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MAN TGA 8.210 2006: No Indicators, Clocks, CAN Unit Failure, Alternator Issues, Delphi Diagnostics

Silva 13632 13
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  • #1 16426416
    Silva
    Level 13  
    MAN TGL 8.210
    Born in 2006

    No clocks,
    (no tachometer, speedometer, air gauges)
    Sometimes the tachometer will "click".
    The display shows "CAN unit failure"
    The problem appeared after trying to start the car on "weak" batteries.
    The car did not start, the battery was charged and it started,
    but the indicators are gone.
    (I anticipate questions about the start-up support functions in the loader, nothing like that
    was used)

    4 months earlier, the alternator had to be repaired (no charging),
    After the repair, there is charging, but after starting the car, you need to increase the speed for a moment
    for the alternator to "click" to start charging (charging voltage 28.4V).

    Diagnostics done with Delphi Trucks
    Many old bugs have been deleted,
    There are only:

    03300 - ZBR2 Alternator / starter

    06052 - I-CAN error, No chassis number message

    06004 - instrumentation,


    Fuses (all good), relays, connectors in ZBR checked.
    Proven harness from ZBR to Instruments.
    Proven cables from ZBR to the alternator.
    Proven tachograph cables.
    Checked weights near the central electric board
    Proven impedances in cables from I-CAN, T-CAN, M-CAN, all good.
    Partially proven FFR bundles,
    Visually checked wires on the motor, disconnected / plugged in connectors to the EDC.

    The only thing I found were the wires in the OBD-II diagnostic socket were changed,
    K line plugged into "3", I moved to position 7.

    Is the error description I-CAN error, No chassis message
    Means that you have to go to the service and connect MAN cats 2?
    Do you look further?
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  • #2 16426538
    onepiotr
    Level 25  
    I suppose you have a damaged ZBR. I get these for repair. They often rain in such situations. Service equipment will not help here.
    Was the "mother" hooked up at startup? Was there just normal charging?
  • #3 16426573
    Silva
    Level 13  
    Just charging, then the wires taken off. Something must have happened before loading when he didn't have the strength to spin anymore.
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  • #4 16426580
    onepiotr
    Level 25  
    Whatever it is, there is a communication error - the ZBR cannot see the instrument, and the alternator "W" clamp is defective: /
    ZBR for diagnostics.
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  • #5 16426609
    svavecone
    Level 25  
    The easiest way ..... replace the ZBR driver from another car and check the operation of the above indications.
    ZBR are compatible with most functions, so you can easily replace it with TGA TGL TGM TGX TGS.
    If you do not have access to the swap, at least remove the driver, open the housing and look at the electronics on the PCB .... look for cracks and burns. It will not take long and may clear up many doubts.
    Check also the fuses in the battery compartment ..... items 2.
  • #6 16426660
    Silva
    Level 13  
    I also bet on this box, unless there is a fault in the clocks. Wires from "W" checked. In Delphi, you can read the alternator RPM, but not immediately.
    You have to click several times or wait a while before the value or graph appears in the program.

    In my ZBR, there is no pin No. 8 in the "M" socket (alternator S terminal), and the cable from the alternator (S terminal) to the M socket connector is there.
    Terminal L - there are wires and pin No.4 in the M.


    I am still wondering if this is not a problem but some bug in the ZBR2 firmware. Hence my question about MANcats in the first post. I have never seen this diagnostic program on the eyes, so I wonder if it is not a matter of clicking a reset in this program?

    Or maybe in the MAN service they will replace this box for me immediately and they will not last long
    think about uploading anything?

    My guess is that if I find a ZBR in the same version for a replacement,
    there is a good chance that something will not work anyway.

    Numbers from my ZBR:

    WABCO 115 31/06
    086584 446 210 005 0
    ECU ZBR2
    81.25806.7070
    N132345
    PNR: 00970050
    MA: 03
    1730086584

    @svavecone
    I've already looked at it inside, it looks like new.
    Basic transitions checked, I'm at the stage of dissolving the varnish.
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  • #7 16428401
    svavecone
    Level 25  
    Each ZBR is strictly programmed for the car in which it is located, even if you hit an identical car, you will still have errors about the VIN, so when you are sure of damage to the ZBR, it is best to replace it with the same number or higher and reprogram.
    Unfortunately, apart from erasing errors, no reset can be done with ManCat.
    The "S" ... terminal is not connected by the manufacturer.

