Tata - Indigo - Owners Manual - 2002 - 2002

TATA INDIGO e-CS CNG SUPPLEMENT (This manual should be read in conjunction with Indigo e-CS Owner’s Manual & Service Book) Passenger Vehicle Business Unit Pune 1 CONTENTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2 DESCRIPTION Introduction to CNG Safety precautions Starting the engine How to shift the fuelling modes Instrument cluster 5.1 Fuel gauge 5.2 Multifunctional LCD,Odometer, Tripmeter & Dimmer Engine compartment Cylinder Manual Shut OFF valve CNG Pressure Gauge CNG Cylinder Cylinder Filler Valve Safety Regulations CNG Complience Plate In Case of Blown Fuse Fuse Box in Cabin Spare Wheel Removal Technical Specifications Maintenance Trouble Shooting Service Schedule - CNG PAGE NO. 3 3 6 7 8 9 10 11 12 12 13 13 15 15 16 17 19 20 21 21 22 INTRODUCTION & SAFETY PRECAUTIONS 1. INTRODUCTION TO CNG : 2. SAFETY PRECAUTIONS CNG (COMPRESSED NATURAL GAS) is obtained by compressing purified natural gas to less than 1% of its volume at standard atmospheric pressure. CNG is a colorless, odorless, non-toxic but inflammable and lighter than air. To get the best out of CNG fuel, the engine must be tuned and regularly serviced (both as regards to the mechanical and the electrical parts) in addition to routine maintenance required by the vehicle. BENEFITS OF CNG : • Never carry out any repair work on your own or from any other personnel. Always get the car repaired / serviced at TATA authorized service centre only. • Ensure that the Battery Ground terminal is disconnected before start of any repairs. Re-connect it once the repair activity is completed. • Check CNG system components periodically for leakage. • If you smell other than natural gas when refueling or if you hear a hissing sound, follow these directions: a. Do not panic. Park your vehicle in a well ventilated area and apply the parking brake. Roll down all the windows and keep the doors fully open for ventilation. b. Turn the ignition switch to ’LOCK’ position. c. Switch off ignition switch and manual shut off knob located on cylinder valve before servicing / repairing of any parts in the CNG circuit. • CNG is principally comprised of methane. Due to low density it is compressed at a pressure of around 200 bars to improve the vehicle on board capacity. • Lower maintenance costs when vehicles run on CNG. • With rising petrol costs, CNG has seen the competitive edge with its lower price and high availability. • Vehicle life-span can be prolonged since there is no carbon generated during combustion and hence, engine and the oil in the engine are much cleaner. • Due to its low hydro-carbon emissions, CNG is widely considered to be an environmentally viable alternative to petrol. DO’S: 3 INTRODUCTION & SAFETY PRECAUTIONS e. Immediately contact nearest TATA authorized service centre for further assistance. NOTE: In case of gas leakage, ECU will automatically switch the fuel mode from CNG to Petrol. The ECU will not allow you to switch to CNG mode until the leakage is rectified. CNG cylinder OPEN / CLOSE knob in boot space d. Also ensure CNG gas pressure at pressure gauge is Zero. For doing so, we can run vehicle in CNG mode after shutting off cylinder valve. Do not run the vehicle until leakage is rectified. • Get CNG Cylinder checked after every 5 years at Govt. approved test Agency. Never fill CNG cylinder with air, LPG or any fuel except CNG. • Keep the car away from any Fire source. • Remove the CNG tank during the welding/brazing work on the Car. • Check/replace air filter as per service schedule mentioned. Clean it during every service. NOTE: • It is essential to have at least 10 liters of petrol AT ALL TIMES to ensure trouble free operation in case of