Testman Pro

ZF diagnosis tool

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Description and menu layout

ZF diagnosis tool

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Table of contentsPage

Description and menu layout ............................................................................................................................... 1

Table of contents.................................................................................................................................................... 2

Preface .................................................................................................................................................................... 3

Important work safety information..................................................................................................................... 4

Operation................................................................................................................................................................ 5

Function table ........................................................................................................................................................ 6

TestmanPro Directory Structure......................................................................................................................... 9

Screenshot ............................................................................................................................................................ 10

DPA DriversTestmanPro.................................................................................................................................... 12

TestmanPro DPA Drivers Programming and Updating................................................................................. 13

Inserting and starting PDF files......................................................................................................................... 14

Troubleshooting in the Event of Faulty Communication ............................................................................... 16

ZF diagnosis tool

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Preface

This documentation has been developed for specialist staff who have been trained by ZF Friedrichshafen AG to undertakemaintenance and repair work on ZF products.

The document makes reference to a volume production ZF product in accordance with the state of development onthe date of issue.However, due to continuing technical development of the assembly in question, repair work might require work practicesand adjustment or test data other than that specified here.We therefore recommend that work done on your ZF product is carried out only by supervisors and fitters who have hadtheir practical and theoretical knowledge updated on a regular basis at our after-sales service training center.

ZF FRIEDRICHSHAFEN AGCommercial Vehicles/Special Transmissions DivisionService Plant 2Tel.: 00 49 75 41 77-0 Fax: 00 49 75 41 77-5726

Service points equipped by ZF Friedrichshafen AG all over the world offer you:1. Continuously well-trained staff2. Specified equipment, e.g. specialized tools3. Genuine ZF spares, to our latest specifications - All work performed in these service points is carried out canconscientiously and with care.Warranty:Repair work carried out at ZF service points is covered by warranty in accordance with the prevailing contractualconditions.Damage resulting from work caused by non-ZF personnel in an improper and professional manner, together with follow-oncosts caused by such work, is excluded from the contractual liability agreement. This also applies where genuine ZF spareshave not been used.

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Important work safety information

Companies which repair ZF assemblies are responsible for their own work safety.To avoid injury to personnel and damage to products, all safety regulations and legal requirementswhich apply to repair and maintenance work must be observed.

Before starting work, repair staff must familiarize themselves with these regulations.

Personnel required to carry out repairs on these ZF products must receive appropriate training in advance.It is the responsibility of each company to ensure that their repair staff is properly trained.

The following safety instructions appear in this manual:

NOTE:Refers to special processes, techniques, methods, information etc.

CAUTION:This is used when incorrect, unprofessional working practices could damage the product.

DANGER!This is used when lack of care could lead to personal injury or damage to property.

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Operation

Testman Pro can be operated using the mouse or keypad.

When using the mouse, you simply have to select the button shown on the sensitivesurface and activate this by clicking with the left-hand mouse key.

When using the keypad, the buttons can be operated using various keypad commands.

The meaning of the symbols is shown in the following table:

Can only be operated with the mouse

Can be operated with mouse and keypad (e.g. press the ENTER key).Note:The keypad designations may vary depending on language and keypad manufacturer!

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Function table

Button Description Can be operated with:

OK, confirmation of a function or end of adisplay (e.g. test device) Abort Help screen, additional information is displayed Print out a screen page +

Back to previous page System functions

Multiplicationbutton

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Function table


Page up a screen page. Page down a screen page. Increase or decrease a page section (e.g.circuit diagrams) Increase screen content. Reduce screen content.

Menu selection(e.g. diagnosis).

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Function table


With the next 2 functions, you can use the keyboard to proceed in small steps by holding downeach key briefly, or in large steps by holding the key down for longer. When using the mouse,you can only proceed in small steps.

Settings can be changed to the left.(e.g. using key 1). Settings can be changed to the right.(e.g. using key f).

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TestmanPro Directory StructureTestmanPromain directory(files must not bemoved).

Target folder for individual application files,Variable index lists, license, and variousapplications which TestmanPro requires.

Target directory forPDF documentation

Project folder comprises the individualapplications.ASTronic2

Target directory for vehicletechnical data andstatistics memory files.

TargetASTronic2directory forHEX programming files. Ecomat target directory for vehicletechnical d,ata.Ecomat target

directory for BINprogramming files.Intarder EST42/48

Target directory forvehicle technical data. Intarder EST42/48

Target directory forEOL programming files. WSK target directory for vehicletechnical data.

WSK EST41/61Target directory, EOLprogramming files.ASTronic2Test rig protocols.

Basic Data Loggerdirectory Target directory for registered and saved

Data Logger files.Basic directory forstatistics diagram tooland storage forstatistics file .sta.

Recommended directory forstatistic diagram files saved. Currently not needed.

Basic Flash data for DPA05. Files must not be moved.

Basic Flash data for DPA05. Files must notbe moved.

USB driver for DPA05. Files must not bemoved.

Screenshot tool, refer to next page for description.Files should not be moved.

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ScreenshotThe Screenshot tool provides a simple means of turning screenshots into graphics files, or forprinting them out.When a graphics file is generated, there is an entirely free choice for naming the image and selectinga target directory.

Whenever Testman is loaded or updated, the Screenshot tool is automatically set up in the Autorundirectory, i.e. you will therefore find this application on the task bar beside the system clockwhenever you boot your computer.

When you press the Print button, a .jpg image is created and saved automatically.When you press the Print button together with the Shift function, the screen image is only printed(i.e. it is not saved).

Whenever you select the icon using the right-hand mouse button, you can select the appropriate filename and target directory in the Options function. You can also select any of the following functions:Create Image File; Print Screen (Screen Dump); Minimize Application and Close Application.

