce power
losses.

n With considerably simplified connections, the

new Intarder can be attached to manual or auto-
matic transmission systems and can be optimally
integrated in the vehicle's brake management
system, including the cruise control function.
n The heat exchanger also offers cooling and heat-
ing functions for the transmission. Thanks to its
active support, the required transmission fluid
temperature – and thus also the optimum effi-
ciency for fuel consumption – is reached much
more quickly.
The Intarder is available for manual ZF synchro-
n 
mesh transmissions with 9, 12, and 16 speeds
and the automatic AS Tronic transmissions.
n Hydrodynamic, wear-free
hydraulic retarder
n Braking is independent of
engine speed
n No interruption in braking
force when engaging the
clutch or the gears
For additional information visit:
www.zf.com/products/intarder

25
ZF Power Take-Offs:
More Than Just Driving
Commercial vehicles with ZF power take-offs (PTOs) have special
capabilities. The PTOs turn them into true specialists for specific
tasks which can be performed while driving or parked. They can
collect garbage, clean sewage systems, clean streets, clear the
snow, mow slopes, mix and pump concrete, or lift and dump heavy
loads. Those are just a few of the many possibilities.

26
1 2

1 Engine-dependent PTO (NMV)

2 Clutch-dependent PTO (N/10)
3 Drive-dependent PTO (N/PL)
n Engine-dependent PTOs are arranged between
engine and transmission and are driven directly
by the engine via a special coupling. Applica-
tions: High-pressure pumps for fire trucks, sewer
cleaning and suction vehicles, drilling devices,
concrete mixers and pumps.

n Clutch-dependent PTOs are fitted on the output

or laterally on the transmission housing. They
only operate when the engine is running and
the vehicle clutch is closed. Applications: water,
sludge, and hydraulic pumps, compressors,
winches, turntable-equipped fire trucks, working
platforms, etc.

n Drive-dependent PTOs are connected to the n Drive of additional units

transmission output shaft. They are active as
soon as the drive wheels of the vehicle begin to
move. They supply the hydraulic system of dual-
circuit steering systems with working pressure.
This means that drivers can still steer the vehicle
in the case of engine failure.
n For a wide range of applications
n Retrofit is also possible
For additional information visit:
www.zf.com/products/pto

27
Innovative Driving:
With ZF Hybrid Technology
Future driveline technology must strike a balance between eco-
nomic and ecological requirements. Just like the hybrid concepts
offered by ZF. For trucks, ZF relies on parallel hybrid systems
where combustion engine and electric motor are arranged in paral-
lel and controlled via the transmission. They can be implemented
in an economically feasible way – integrated into existing vehicle
concepts as an alternative to manual or automatic transmissions.

The advantages of ZF hybrid technology for commercial vehicles

become particularly obvious in inner city traffic which is character-
ized by frequent starting and braking. During start/stop operation,
the combustion engine is switched off at standstill. The electric
motor performs the starting process independently, without any
restrictions in driving performance or comfort. In turn, the energy
generated during braking is used for charging the hybrid batteries
(recuperation). If boosting, i.e. electrically supported acceleration
and purely electric driving are also possible, trucks consume up to
30 percent less fuel. Equipped with ZF hybrid technology, com-
mercial vehicles make headway in a fuel-saving, environmentally
friendly, and considerably quieter way than in the past, which gives
them the ‘green’ light for the new environmental zones in the city
centers.

28
1 2

1 HyTronic lite
2 Hybrid module
with electric motor

HyTronic

n The ZF-HyTronic hybrid concept builds upon
the proven AS Tronic lite automatic transmission
and is suitable for applications in delivery trucks.
As a full hybrid system – consisting of transmis-
sion, 60 kW electric motor, inverter, high-voltage
batteries, and power routing – it offers all func-
tions from start/stop operation and recuperation
to boosting and purely electric driving.
n One advantage, particularly for municipal vehi-
n The complete system can easily be installed in
vehicle types which have been equipped with
manual or automated transmissions in the past.
The modular hybrid kit will be used both by
vehicle manufacturers as a complete system
and by system providers as a hybrid powerpack
consisting of a hybrid module, inverter, and
high voltage battery. To make sure that optimum
efficiency is always achieved in the interaction
of the electric motor, combustion engine, and
transmission, ZF supports vehicle manufacturers
in system integration when it comes to energy
management. The hybrid kit’s modular design
allows for applications in all truck classes.
cles with special tasks: The electric motor can
also be used as power source during generator
operation. Fuel consumption and noise pollution
caused by power take-offs are reduced.
For additional information visit:
www.zf.com/products/hytronic

ZF

OEM

High voltage

Power Supply
Auxiliaries

High voltage
Inverter

DC/DC

Cooling system

EDC TCU/ H2O Battery

HCU 340V

ECU ECU ECU

Hybrid CAN

ABS/EBS
Vehicle CAN
29
ZF Driveline Technology –
Tailor-Made Products
in Operation Worldwide

ZF targets the emerging markets Brazil, Russia, India, and China

with economical and robust commercial vehicle transmissions.
Various production locations in these countries guarantee that the
’local' customers’ requests and requirements can be implemented.

Truck transmissions such as the 9-speed manual Ecomid transmis-

sion for the Indian market, the Ecomid and Ecosplit transmissions
which are produced at the location of the joint venture ZF Kama in
Naberezhnye Chelny, as well as the 5 S 400 manual transmission
manufactured in Hangzhou, China, have been adapted to the spe-
cific requirements of the markets.

Approx. 700 Service Centers guarantee the worldwide supply of

spare parts and swing units and help our customers save expen-
sive downtimes or failure costs. Service increasingly also includes
the provision of knowledge of the vehicle and transmission as well
as some advice on how further savings can be achieved with the
product in individual practice.

30
On-Site Service:
Partner of Fleet Operators

n Transmissions deliver high performance in tough everyday

operation. High mileage with almost no wear is normal. Nev-
ertheless, even the best technology requires expert mainte-
nance and occasional repairs. Also in this case, ZF is there to
serve its customers, always nearby with more than 700 service
centers around the globe.

n The wide range of services aims at supporting the competi-

tiveness of all ZF partners in the long run: First, by offering
comprehensive consulting and support, second, by installing
original spare parts and replacement units as well as technical
add-ons in the vehicles. Transmissions are replaced world-
wide in the shortest time possible. A further advantage of the
service is the adaptation of commercial vehicles to changed
conditions. Based on a thorough analysis of requirements and
performance parameters, ZF will find the best optimization
solution for more efficiency.

31