Testman Pro

ZF diagnosis tool Table of contents Page 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 2

ZF diagnosis tool Preface This documentation has been developed for specialist staff who have been trained by ZF Friedrichshafen AG to undertake maintenance and repair work on ZF products. The document makes reference to a volume production ZF product in accordance with the state of development on the date of issue. However, due to continuing technical development of the assembly in question, repair work might require work practices and 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 had their practical and theoretical knowledge updated on a regular basis at our after-sales service training center. ZF FRIEDRICHSHAFEN AG Commercial Vehicles/Special Transmissions Division Service Plant 2 Tel.: 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 staff  2. Specified equipment, e.g. specialized tools 3. Genuine ZF spares, to our latest specifications - All work performed in these service points is carried out can conscientiously and with care. Warranty: Repair work carried out at ZF service points is covered by warranty in accordance with the prevailing contractual conditions. Damage resulting from work caused by non-ZF personnel in an improper and professional manner, together with follow-on costs caused by such work, is excluded from the contractual liability agreement. This also applies where genuine ZF spares have not been used. 3

ZF diagnosis tool 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 requirements which 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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ZF diagnosis tool  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 sensitive surface 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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ZF diagnosis tool Function table Button

Description OK, confirmation of a function or end of a display (e.g. test device)  Abort Help screen, additional information is displayed Print out a screen page Back to previous page System functions

Can be operated with:

     

+

Multiplication button 6

ZF diagnosis tool Function table Button

Description

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).

Can be operated with:

      7

ZF diagnosis tool Function table Button

Description

Can be operated with:

With the next 2 functions, you can use the keyboard to proceed in small steps by holding down each 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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ZF diagnosis tool TestmanPro Directory Structure TestmanPro main directory (files must not be moved).

 ASTronic2 Target directory for vehicle technical data and statistics memory files.

Intarder EST42/48 Target directory for  vehicle technical data.

 ASTronic2 Test rig protocols.

Basic directory for  statistics diagram tool and storage for  statistics file .sta.

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

Target directory for  PDF documentation Project folder comprises the individual applications. Target  ASTronic2directory for  HEX programming files. Ecomat target directory for BIN programming files. Intarder EST42/48 Target directory for  EOL programming files. WSK EST41/61 Target directory, EOL programming files. Basic Data Logger  directory

Recommended directory for  statistic diagram files saved.

Ecomat target directory for vehicle technical d,ata.

WSK target directory for vehicle technical data.

Target directory for registered and saved Data Logger files.

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

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

USB driver for DPA05. Files must not be moved.

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

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ZF diagnosis tool Screenshot The Screenshot tool provides a simple means of turning screenshots into graphics files, or for  printing them out. When a graphics file is generated, there is an entirely free choice for naming the image and selecting a target directory. Whenever Testman is loaded or updated, the Screenshot tool is automatically set up in the Autorun directory, i.e. you will therefore find this application on the task bar beside the system clock whenever 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 file name 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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ZF diagnosis tool Screenshot

Select target directory

Select any file prefix Save screen contents as a graphics file (*.jpg)

Print screenshot

Minimize application

Close application

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ZF diagnosis tool DPA DriversTestmanPro PC driver 

TestmanPro in conjunction with DPA04 / 05 can be checked and/or updated using a dialog window. The following description illustrates the individual functions.  After starting the TestmanPro, you can verify the new drivers by clicking on the ZF symbol in your task bar  (DPA04/05 must be powered at correct operating voltage):

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

DPA04i driver  USB driver  When required, you can select your COM port here.

On request, you can extend the time until the timeout here (for  PCs with smaller  working capacities this may be necessary so to avoid a preliminary ..abortion of  communication .

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ZF diagnosis tool TestmanPro DPA Drivers Programming and Updating  After 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 not the 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 prove necessary (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 the software (driver for W indows / 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. This also 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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ZF diagnosis tool Inserting and starting PDF files Testman Pro not only allows for communication between laptop and control unit but is also a source of information for various pieces of documentation such as manuals, repair  manuals and lists of lubricants. These files are also supplied depending on the application in question. Furthermore, up to 5 individual links to PDF files can be created and can be started via the Testman Pro menu. The links can be created in a configuration file. The configuration files are created in the ..\GDS3000\apps\pdf directory for each application 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 configuration file must be adapted accordingly (see next page).

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ZF diagnosis tool Description of the first data line of the configuration file n;Name1;pdf/file name1;....;Name4;pdf/file name4; n NameX File nameX

-> Number of documents (max. 4) -> Button text in Testman Pro -> 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 (\) st - Data must be available in the 1  line - Lines MUST always end with a semicolon Example: 2;system manual;pdf/sys_manual.pdf;adjustment data;pdf/adjust_data .pdf; 15

ZF diagnosis tool Troubleshooting in the Event of Faulty Communication Possible cause

Remedy

Cable connections are not OK.

Check that all cables are correctly connected and check that all cables and connectors are undamaged. Check ISO connecting cable. ZFF 0501 211 103 ZFP 6029 017 005

Wrong ISO connecting cable.

Incorrect setting for COM port (interface). DPA is not recognized by the PC.

Incorrect address code.

Set and check COM port (interface) (refer to pages 12-13) Check connection. Check DPA operating voltage. If necessary, reprogram the DPA (refer to pages 12-13) As standard, TestmanPro uses the correct address code but you may still need to change the address code on some old control units.

Possible for    DPA: 03 04 05

X

X

X

X

X

X

X

X

X

X

X

X

X

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ZF diagnosis tool Troubleshooting in the Event of Faulty Communication Possible for    DPA: 03 04 05

Possible cause

Remedy

Control unit detects voltage supply at EUPR input.

UPRG switch on DPA must be in OFF position during normal diagnosis and there should be no electrical power supply to the EUPR input on the control unit. Check L line on control unit. During diagnosis process, K line should not be connected to an electrical power source.

X

X

X

X

X

X

Check that DPA is correctly connected. Check vehicle current supply (Terminal 30). Switch on ignition if necessary (Terminal15). Check ground connection. DPA04 may have lost its programming. Reprogram the DPA. DPA05 may have lost its programming. Reprogram the DPA. Check with specialist provider that the adapter  you have just purchased is working properly. Ensure that cable is kept short (as short as possible)!

X

X

X

L line excited (ISO mode).

Green UBATT lamp off.

Green UBATT lamp flashing. Green LED OK lamp not flashing.

USB->COM adapter is not working correctly.

X X

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