The Future of Construction – Intelligent System Solutions by ZF

Electrification – New modular e-platform ZF eTRAC covers power range from 20-230 kW for construction machinery

The eTRAC electric drive system satisfies all the expectations for performance and productivity found in traditional drivelines and combines them with the benefits and opportunities that electric systems have to offer. Thanks to its modular design this new range of electric central drives can easily be adapted for various vehicle applications. With several solutions for compact machinery and mobile excavator applications already in series production, ZF now completes the range of electric central drives with its latest development – eTRAC eCD100 and eCD210 (fig. 2 and 3).

The modular transmission portfolio covers the power range from 20-230 kW for construction machinery and material handling applications, such as:

• Compact loaders
• Telescopic handlers
• Mobile Excavators
• Wheel Loaders
• Forklifts

ZF eTRAC delivers zero‑emission mobility without compromising on performance, combining highly efficient electrical components with a robust and reliable mechanical driveline.

The modular system can be driven independently from the power source. It fits in both battery-electric vehicles and fuel-cell battery electric vehicles, which will also play a big role in the future of construction machineries.

Decarbonization – Fuel saving powershift and CVT technology for construction and earth moving applications

Whilst batteries are a suitable source for electric compact and medium vehicles, alternative fuels are a promising power source for medium and large size vehicles to reduce their CO2 footprint.

Despite all the different power sources entering the market recently – be it hydrogen, eFuels or, for example, bio-diesel – conventional drives with powershift and power split transmissions will remain to be the backbone of the vehicle´s system architecture.

No matter the power source, conventional diesel, alternative fuels, or electrification: ZF is more than up to these challenges. With the well-established ERGOPOWER powershift transmission as well as highly efficient cPOWER CVT technology ZF can provide the right driveline technology, independent from the power source (fig. 4 and 5).

Particularly in earthmoving applications, where machines operate under constant high loads, efficiency directly impacts productivity and fuel consumption. ZF ERGOPOWER with its intelligent differential management system ERGOTRACTION III is the right solution, delivering reliable power transfer and high efficiency. Combined with the durable and high‑performance MULTITRAC axle, ZF offers a robust and efficient driveline system tailored to extreme loads and operating conditions (fig. 6 and 7).

Vehicle Intelligence – Future-proof transmission control unit EC5 enabling advanced driver assistance functions

With the previously mentioned ERGOTRACTION III concept, the EC5 Drive Control Unit enables fully automated, situation‑dependent differential lock management. Operating continuously in the background, the system ensures optimal traction without affecting normal driving, allowing the driver to fully focus on vehicle operation (fig. 8).

Building on these intelligent control capabilities, the EC5 also enables Transmission‑Based Deceleration Assist for automated vehicle deceleration via the transmission, without using the service brake. Triggered by external signals such as obstacle detection, the function helps reduce reaction time in critical situations while remaining fully overridable by the operator.

As vehicle intelligence and connectivity increase, Cyber Security becomes essential for system safety and integrity. The EC5 Drive Control Unit is cyber‑security‑ready, designed to comply with upcoming EU regulations, while ensuring seamless OEM integration through unchanged interfaces and plug‑and‑play hardware.

Efficiency – Increased torque density for Mobile Drives

In the Construction and Mining Industry, machine efficiency is a key factor in increasing site productivity and minimizing downtime. Addressing these growing demands, ZF Industrial Drives is presenting its latest advancements in Large Drive Systems for mobile applications – the GPT 4F Travel Gearbox Series, covering a range from 73,750 to 2,212,500 ft-lbs (100 – 3,000 kNm) output torque.

The next generation of ZF Planetary Gearboxes combines a compact design with significantly higher output torque, along with optimized service concepts that support greater availability and reduced maintenance effort (fig.9).

The Travel Gearbox Series GPT 4F is designed for Mining Excavators, Large Construction Machines and for Crawler Cranes with machine weights from 50 to 1,000 tons. By using the latest design and manufacturing tools, the gearboxes show a significantly increased torque density, while maintaining a compact design (fig. 10).

In this context, ZF is showcasing the modified GPT 450 4F Travel Gearbox for Excavator and Crane applications. The GPT 450 4F is suited for output torques up to 368,000 ft-lbs (500 kNm) and is designed to deliver highest reliability in harshest operating conditions.

The new generation of ZF Planetary Gearboxes is also available with the performance management system ProVID. The sensors and software of the ZF ProVID system enable a permanent condition analysis and a significant extension of service life through preventive maintenance measures.

To complete the Gearbox portfolio for Construction Machinery, ZF also offers GFB Swing Gearboxes and GFC Pump Distribution Gearboxes in different sizes.

Lifecycle Performance – Aftermarket Solutions for Maximum Uptime

To meet the increasing demands for flexibility, efficiency and reliability throughout the entire machine lifecycle, ZF complements its system expertise with a strong and comprehensive Aftermarket portfolio. Built on decades of experience in Off Highway applications, ZF Aftermarket supports construction machinery operators and service partners with robust components and integrated service solutions designed for extreme loads, harsh environments and demanding duty cycles.

The portfolio includes for example torque converters, oils (fig. 11) and hydraulic brake components, engineered to ensure optimal performance while minimizing downtime. Workshops benefit in particular from comprehensive technical training and detailed documentation, enabling them to maintain consistently high service standards. ZF’s global service ecosystem further supports professional repair operations with diagnostics, repair solutions and remanufacturing options, while a strong global logistics network ensures fast delivery times and high parts availability. With this end to end Aftermarket approach, ZF provides reliable support worldwide – with North America representing a key market for future growth.