ZF diagnosis tool

Description and menu layout

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
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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.
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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.

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:

8
87

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!

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:

87
8
8
87
87
87

Multiplication
button
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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:

87
87
8
8
8
87
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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).

87
87

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.

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
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!

PC driver
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 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. 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 (\)
- 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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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

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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.

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)!

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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