    I would also replace the entire clocks for testing purposes.
    Air pressure sensors are connected to the ZBR, but you can read them in Instruments, since you do not have errors in the ZBR about sensors, the lack of readings is strictly between the ZBR and the Instrument. While the error, e.g. 6052, may result from the CAN being occupied by some higher priority error, the pressure signals cannot be disturbed by something else ... so, Instr or ZBR is damaged / no power ... or CAN wires ... but you have already checked these: /
    I would also disconnect the T-CAN bus .... the tachograph so that the instruments would only be connected to the ZBR .... for testing purposes of course.
    Perhaps the alternator is another fault, not related to the above, but the common entity for all faults is ZBR.
    (replace both components and check the operation of the pressure clocks, it is the easiest to do)
    Good luck :)
  • #8 21543878
    robert209
    Level 5  
    Man TGM 13.290
    Year 2023

    I have dark clocks. Re a similar problem.
    The car has been standing a lot (under development) and is new.
    They stopped working while it was stationary, nothing has been messed with the electrics. At the service centre they want to replace with new ones for 8500.
    Sometimes they will work for a while, but generally dark, fuel gauges etc don't work either.
    Similar problem in a second MAN of the same type, but in this one after switching off the main power with the breadboard and switching on, the clocks got up.

    Please help.
  • #9 21544045
    ROKADI

    Level 22  
    Hello, please enter the vin of your vehicle to know what kind of clocks you have
  • #10 21544323
    robert209
    Level 5  
    >>21544045 .

    vin: WMA36DZZXPP219234 year 2023
    engine no. 22866085796614

    Thanks to the conversation above I looked in the battery box and discovered that the socket from one of the fuses was not making good contact. The clocks didn't fire, but something changed as the fuel and AdBlue readings got up. Maybe something needs to be reset, does disconnecting the clamps for a while help?
  • #11 21544587
    TruckElectronica

    Level 23  
    robert209 wrote:
    vin: WMA36DZZXPP219234 year 2023
    This is already a TG3 generation car if you have checked the fuses and they are ok then the best option is diagnostics and you will know .... by the way i have already replaced several clocks
    in this one.
  • #12 21544679
    robert209
    Level 5  
    >>21544587 .

    Apparently it can't be diagnosed as long as the clocks are inoperable....
  • #13 21546788
    ROKADI

    Level 22  
    Hello, there was a service action if the clocks were wrongly woken up or no diagnostics were wrongly fitted but this vehicle probably has a warranty
  • #14 21547798
    kakibara
    Level 34  
    Depends on what is signed at the time of purchase one, two and three year warranty. Depends what customer and what package.
    In tgm tgl there is an action under the left flap (under the bonnet) for touching wires.
    Do a system update.
    Check how the wire is plugged into the meter (straight or at a 90 degree angle) - change the connector. Diop errors.
    Replace the meter.
    With working or not it can be diagnosed.
    I don't know if it was the system that made the clocks go out, but Man ordered/asked some time ago to carry out a TI action and the clocks went out until just before the action was carried out, then the ground was switched off, the function was restored for a while and it went out again - was this to motivate the user to come to the workshop quicker or simply the system's reaction to the compilation of the problem? Not looking for it.

    As for the fact that the car was standing still, let's just say - I personally installed cameras for this model, (it just came off after delivery to the yard) after connecting the battery and starting the car -EOI to be replaced.
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Topic summary

A MAN TGL 8.210 truck from 2006 exhibits multiple electrical issues including non-functional instrument cluster (no tachometer, speedometer, air gauges), intermittent tachometer clicking, and a "CAN unit failure" message. The problem arose after attempting to start the vehicle with weak batteries. Prior to this, the alternator was repaired due to no charging; post-repair, charging occurs only after increasing engine speed briefly. Diagnostics via Delphi Trucks revealed persistent faults: 03300 (ZBR2 Alternator/starter), 06052 (I-CAN error, no chassis number message), and 06004 (instrumentation). Fuses, relays, connectors, and wiring from the ZBR to instruments were verified intact. Discussion points to a likely damaged ZBR (central control unit), which is often programmed specifically for each vehicle, complicating replacement without reprogramming. The alternator "W" clamp and CAN communication errors are noted. Suggested troubleshooting includes swapping the ZBR with a compatible unit from similar MAN models (TGA, TGL, TGM, TGX, TGS), inspecting the ZBR PCB for physical damage, and checking battery compartment fuses. Firmware bugs in the ZBR2 and diagnostic software limitations (ManCat) are considered. Replacement of the instrument cluster is also proposed for testing. Additional discussion on similar issues in newer MAN TGM 13.290 (2023) models highlights problems with dark or non-functional clocks, fuse contact issues, and the importance of system updates and warranty service actions. Diagnostics may be hindered if instrument clusters are inoperative. A known service action involves checking wiring under the bonnet and possibly replacing meters. Overall, the root cause is likely a faulty ZBR unit or instrument cluster, with CAN bus communication errors and alternator signal wiring also implicated.
Summary generated by the language model.
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