1. INSTRUMENT CLUSTER
Copyright © MILE 2011 MILE / XUV500 / IC / VER 01 / JUL 2011

2. System Configuration Complete Digital Instrument Cluster
Connected to other ECUs via CAN
TPMS Interface for Learning & Acknowledgement
IC Interface for Information, Alerts & Display
MBFM interface for ODO reading backup storage

3. Instrument Cluster

4. Instrument Cluster - Layout
Tell tale zone
Speedometer
LCD Module
Gear information
Odo & Trip meter
Fuel information
Engine Temperature Module
Trip meter switch
TPMS switch
Tachometer
T.P.M.S

5. IC - Self Check 1) Turn on Ignition
All the tell tales in the cluster will turn ON for 3 sec according to the variants
Speedo and RPM pointer will provide one complete sweep

6. IC - Fuel Gauge 1) Turn on Ignition On
All the bars (10) in the LCD indicator will be ON for 3 sec
Each bar indicates a quantity of 7 Ltr approx
Fuel indication will indicate the fuel level by switching ON the corresponding number of bars
If all bars were blinking -> check the connection of fuel sensor

7. IC - Temeperature Gauge
Turn on Ignition On 1)
Engine temperature bar graph BLUE illumination will be ON, if the coolant temperature is less than 105 deg.
Engine temperature bar graph Blue with RED will start blinking when the coolant temperature reaches 105 deg.
RED will start blink at double rate when temperature reaches 1110 deg.
RED comes continuous along with the buzzer when the temperature reaches 114 deg
Engine Torque limitation starts at 110 Deg

8. Teltale Lamps - Engine System check lamp Cruise control indication
Engine Oil pressure
low indication
Stop start indication
Glow plug indication
OBD indication
Engine temperature
Water in fuel indication
- ON whenever water in fuel is sensed by the sensor

9. Telltale Lamps - Brakes
Park brake Indication
- ON when Park brake engaged or Brake pad wear out or EBD related malfunction or Low Brake Fluid in the Reservoir
ABS Malfunction
- ON When ABS system malfunctions or not in operating state
ESP Malfunction
- ON When ESP system malfunctions
- BLINKS when in Intervention
ESP OFF indication
- ON ESP is turned OFF
Hill Decent control malfunction
- ON When HDC malfunctions or not in operating state
Hill Hold control Malfunction
- ON when Front Fog is turned ON

10. Telltale Lamp - Lights High beam indication
- ON when High beam is turned ON
Battery charging indication
- ON whenever battery voltage is less than 9.5V during engine ON
Rear Fog lamp indication
- ON when Rear Fog is turned ON
Front Fog lamp indication
- ON when Front Fog is turned ON
Left turn indication
- ON whenever left turn lamps were turned ON
Right turn indication
- ON whenever right turn lamps were turned ON

11. Telltale Lamps - Safety
Immobilizer tell tale
- Blink based on signal from MBFM
Driver seat belt indication
- ON when driver seat belt is not engaged
Door open indication
- ON when any door including bonnet is open
Airbag malfunction indication
- ON whenever Airbag System malfunction
TPMS
- ON when tire pressure related alerts were present
ITM malfunction indication
- ON whenever AWD System malfunctions

12. Functional Description
S.No
Features/Tell tales
Tell tale symbol
Functionality 1
Self check NA
During Ignition ON, all tell tales will come ON for 3 sec, Speedometer needle and Tachometer needle will sweep completely once. General illumination in the cluster will come ON and all symbols in the LCD will come for 3 sec. 2
General Illumination
Ignition ON & Park OFF
General illumination in the cluster, will come ON and glow with 80% illumination
Ignition ON & Park ON
General illumination in the cluster will illuminated according to the intensity control switch
Ignition OFF & Park ON 3
Speedo meter
Speedo meter needle will move according to the vehicle speed value received.