empty CNG tank. CNG Pressure Gauge in Engine Compartment 4 • Run your car in petrol mode for at least 10kms after every 300kms covered in CNG mode to keep the petrol system in good condition. INTRODUCTION & SAFETY PRECAUTIONS DON’TS • Do not install an LPG, Propane or any other cylinder in place of CNG cylinder. It is illegal and unsafe. • Never alter CNG system confugration. Do not adjust / tamper CNG system settings. Never place inflammable, explosive, corrosive material and sharp objects near CNG cylinder. • Do not jump start your vehicle if you suspect any CNG leak. • Do not drive your vehicle in case of CNG leak. CNG is flammable and highly explosive. You could be killed or seriously injured if leaking gas is ignited. • Never place inflammable, explosive, corrosive material near CNG cylinder. • While loading or unloading particulars near boot area, take extra precaution for preventing any damage to cylinder and cylinder valve. • Don’t smoke inside or near the CNG vehicle. • Over filling the CNG cylinder can cause safety issues like gas leakage. Please DO NOT over fill the tank beyond its capacity. • Never use naked flame/fire to check gas leakages. • Do not use high pressure washer fluid/water jets at electrical devices & their connectors during washing. This is to prevent malfunction / failure of electrical system due to water ingress. 5 STARTING THE ENGINE 3. STARTING THE ENGINE NOTE: Your Engine can start in Petrol mode only irrespective of the position of Fuel Selector Switch (Petrol or CNG) • To start, turn the ignition key to “IGN” position. Ensure the “MIL” lamp turns “ON”. • Select the desired fuel operating mode by pressing the Fuel Selector Switch. • Keep the clutch pedal fully pressed and crank the engine. DO not press the accelerator pedal. • If the engine cranks but fails to start then repeat the above procedure. Release the key as soon as the engine starts. Ensure that the “MIL” lamp is “OFF”. NOTE: • Irrespective of the position of the fuel selector switch (Petrol or CNG), your car’s engine will start using petrol based on the programmed warming up condition and later switch over automatically to CNG (if CNG mode is selected). • Ensure that your car has sufficient petrol in the tank as petrol is used for starting until the engine warms up. 6 • Ensure that you run your car in “PETROL” mode for at least 10kms for every 300kms covered in “CNG” mode to ensure proper working of petrol fuel supply system. FUELLING MODES & CNG LAMP 4. HOW TO SHIFT THE FUELLING MODES You can switch from PETROL to CNG and vice versa by operating fuel selector switch located on right hand side of dashboard near steering wheel. See below picture. A. PETROL to CNG mode You can shift to CNG fuel mode by pressing the fuel selector switch. The “CNG” lamp on the instrument cluster starts flashing during the changeover to CNG mode and glows permanently after changing to CNG mode indicating that the car is running on CNG. B. CNG to PETROL mode Similarly you can switch to PETROL fuel mode by pressing the fuel selector switch. After successful transition to PETROL mode, the green “CNG” lamp goes OFF. This indicates that the car is running on petrol. CNG LAMP : This lamp glows when you select the CNG fuel mode. This lamp will not glow when you select petrol fuel mode. IMPORTANT: In case of fuel mode switching from PETROL to CNG mode during normal running, initially the CNG lamp toggles indicating the transition and when the CNG lamp glows permanently, this indicates the completion of the transition to the required fuel mode. • Fast flashing of the’ CNG’ lamp on instrument cluster indicates the fault in CNG system. Car will automatically switch to Petrol mode. Get the car checked / repaired at the nearest Authorized TATA service center. • Very Slow flashing of the’ CNG’ lamp indicates the empty tank / NO CNG supply (loss of pressure). Get the CNG tank re-filled. 