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Test step list, ZBR2

Test step list, ZBR2

Important! The tests must only be performed with the vehicle at a standstill, the parking brake applied
and the vehicle engine switched off.

Test description
The test step list enables you to check the central on-board computer components or functions using a
multimeter (e.g. FLUKE 87).

Rectangular signals or clocked signals can also be checked using an oscilloscope or multimeter
(Skopemeter) 123 (FLUKE).

In the test step list in this section (example: test step 1), the first test contact is designated "Pin F1/12" and
the second test contact is designated "Pin M/16". Use a multimeter to measure the resistance between these
pins. Measurements are taken directly on the central on-board computer. The measuring mode to be set on
the measuring instrument (multimeter) is shown between test contacts (pins) listed in column 2.

Example: Setting “V” = Voltage measurement

Example: Setting “Ω” = Resistance measurement
Once the test requirements have been fulfilled, the value indicated on the measuring device (actual
characteristic) can be compared with the desired value (desired characteristic).

Two sample measurements are described below:

If voltages are being measured, switch on the ignition and leave the central on-board computer connectors
connected.

The figure above is a measurement example based on the TGA.

In this example, the voltage supply for headlight low beam, right is measured between pin BR/2 - positive line
and pin M/16 - ground line.

The measured value obtained using the FLUKE 87 multimeter is 22.89V (battery voltage).

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If resistances are being measured, switch off the ignition and leave the central on-board computer connectors
disconnected.

The figure above is a measurement example based on the TGA.

In this example with the T-CAN driveline databus, the resistance is measured between pin M/1 (T-CAN high
signal line) and pin M/7 (T-CAN low signal line).

The measured value obtained using the FLUKE 87 multimeter is 60.4Ω.

Test step list

SN: ............................................................... Tester: ..........................................................
Customer:......................................................... First registered: .............................................
Vehicle model: ................................................ Chassis no.: ............................................
Engine model: ...................................................... Engine number:.............................................
CR high-pressure pump: ................................. Control unit no.: ...........................................
Mileage: ................................................ Date:.........................................................
MAN-cats II must be used to produce a summary of the ZBR2 error memory to accompany the completed
test step list.

Use the overviews for troubleshooting.

When a voltage is being measured, the ignition is switched on.
When a resistance is being measured, the ignition is switched off and the central on-board computer is
disconnected.
Voltages and resistances between the pins are measured using a multimeter (e.g. FLUKE 87).
Never measure at the plug contacts themselves without using suitable test probes! Danger of
bending open the contacts!

Digital inputs
Measuring device Starter Measured
Test Desired value
Pin+ Pin- switch value
Info., emergency off F1/12 M/16 ON approx. 4V ..................

Reverse gear engaged M/6 M/16 ON 16 - 32V (Ubat) ..................

0V
Limit switch, wiper motor in end position 16 - ..................
F1/10 M/16 ON
(park position) 32V (Ubat) when ..................
wipers running

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Alternator, terminal L M/4 M/16 ON approx. 1.5V ..................

Fault, trailer ABS X/2 M/16 ON approx. 20V ..................
Button, interim
X/6 M/16 ON approx. 20V ..................
lubrication

Analogue inputs
Test Measuring device Starter switch Desired value Measured
Pin+ Pin- value

Cab lock R1/1 M/16 ON Unlocked: approx. ..................

20V ..................
Locked: 0V
Fill level, clutch fluid (on-
board computer R1/2 M/16 OFF approx. 2.2kΩ ..................
disconnected)
Vacuum, air filter X/3 M/16 ON 0.5 - 4.5V ..................
Coolant level (on-board
R1/3 M/16 OFF approx. 2.2kΩ ..................
computer disconnected)
Oil level, steering oil
R1/6 M/16 ON approx. 0V ..................
reservoir
Fill level, windscreen
F1/7 M/16 ON approx. 20V ..................
washer pump
0.5 - 4.5V (if ECAM
Reservoir pressure, ..................
R1/11 M/16 ON default function)
circuit 1 ..................
0V (with ECAM)
0.5 - 4.5V (if ECAM
Reservoir pressure, ..................
R1/9 M/16 ON default function)
circuit 2 ..................
0V (with ECAM)
0.5 - 4.5V (if ECAM
Reservoir pressure, ..................
R1/8 M/16 ON default function)
circuit 3 ..................
0V (with ECAM)
0.5 - 4.5V (if ECAM
Reservoir pressure, ..................
M/2 M/16 ON default function)
circuit 4 ..................
0V (with ECAM)
Fuel fill level 1 (on-board
R1/13 M/16 OFF 10 - 72Ω ..................
computer disconnected)

Sensing of controls
Test Measuring device Starter Desired value Measured
Pin+ Pin- switch value

Wake-up, computer - F1/11 M/16 ON 16 - 32V (Ubat) ..................

diode, central on-board
computer wake-up
TRUCKS: Door contact
switch Right step
- Right door open
- Right door closed
BUSES: Aisle buzzer
(short signal when ..................
locking or unlocking
via central locking)
otherwise: approx.
4V
16 - 32V (Ubat) ..................
F1/8 M/16 ON approx. 2.5V ..................
16 - 32V (Ubat) ..................