13. Functional Description
S.No
Features/Tell tales
Tell tale symbol
Functionality 4
Tachometer NA
Tachometer needle will move according to the Engine RPM value received. 5
Fuel bar graph
Fuel bar graph will have 10 bars. Each bar will switch ON according to the Fuel level in the tank.
Last 2 bar in the Fuel bar graph indicates the Reserve and the last bar will blink when the Fuel level reaches the very low value (7 liters). 6
Odometer & Trip meter
Odometer will display the distance covered in kms/miles according to the variant.
Trip.
ODO
Short press of Trip in ODO will change to Trip A
Long press of Trip in ODO will Reset ODO (only if Km is less than 255)
Trip A
Short press of Trip in Trip A will change to Trip B
Long press of Trip in Trip A will reset Trip A
Trip B
Short press of Trip in Trip A will change to ODO
Long press of Trip in Trip A will reset Trip B

14. Functional Description
S.No
Features/Tell tales
Tell tale symbol
Functionality 7
Gear Information NA
Will display the gear information in digits according to the gear information received. 8
Engine Temperature
Engine temperature tell tale will start blinking when the coolant temperature reaches 105 deg and start blink at double rate when temperature reaches 110 deg and start coming continuous
Buzzer alert comes when the temperature reaches 114 deg 9
Battery Charging Tell tale
Tell will be ON when Engine OFF
Tell tale will be OFF when Engine ON and alternator charging terminal is high and the battery voltage is greater than 12.5V 10
Engine Oil pressure tell tale
Tell tale will be ON if Engine OFF
Tell tale will be ON if Oil pressure switch detects low (Through CAN from EMS) when Engine ON and provide buzzer alert twice. 11
Turn Right/Turn Left Telltale
Left / Right turn tell tale will Flash according to the Left / right turn indication which got activated irrespective of the ignition status. Both tell tale will flash, if both inputs were available
Buzzer alert will come along with Tell tale when ignition in ON condition

15. Functional Description
S.No
Features/Tell tales
Tell tale symbol
Functionality 12
Water in Fuel Tell tale
Telltale OFF - If no water accumulated in the fuel filter
Telltale ON - water accumulated inside fuel filter. 13
Immobilizer Tell tale
Tell tale will blink when the vehicle in locked condition/ignition off
Tell tale will go off once the ignition turned ON and immobilizer authentication is pass 14
Engine Check Tell tale
Telltale OFF - No Engine/sensor related error
Telltale ON - Engine and sensor related error detected.
Feedback of the tell tale status will be provided to EMS through CAN. 15
High beam Tell tale
Tell tale OFF – When High beam is OFF
Tell tale ON – When High beam is ON

16. Functional Description
S.No
Features/Tell tales
Tell tale symbol
Functionality 16
Park brake Tell tale
Telltale ON when any of the below occurred
1. Park brake is engaged
2. Brake fluid is low
3. Brake pad wear worn
4. EBD not available.
Telltale OFF - when any of the above condition not exists. 17
Door open Tell tale
Tell tale ON – When any door including tail and Bonnet is open
Tell tale OFF – When all doors were closed 18
Seat belt Tell tale
Tell Tale ON – When Driver seat belt is not engaged
Tell tale OFF – When Driver seat belt is engaged
Buzzer chimes will be provided for 3 times in ignition cycle when Driver seat belt not engaged and vehicle is cranked 19
OBD
Telltale ON - When emission control related issue in vehicle
Tell tale OFF - When no issue on emission control issues
Feedback of the tell tale status will be provided to EMS through CAN.

17. Functional Description
S.No
Features/Tell tales
Tell tale symbol
Functionality 20
Glow plug tell tale
Telltale ON, when glow plug has not reached starting temperature, otherwise Telltale OFF. 21
Rear Fog lamp Tell tale
Telltale ON - when the rear fog lamp is ON.
Telltale OFF- rear fog lamp is OFF. 22
Front Fog lamp tell tale
Telltale ON - when the front fog lamp is ON.
Telltale OFF - front fog lamp is OFF. 23
Airbag malfunction tell tale
Telltale ON, Airbag system problem, otherwise Telltale OFF. 24
ABS Tell tale
Telltale ON - ABS not available/malfunction.
Tell tale OFF - ABS available 25
Cruise tell tale
Telltale ON - when Cruise control ON
Telltale OFF - When Cruise OFF 26
4WD warning tell tale
Tell tale ON – When ITM malfunctions
Tell tale OFF – When no malfunction in ITM