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Screenshot

Close applicationMinimize application

Save screen contentsas a graphics file (*.jpg)

Print screenshot

Select any file prefix

Select target directory

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DPA DriversTestmanPro

TestmanPro in conjunction with DPA04 / 05 can bechecked and/or updated using a dialog window.The following description illustrates the individualfunctions.

After starting the TestmanPro, you can verify the newdrivers by clicking on the ZF symbol in your task bar(DPA04/05 must be powered at correct operatingvoltage):

Important:Please consult the documentation accompanying thissoftware to check the latest version status!

When required,you can selectyour COM porthere.

PC driver

DPA04i driver

On request, youcan extend thetime until thetimeout here (forPCs with smallerworkingcapacities thismay be necessaryso to avoid apreliminary..abortion ofcommunication).

USB driver

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TestmanPro DPA Drivers Programming and UpdatingAfter the installation, the PC and DPA version must be available in the system as shown in the figure (refer to page 12). If that is notthe case, then the DPA04/05 must be re-programmed as follows:

Note to DPA05: With DPA05 the DPA cannot be programmed via the USB port. However, this is only true for complete programming, not for

DPA05 updates.However, this is not usually required because updating is usually sufficient. Nevertheless, if complete programming does provenecessary (complete loss of data), this can be performed using the COM interface.If the computer does not have a COM interface, a standard USB -> COM adapter needs to be used (not in the ZF scope of supply,please source from a specialist provider).

If the system detects a missing USB driver or one which has not been updated, please follow the instructions provided by thesoftware (driver for Windows / DPA05 available in the GDS3000\usb_driver).

Note to DPA04: The DPA04i can only be programmed if the computer has a COM 1 or a COM2. If this is not the case, the entire GDS3000\

dpaload_uni directory can be copied onto another computer and the DPA can then be programmed from that other computer. Thisalso needs to be taken into consideration if the DPA is connected up via a USB->COM adapter (not in the ZF scope of supply,please obtain from a specialist provider).

Complete programming:1. Connect the DPA04/05 to the COM interface of your PC.2. Connect the DPA04/05 to a 24 V power source.3. Click on Load DPA.USB Update (only DPA05):1. Connect the DPA05 to the USB interface of your PC.2. Connect the DPA05 to a 24 V power source.3. Click on UpdateDPA05.

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Inserting and starting PDF files

Testman Pro not only allows for communication between laptop and control unit but isalso a source of information for various pieces of documentation such as manuals, repairmanuals and lists of lubricants.These files are also supplied depending on the application in question. Furthermore, upto 5 individual links to PDF files can be created and can be started via the Testman Promenu.

The links can be created in a configuration file.

The configuration files are created in the ..\GDS3000\apps\pdf directory for eachapplication during installation.The file name always consists of the docu_ prefix as well as a project abbreviation(e.g. docu_as2.txt).

In order to create PDF links, the first line in the relevant project-dependent configurationfile must be adapted accordingly (see next page).

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Description of the first data line of the configuration file

n;Name1;pdf/file name1;....;Name4;pdf/file name4;

n -> Number of documents (max. 4)NameX -> Button text in Testman ProFile nameX -> File name of PDF file (always with pdf/...)

Important information:

- A maximum of 4 individual PDF documents can be linked- PDF files must ALWAYS be linked with - 'pdf/...'!!! IMPORTANT: use slash(/) and NOT backslash (\)- Data must be available in the 1st line- Lines MUST always end with a semicolon

Example:

2;system manual;pdf/sys_manual.pdf;adjustment data;pdf/adjust_data .pdf;

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Troubleshooting in the Event of Faulty Communication

Possible cause RemedyPossible for DPA: 03 04 05

Cable connections are not OK. Check that all cables are correctly connectedand check that all cables and connectors areundamaged.

X X X

Wrong ISO connecting cable. Check ISO connecting cable.ZFF 0501 211 103ZFP 6029 017 005

X X X

Incorrect setting for COM port (interface). Set and check COM port (interface)(refer to pages 12-13)

X XDPA is not recognized by the PC. Check connection.

Check DPA operating voltage.If necessary, reprogram the DPA(refer to pages 12-13)

X X

Incorrect address code. As standard, TestmanPro uses the correctaddress code but you may still need to changethe address code on some old control units.

X X X

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Troubleshooting in the Event of Faulty Communication

Possible cause RemedyPossible for DPA: 03 04 05

Control unit detects voltage supply atEUPR input.

UPRG switch on DPA must be in OFF positionduring normal diagnosis and there should be noelectrical power supply to the EUPR input on thecontrol unit.

X X X

L line excited (ISO mode). Check L line on control unit. During diagnosisprocess, K line should not be connected to anelectrical power source.

X X X

Green UBATT lamp off.

Check that DPA is correctly connected.Check vehicle current supply (Terminal 30).Switch on ignition if necessary (Terminal15).Check ground connection.

X X X

Green UBATT lamp flashing. DPA04 may have lost its programming.Reprogram the DPA.X

Green LED OK lamp not flashing. DPA05 may have lost its programming.Reprogram the DPA.X

USB->COM adapter is not working correctly.

Check with specialist provider that the adapteryou have just purchased is working properly.Ensure that cable is kept short (as short aspossible)!

ZF-Testman Pro, ZF diagnosis toolDescription and menu layoutTable of contentsPrefaceImportant work safety information OperationFunction tableFunction table 2Function table 3

TestmanPro Directory StructureScreenshotScreenshot 2

DPA DriversTestmanProTestmanPro DPA Drivers Programming and UpdatingInserting and starting PDF filesDescription of the first data line of the configuration fileTroubleshooting in the Event of Faulty Communication 1Troubleshooting in the Event of Faulty Communication 2

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