TRUCKS: Door contact

switch Left step 16 - 32V (Ubat) ..................

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- Left door open approx. 2.5V ..................

- Left door closed F1/9 M/16 ON 16 - 32V (Ubat) ..................
BUSES: Aisle buzzer
Button, windscreen
washer approx. 2.5V ..................
F1/4 M/16 ON
- not actuated 16 - 32V (Ubat) ..................
- actuated
Interval switch
approx. 2.5V ..................
- not actuated F1/5 M/16 ON
16 - 32V (Ubat) ..................
- actuated
Grease quantity, central
lubrication system (on-
F2/8 M/16 OFF 1.47kΩ ..................
board computer
disconnected)
Pump strokes, central
lubrication system (on-
F2/11 M/16 OFF 1.47kΩ ..................
board computer
disconnected)
Button, headlight
flash/headlight high
F1/13 M/16 OFF 2.2kΩ ..................
beam (on-board
computer disconnected)
Switch, turn indicator, left
(on-board computer F1/15 M/16 OFF 1.47kΩ ..................
disconnected)
Switch, turn indicator,
right (on-board computer F1/16 M/16 OFF 1.47kΩ ..................
disconnected)
Hazard warning light
switch (on-board F1/1 M/16 OFF 1.47kΩ ..................
computer disconnected)
Switch, headlight low
beam (on-board F1/17 M/16 OFF 1.47kΩ ..................
computer disconnected)
Switch, parking lights
(on-board computer F1/14 M/16 OFF 1.47kΩ ..................
disconnected)

Digital outputs
Test Measuring device Starter Desired value Measured
Pin+ Pin- switch value

Check lamp, fog lamps X/12 M/16 ON 16 - 32V (Ubat) ..................

Relay, parking/tail lights X/17 M/16 ON 16 - 32V (Ubat) ..................

Holding output, battery
R2/18 M/16 ON 16 - 32V (Ubat) ..................
master switch
16 - 32V (Ubat)
(clocked signal*
Solenoid valve, flame ..................
M/13 M/16 ON when flame start
start ..................
active)
otherwise: 0V
Relay, consumers,
F2/12 M/16 ON 16 - 32V (Ubat) ..................
terminal 15/ignition "ON"
Relay, reversing light F2/13 M/16 ON 16 - 32V (Ubat) ..................

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Check lamp, hazard 16 - 32V (Ubat)

F2/16 M/16 ON ..................
warning lights (clocked signal)
16 - 32V (Ubat)
Warning buzzer
F2/9 M/16 ON (permanent or ..................
(instrumentation)
clocked signal)
Check, failure,
X/14 M/16 ON 0V ..................
instrumentation
16 - 32V (Ubat)
Heating element for HGS ..................
M/18 M/16 ON (when HGS active)
heating ..................
otherwise: 0V
16 - 32V (Ubat)
(when engine ..................
Engine running F2/17 M/16 ON
running) ..................
otherwise: 0V
Headlight low beam, left BL/6 M/16 ON 16 - 32V (Ubat) ..................
Headlight low beam, right BR/2 M/16 ON 16 - 32V (Ubat) ..................
Headlight high beam, left BL/5 M/16 ON 16 - 32V (Ubat) ..................
Headlight high beam,
BR/1 M/16 ON 16 - 32V (Ubat) ..................
right
Step and interior lighting,
F2/4 M/16 ON 16 - 32V (Ubat) ..................
left
Step and interior lighting,
F2/5 M/16 ON 16 - 32V (Ubat) ..................
right
Auxiliary high beam
BL/1 M/16 ON 16 - 32V (Ubat) ..................
headlight, left
Auxiliary high beam
BR/4 M/16 ON 16 - 32V (Ubat) ..................
headlight, right
Washer pump, headlight
F2/1 M/16 ON 16 - 32V (Ubat) ..................
cleaning system
Windscreen
F2/15 M/16 ON 16 - 32V (Ubat) ..................
wiper/washer pump
Fog lamp, left BL/2 M/16 ON 16 - 32V (Ubat) ..................
Fog lamp, right BR/5 M/16 ON 16 - 32V (Ubat) ..................
Central lubrication pump
- motor, central X/16 M/16 ON 16 - 32V (Ubat) ..................
lubrication system

Analogue output
Measuring device Measured
Test Starter switch Desired value
Pin+ Pin- value
Alternator, terminal S M/8 M/16 ON approx. Ubat ..................

Frequency inputs
Measuring device Measured
Test Starter switch Desired value
Pin+ Pin- value
Alternator, terminal W M/14 M/16 ON approx. 4V ..................