18. Functional Description
S.No
Features/Tell tales
Tell tale symbol
Functionality 27
TPMS Warning
Tell tale blink for 30sec and ON continuously when error on TPMS system or sensor
Tell tale ON directly when there is low/high pressure or High temperature
Tell tale OFF when Tire pressure and temperature is normal 28
ESC OFF Indication
Tell tale ON - when ESC switch is turned OFF 29
ESC Malfunction
Tell tale ON - when ESC malfunction
Tell tale Blink – When it Intervene 30
Start Stop indication
Tell tale ON when Engine stopped due to Stop Start
Tell tale Blink when Engine about to Stop due to Stop start if already engine ON
Tell tale Blink when Engine about to Start due to Stop start of already engine OFF

19. Functional Description
S.No
Features/Tell tales
Tell tale symbol
Functionality 31
Average Fuel consumption NA
Calculates the Avg fuel consumption and send it to IS through CAN 32
Distance to Empty
Calculates the Distance can travel with the available fuel and fuel consumption and send it to IS through CAN 33
Instantaneous fuel consumption
Calculates the instantaneous fuel consumption and send the same to IS through CAN

20. Cluster – ODO & Trip Meter Readings
Use the switch on the right hand side of cluster to use Trip A, Trip B and reset the ODO values in cluster.
Short press of less than 1000ms will change ODO screen from main screen to Trip A to trip B and back to the main screen.
Along press of more than 1000ms will reset the values in ODO.
Note: Trip A & B can be reset at any value but the main ODO screen can only be reset before 255km only once.
Similar Button on the RHS

21. Cluster – ODO & Trip Meter Readings
To learn the TPMS values in a vehicle follow the below given steps:
1. Put the switch in OFF condition.
2. Press the TPMS switch on left hand side of the cluster.
3. Put the ignition in ON condition.
4. Release the TPMS switch.
5. Start the TPMS learning activity,

22. Cluster – Replacement Services
When a Instrument Cluster is replaced during service:
ODO values have to updated using the Flash Tool.
The new value may be ± 5km of the original value.
ODO values can be updated by the bellow method:
Connect the Python/ Neovi tool to the vehicle and the computer station.
Open the W201 diagnostic flash tool.
Press Connect.
Go to Instrument Cluster.
Got to Write ECU data
In the ODO value box, write the required ODO value in the box next to ODO value.
Click on OK

23. Cluster – Service Reminder
Based on the KMs Covered, The IC sends the “Vehicle is Due for Service’ alert to the IS through CAN for displaying
After Service is done at Dealership, it has to be RESET by using Smart Tester

24. Cluster Interface

25. Cluster Connection

26. Cluster Diagnostics S.No Malfunction Causes Action 1
Speedo meter needle always shows 220 kmph after self check
Speed value is not coming to the cluster through CAN
Connect the diagnostic tester and check for the Speed sensor related DTC in EMS / Wheel speed sensor related DTC in ABS/ESP. If so correct accordingly
Connect the diagnostic tester and check for the CAN related DTC in Cluster for EMS or ABS/ESP. If so check the connection between Cluster and EMS or ABS/ESP
Cluster problem
Change the cluster and check for the operation 2
Speedo meter needle struck in between at intermediate position

27. Cluster Diagnostics S.No Malfunction Causes Action 3
Tachometer needle always shows RPMS
Engine Speed value is not coming to the cluster through CAN
Connect the diagnostic tester and check for the Engine speed related DTC in EMS. If so correct accordingly
Connect the diagnostic tester and check for the CAN related DTC in Cluster for EMS. If so check the connection between Cluster and EMS 4
Tachometer needle struck in between at intermediate position
Cluster problem
Change the cluster and check for the operation 5
LCD module illumination is not coming ON