7 INSTRUMENT CLUSTER 5. INSTRUMENT CLUSTER MIL SIL SET Knob 8 LCD MODE Selector Knob Fuel Gauge CNG Lamp FUEL GAUGE 5.1 FUEL GAUGE: The fuel gauge indicates the approximate fuel level in the tank. When the engine is in Petrol mode, the gauge shows the level of petrol and when it is in CNG mode the green “CNG” lamp in the instrument cluster glows and shows the CNG level. When the needle touches the red band (indicating reserve capacity has been reached.), a visual warning indication (amber coloured) comes ‘ON’ indicating the fuel level is low. Refill the fuel tank at the earliest. Sr. No. 1 2 3 4 CNG pressure (bar) 15 100 150 200 Fuel gauge indication Empty low 1/2 3/4 Full Low Fuel Warning Indicator Fuel Gauge CNG Lamp NOTE: The gauge may show slightly more or less than the actual amount. The tank temperature, filling method and ambient conditions may affect the pressure and temperature of the natural gas. 9 MULTIFUCTIONAL LCD 5.2 MULTIFUNCTIONAL LCD, ODOMETER, TRIPMETER AND DIMMER: Odometer Tripmeter / CNG MASS / Intensity level of illumination The speedometer indicates the car speed in km/hr. The odometer records the total distance the car have been driven. The tripmeter can be used to measure the distance travelled on each trip or between fuel fillings. LCD has two line display. The first line displays the Odometer count. The second line displays either of Tripmeter A, Trip meter B, CNG MASS (in kg) and Intensity level of panel illumination. The selection and control of functions are done through ‘MODE’ and ‘SET’ pushbuttons (knobs) provided on either side of the LCD. The ’MODE’ knob is used to select one of Tripmeter A, Tripmeter B, CNG MASS or Intensity level of panel illumination. Switching among the above functions can be done by pressing the MODE knob. 10 ENGINE COMPARTMENT 6. ENGINE COMPARTMENT 1 2 3 13 1. 2. 3. 4. 5. Windshield Washer Filling Cap Engine Coolant Tank Brake Fluid Container Engine Oil Filler Cap CNG Pressure Regulator 4 5 12 6. 7. 8. 9. 10. CNG Pressure Gauge CNG ECU Fuse Box & Relay Petrol ECU Battery 6 7 8 9 10 11 11. Air Filter 12. Dip Stick 13. Power Steering Oil Container 11 CNG FILLING 7. CYLINDER MANUAL SHUT OFF VALVE / KNOB : 8. CNG PRESSURE GAUGE : A manual shut OFF knob is fitted to cylinder valve. Cylinder valve is mounted on CNG cylinder. CNG pressure gauge indicates the high pressure in the system. It is located in Engine compartment. CNG cylinder OPEN / CLOSE knob in boot space CNG Pressure Gauge in Engine Compartment Manual shut OFF Knob Operation: CNG supply can be cut OFF by closing the manual shut OFF valve / knob. Valve Closing : Turn the knob completely in clockwise direction to close the CNG supply to Engine. Valve Opening : Turn the knob completely in anti-clockwise direction to open the CNG supply to Engine. 12 CNG CYLINDER & CNG FILLER VALVE 9. CNG CYLINDER: 10. CNG FILLER VALVE : The CNG cylinders are located in boot space.CNG is stored in a high pressure cylinder at a pressure of 200 bar (working pressure). CNG filler valve is used to fill CNG in the cylinder. It is fitted near petrol filling location. CNG should be filled by gas filling nozzle at filling station. 1 3 2 CNG cylinderin boot space The maximum storage pressure of CNG in cylinder is up to 260 bar (i.e. cylinder test pressure). 