16 - 32V (Ubat) (short ..................

X/7 M/16 ON
Feedback, central signal when locking ..................
locking - central on-board or unlocking via

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computer central locking)

otherwise: 0V

Position sensor pickup

Measuring device Measured
Test Starter switch Desired value
Pin+ Pin- value
Level, front axle -
position sensor, front
R2/17 M/16 OFF 90 - 180Ω ..................
axle (on-board computer
disconnected)

Inputs and outputs for current sensing

Test Measuring device Starter switch Desired value Measured
Pin+ Pin- value

Turn indicator, trailer, left R2/3 M/16 ON 16 - 32V (Ubat) ..................

Turn indicator, trailer,
R2/2 M/16 ON 16 - 32V (Ubat) ..................
right
Turn indicator, tractor,
R2/1 M/16 ON 16 - 32V (Ubat) ..................
rear left
Turn indicator, tractor,
BL/4 M/16 ON 16 - 32V (Ubat) ..................
side/front, left
Turn indicator, tractor,
R2/13 M/16 ON 16 - 32V (Ubat) ..................
rear right
Turn indicator, tractor,
BR/3 M/16 ON 16 - 32V (Ubat) ..................
side/front, right
Rear fog lamps, tractor R2/16 M/16 ON 16 - 32V (Ubat) ..................
Rear fog lamps, trailer R2/15 M/16 ON 16 - 32V (Ubat) ..................
Brake lamp, trailer R2/5 M/16 ON 16 - 32V (Ubat) ..................
Brake lamp, tractor R2/4 M/16 ON 16 - 32V (Ubat) ..................
Side marker lights, left R2/6 M/16 ON 16 - 32V (Ubat) ..................
Side marker lights, right R2/7 M/16 ON 16 - 32V (Ubat) ..................
Voltage supply, trailer,
R2/14 M/16 ON 16 - 32V (Ubat) ..................
ABS

Stepper motor activation

Measuring device Measured
Test Starter switch Desired value
Pin+ Pin- value
16 - 32V (Ubat)
Headlight height rectangular signal*
BL/3 M/16 ON ..................
adjustment, left when headlight low
beam "ON"
16 - 32V (Ubat)
Headlight height rectangular signal*
BR/6 M/16 ON ..................
adjustment, right when headlight low
beam "ON"

* check with an oscilloscope or Scopemeter 123 made by FLUKE

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The diagram above shows the signal characteristics for left/right headlight adjustment (channel A).

CAN databus, driveline

Measuring device Measured
Test Starter switch Desired value
Pin+ Pin- value
Resistance between T-
CAN High and T-CAN
M/1 M/7 OFF approx. 60Ω ..................
Low, on-board computer
disconnected
Voltage between T-CAN 1.8 - 3.2V
M/1 M/16 ON ..................
High and ground Rectangular signal *
Voltage between T-CAN 1.8 - 3.2V
M/7 M/16 ON ..................
Low and ground Rectangular signal *

* check with an oscilloscope or Scopemeter 123 made by FLUKE

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The diagram above shows signal characteristics for the driveline CAN databus high signal (channel A) and
the driveline CAN databus low signal (channel B).

CAN databus, instrumentation

Measuring device Measured
Test Starter switch Desired value
Pin+ Pin- value
Resistance between I-
CAN High and I-CAN
R2/9 R2/10 OFF approx. 120Ω ..................
Low, on-board computer
disconnected
Voltage between I-CAN 1.8 - 3.2V
R2/9 M/16 ON ..................
High and ground Rectangular signal *
Voltage between I-CAN 1.8 - 3.2V
R2/10 M/7 ON ..................
Low and ground Rectangular signal *

* check with an oscilloscope or Scopemeter 123 made by FLUKE

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The diagram above shows signal characteristics for the instrumentation CAN databus high signal (channel A)
and the instrumentation CAN databus low signal (channel B).

Diagnosis, K-line
Measuring device Measured
Test Starter switch Desired value
Pin+ Pin- value
Voltage supply, K-line,
diagnosis
16 - 32 V (Ubat - 2V)
TRUCKS: BUSES:
M/10 M/16 ON (MAN-cats II not ..................
Diagnosis socket (X200)
connected)
Condition: No data traffic
on K-line
Voltage supply, K-line,
diagnosis
0 - 32 V (Ubat - 2V)
TRUCKS: BUSES:
M/10 M/16 ON (MAN-cats II ..................
Diagnosis socket (X200)
connected)
With data traffic on K-
line

Deleting the error memory

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No more active errors are allowed to be stored in the error memory once all tests have been performed and
no errors are found!

Before deleting the error memory, download it using MAN-cats II and if it contains any non-diagnosed errors
then these must be archived. Then delete the error memory.

There must not be any errors in the memory when the ignition is switched back on. Otherwise, search for the
error and remedy the problem.

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