28. Cluster Diagnostics S.No Malfunction Causes Action 6
ODO meter is not getting updated
Speed value is not coming to the cluster through CAN
Connect the diagnostic tester and check for the Speed sensor related DTC in EMS / Wheel speed sensor related DTC in ABS/ESP. If so correct accordingly
Connect the diagnostic tester and check for the CAN related DTC in Cluster for EMS or ABS/ESP. If so check the connection between Cluster and EMS or ABS/ESP
Cluster problem
Change the cluster and check for the operation 7
ODO display is not coming ON 8
ODO is not changing from ODO display to Trip A / Trip B
Trip switch problem in the cluster

29. Cluster Diagnostics S.No Malfunction Causes Action 9
Gear information is not coming ON
Gear information is not coming ON through CAN
Connect the diagnostic tester and check for the CAN related DTC in Cluster for EMS. If so check the connection between Cluster and EMS
Connect the diagnostic tester and check for the Reverse Gear related DTC in EMS. If so correct accordingly
Cluster problem
Change the cluster and check for the operation 10
Reverse Gear information alone is not coming in the LCD
Reverse Gear signal to EMS is not proper
Connect the diagnostics tester and check for the Reverse switch related DTC in EMS.
Check the Reverse Gear connection to the EMS ECU. 11
Fuel display in the LCD is not coming at all 12
All the bars in Fuel bar graph in the LCD display is continuously blinking
Fuel sensor/connection to the cluster is either open or short
Connect the diagnostic tester and check for the Fuel sensor related DTC.
Check the Fuel sensor connection to the sensor.

30. Cluster Diagnostics S.No Malfunction Causes Action 13
Fuel bar graph is not showing the correct value
Fuel sensor problem
Check the Fuel sensor resistance according to the volume
Cluster problem
Change the cluster and check for the operation 14
Temperature indication bar graph (Blue and Red) is not coming 15
Temperature indication bar graph (Blue and Red) blinking
Engine coolant temperature value is not coming through CAN / Value out of range
Connect the diagnostic tester and check for the CAN related DTC in Cluster for EMS. If so check the connection between Cluster and EMS
Connect the diagnostic tester and check for the Engine coolant sensor related DTC in EMS. If so correct accordingly

31. Cluster Diagnostics S.No Malfunction Causes Action 16
Cluster General illumination is not coming
Illumination Intensity level value in the CAN is always low from MBFM
Connect the diagnostic tester and check for the Global intensity control related DTC in MBFM. If so correct accordingly
Cluster problem
Change the cluster and check for the intensity level 17
TPMS tell tale is blinking and coming ON always
TPMS sensor related error
Connect the diagnostic tester and check for the TPMS related DTC in MBFM. If so correct accordingly
TPMS sensor Fault
Change the corresponding TPMS sensor by seeing infotainment system 18
Buzzer sound is not coming
Change the cluster and check for the operation

32. Cluster Diagnostics DTC CODE DTC DESCRIPTION DTC SYMPTOM ACTION B1801
Battery voltage too high
Battery voltage to the cluster is too high > 16V
Check for the battery voltage and connection to the cluster
B1802
Battery voltage too low
Battery voltage to the cluster is too low <9V
B1810
Fuel sender open
Fuel sensor connection to the cluster is open
Check the connection between the Fuel sensor and cluster. Also check whether Fuel sensor connection has short to battery.
B1811
Fuel sender short
Fuel sensor connection to the cluster is short
Check the connection between the Fuel sensor and cluster. Also check whether Fuel sensor connection has short to ground.
B1820
EEPROM Failure
Defect in the cluster
Change the cluster
U1205
IC Bus Off Error
Error on CAN bus
CAN cable needs to be checked for short / open.
Change the cluster and check for the operation
U1305
IC VIN Mis-Match Error
VIN number not matching with the EMS
Correct VIN number needs to be flashed in cluster/ EMS

33. Thank You
Copyright © MILE 2011 MILE / XUV500 / IC/ VER 01 / JUL 2011