1. CNG Filler Cap 2. Petrol Filler Cap 3. Microswitch with LED CNG tank capacity : 60 liters of Water capacity 13 CNG FILLER VALVE IMPORTANT : • Open the filler valve / receptacle cap. • Keep the Ignition switch in “OFF” condition during CNG refilling. • Do not use your mobile phones when you are at a filling station. • After filling the CNG, if the filler valve is kept open, you will not be able to start the vehicle. Always close the filler valve / receptacle cap properly, in order to start the vehicle • Now CNG can be filled by gas filling nozzle at fillingstation. For filling the CNG, follow the below procedure. • Rotate the filler valve / receptacle cap in anticlockwise direction. 14 • Close the cap properly once the CNG gas is filled. NOTICE • When the filler valve / receptacle cap is opened (or not in place), the LED on the CNG refueling sensor starts glowing (RED colour), and when the cap is closed (in place) the LED goes off. • In case the vehicle is not cranking / starting, check for the LED on the sensor. If it’s glowing, the filler valve / receptacle cap should be tightened properly. SAFETY REGULATION & CNG COMPLIENCE PLATE 11. SAFETY REGULATION: 12. CNG COMPLIENCE PLATE: FIRE EXTINGUISHER : CMVR (Compliance to Motor Vehicle Rules) plate is fitted near to filler valve with CNG kit identification and installation details. A fire extinguisher is provided on the car near driver seat Method of operation: 1. Check if the pressure gauge needle in green zone. 2. Hold upright ,pull the pin and press the lever. 3. Direct discharge at base of flame with rapid sweeping motion. Your car’s CNG cylinder needs to be recertified every five years as per CMVR (AIS 24, 25 and 26). Please ensure that it is done by a TATA Authorized Service centre and the new date is engraved on the plate. Maintenance : Check pressure on the gauge every week, needle should remain in green region. If it comes to red region, please send for recharging. The Fire Extinguisher is to be refilled every three years even if it is not used. CMVR Plate Location of Fire Extinguisher 15 IN CASE OF BLOWN FUSE 13. IN CASE OF BLOWN FUSE WARNING: Your car’s CNG system is protected against short circuit / overload by a fuse (15A) fitted in the fuse box. Always replace blown fuse with a fuse of correct amperage. Never use a substitute like aluminum coil or wire to replace a blown fuse. When you replace a fuse and the new fuse also blows OFF instantly, have the car inspected at a TATA authorized service centre. To replace a blown fuse: • Open fuse box cover. • Identify blown fuse from its melted wire. • Remove the blown fuse and replace with one of similar amperage. Take your car to a TATA Authorized service centre to find out the reason for the fuse to blow & repair the problem. NOTE: Fuse replacement should preferably be done only at TATA Authorized service centre When the fuse blows OFF, the following may occur: • If your car is running in CNG mode when fuse blows OFF, the CNG system will shut down and will automatically shift to Petrol mode. • In such a case, you can start the car only in Petrol mode • If your car is running in Petrol mode when fuse blows OFF it will keep running in the Petrol mode. 16 FUSE BOX 14. FUSE BOX IN CABIN 17 FUSE BOX Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 18 Function STARTER PROTECTION CIRCUIT FRONT AND REAR FOG LAMP FUEL PUMP LPG/CNG POWER RELAY POSITION LAMP-RH POSITION LAMP-LH BLOWER + W/W + HORN RELAY COIL INDICATOR LAMPS MUSIC SYSTEM & CHIME KEY IN A/C CONTROLS HEAD LAMP LOW BEAM RELAY HEAD LAMP HIGH BEAM RELAY WASH & WIPER INSTRUMENT CLUSTER FUEL CUT-OFF REVERSE LAMP, CLOCK & CIG.LIGHTER STARTER RELAY MUSIC SYSTEM, CLOCK & INST. CLUSTER ROOF,ENGINE,LOAD AREA LAMP C.D.L & IMMOBILISER STOP LAMP & HMSL VENTILATION MOTOR Fuse Rating 5A 20A 15A 15A 5A 5A 5A 10A 5A 10A 15A 15A 25A 10A 20A 20A 15A 5A 30A 10A 30A 2. FUSE BOX - NEAR FIRE WALL- CNG SPARE WHEEL REMOVAL 15. SPARE WHEEL REMOVAL : • Remove the cover and take out the jack. Release the latch provided on the rear seat back and somersault the seat back to access the spare wheel. • Unscrew spare wheel mounting nut. • Once this nut is removed, the wheel can be lifted and taken out. NOTE: • Always use only the recommended size of wheel rims & tyres. Use of non-recommended rims and tyres may have an adverse effect on car safety. • Once the spare wheel is repaired and is ready to be refitted, keep the direction of the air filling nozzle outwards for easy air filling. TYRE PRESSURE : TYRE SIZE 175/65 R14 FRONT 33 Psi / 2.28 bar REAR 33 Psi / 2.28 bar 19 TECHNICAL SPECIFICATIONS 16. TECHNICAL SPECIFICATIONS ENGINE (Bi-fuel: Petrol + CNG) Model Type No. of cylinders Bore X Stroke Capacity Max. Engine output Max. Torque Compression ratio Firing order Fuel system Emission compliance Cooling system capacity TATA 475 SI 70 Water cooled, Multi Point Injection, Single overhead camshaft Engine 4 inline 75 mm x 67.5 mm 1193 cc CNG Mode : 55 Ps at 5000 rpm CNG Mode : 90 Nm at 2650 rpm 10 : 1 1-3-4-2 Sequential Injection with close loop Air / Fuel control BS IV 6.0 Liters ELECTRICAL SYSTEM System Voltage Battery Alternator 12 Volts -ve earth 12V, 55 Ah 90A FUEL TANK CAPACITY Fuel Tank Capacity 20 PETROL : 42 Litres / CNG : 60 LITRES of WATER CAPACITY MAINTENANCE, TROUBLE SHOOTING & WARRANTY POLICY 17. MAINTENANCE : Please use only genuine engine oils, coolants, lubricants, anti rust & sound deadening coats, windscreen sealant, adhesives & fuel additives, spark plugs branded by TATA MOTORS for optimum performance of your car. SR. NO. 1 SR. NO. 1 ITEM GRADE COMPANY Engine oil Gas oil Minimum API-SL/CH4 specification Castrol - Magnetec 10W40 EXXON MOBIL - Super 1000 TM 15W40 ITEM COMPANY GAP Spark Plugs BOSCH FR6 DE0 QTY. 4.0 Liters 0.7 to 0.8mm 18. TROUBLESHOOTING : SR. NO. 1 2 PROBLEM POSSIBLE CAUSE REMEDIES Engine cranks but does not start - CNG mode No CNG CNG filter / fuel lines choked. Athorized service centre Inertia switch tripped Refill CNG Get CNG filter replaced at TATA Safety solenoids not operating. Contact TATA authorized service centre ECU faulty Contact TATA authorized service centre MIL continuous to glow OR CNG lamp fast blinking, even after start. Contact TATA authorized service centre Some faults are detected by the Get the vehicle checked and rectified fuel injection and ignition system at TATA authorised service centre. 21 SERVICE SCHEDULE - CNG 22 100000 - 100500 6 12 24 36 48 60 72 84 At every service At every service • • • • • • • • • • • • • • • • • • • • • • • • At every service • • • • • • • • • • • • At every service • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 10000 30000 At every service Every 3 Years First at 10 000 Subsequently at Every 20,000 • • • • 90000 - 90500 60000 - 60500 1 • 80000 - 80500 50000 - 50500 Month 50000 10000 50000 At every service 100,000 70000 - 70500 40000 - 40500 10 11 12 13 14 30000 - 30500 5 6 7 8 9 20000 - 20500 4 10000 - 10500 3 Check CNG Pipe joints (Leakage) Check Solenoid Valve On Cylinder Valve & Pressure regulator Check Mountings of filler valve, sensor,Pressure gauge, Regulator assembly, Cylinder Cradle Check all joints in low pressure line,CNG rail hoses for leakage. Replace the high pressure filter Cartridge with ‘O’ ring Drain oil from high pressure filter body Replace ‘O’ Ring and Metal Wire filter in filler valve Check Pressure gauge working Replace the pressure regulator’s filter, O-ring & both Diaphragms Change engine oil Replace spark plugs Check for DTC if any Recertification of tank Check tappet clearance and adjust FREQUENCY 5000 - 5500 1 2 OPERATION 1000 - 1500 SR. NO. 19. SERVICE SCHEDULE : 96 108 120 • • • • • • • • •