introduction to cng - welcome to sparsh automobiles€¦ · contents introduction to cng ... manual...

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FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

CONTENTS INTRODUCTION TO CNG...................................................................................................... 3SAFETY PRECAUTIONS (Do’s & Don’ts) .......................................................................... 3LAYOUT OF THE CNG SYSTEM ......................................................................................... 4FUEL MODES ......................................................................................................................... 5SELECTOR SWITCH POSITION ........................................................................................... 5PETROL MODE ....................................................................................................................... 5AUTO MODE ........................................................................................................................... 5FORCED CNG MODE ............................................................................................................ 6AUTOMATIC CHANGEOVER FROM CNG MODE TO PETROL MODE ......................... 6CNG LEVEL GAUGE ............................................................................................................. 6CNG FILLER VALVE .............................................................................................................. 7CNG CYLINDER ...................................................................................................................... 7MANUAL SHUT-OFF VALVE ................................................................................................ 8LIST OF GOVERNMENT APPROVED CNG CYLINDER TESTING STATIONS ............. 9JACK REMOVAL .................................................................................................................... 9INSTRUMENT CLUSTER ..................................................................................................... 10CNG MALFUNCTION WARNING LAMP ............................................................................ 10CNG KIT IDENTIFICATION ................................................................................................. 12CNG WARNING LABEL....................................................................................................... 12FUSE BOX ............................................................................................................................. 12PERIODIC MAINTENANCE SCHEDULE ............................................................................ 13SPECIFICATIONS .................................................................................................................. 14FIRE EXTINGUISHER (if equipped) ........................................................................ 15PARTS DESCRIPTION ......................................................................................................... 15REMOVAL PROCEDURE..................................................................................................... 15PROCEDURE OF OPERATION ................................................................................. 16FITMENT PROCEDURE .............................................................................................. 16REFILLING SCHEDULES ........................................................................................... 16

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INTRODUCTION TO CNG:

CNG (Compressed Natural Gas) is princi-pally constituted by methane. CNG isconsidered as clean burning fuel. Due tolow density of CNG, it is compressed at apressure of around 200 bars to enhance thevehicle on-board storage capacity.

CAUTIONIn case of any symptom of CNG leakageor releasing noise or any externaldamage to CNG piping or duringaccident, do not panic.• Stop the vehicle and switch off the

engine, roll down the windows andopen all the doors

• Ensure to close manual shut off valve.• Contact Maruti Suzuki authorized

workshop immediatly for furtherassistance.

SAFETY PRECAUTIONS (Do’s): SAFETY PRECAUTIONS (Don’ts):

1. If any service or body repair is to becarried out, turn the manual shut offvalve on CNG cylinder valve to closeposition prior to commencement of therepair work.

2. Get the CNG cylinder checked everyfive (5) years from the date of lasttesting / retesting of cylinder bygovernment authorized CNG cylindertesting agency.

3. If the vehicle does not changeover toCNG in AUTO MODE, then have yourvehicle checked by Maruti Suzukiauthorized workshop at the earliest.

4. Switch "OFF" engine while fuel filling(CNG/Petrol).

5. After refueling CNG or Petrol, ensurethat the fuel filler lid is closed. (Other-wise vehicle cannot be started)

6. In AUTO MODE, It is programmed tostart the vehicle in petrol and auto-matically shift to CNG based on theengine temperature etc. Do not pressthe accelerator pedal to change frompetrol to CNG.

1. Do not change/modify the configuration,settings or the components from CNGsystem.

2. The CNG cylinder should not berepaired under any circumstances, incase of any problem, consult with MarutiSuzuki authorized workshop.

3. Do not adjust setting of CNG system.

4. Never install LPG or any other gascylinder in place of CNG cylinder.

5. Avoid carrying inflammable material nearthe CNG cylinder.

6. Do not fill any other type of gas otherthan CNG.

7. Do not press the accelerator pedal tochange from petrol to CNG MODE.

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1 Changeover switch2 High pressure pipe3 Receptacle4 Fuel lid switch5 CNG cylinder valve6 CNG cylinder

7 Vent hose8 CNG controller9 CNG injectors10 Low pressure & temperature sensor11 Engine12 Pressure regulator

13 Water hose14 High pressure sensor15 High pressure gauge16 Low pressure hose17 CNG filter

LAYOUT OF THE CNG SYSTEM

EXAMPLE

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FUEL MODES

NOTE:

• Do not press the accelerator pedal tochangover from petrol to CNG mode.

• With ignition switch "ON" and engine notrunning, blinking of CNG malfunctionwarning lamp indicates that fuel lid isopen. Vehicle will not start in thiscondition.

There are three fuel modes in the vehicle(Petrol, Auto and Forced CNG) which areselectable by pressing the selector switch(1) located on the right side of the steeringwheel on the dashboard.

PETROL MODE

In this mode vehicle starts in petrol andcontinue running in petrol mode. In thismode, petrol indicator is continuously dis-played and CNG indicator will remain “OFF”.

Make sure that the parking brake isapplied fully and the transmission isin Neutral before attempting to startthe engine.

• Stop turning the starter immediatelyafter the engine has started or thestarter system can be damaged.

• Do not crank the engine for morethan 15 seconds at a time. If theengine doesn’t start on the first try,wait about 15 seconds before tryingagain.

CAUTION

wwwww WARNING

SELECTOR SWITCH POSITION AUTO MODE

In this mode engine starts in petrol modeand then automatically changes to CNGmode after reaching programmed warmingup condition. With ignition switch ON andvehicle started in “AUTO MODE”, CNGindicator blinks on the display and PETROLindicator is displayed. After changeover toCNG, CNG indicator will be displayed andPetrol indicator will switch OFFautomatically.

NOTE:It is always recommended to start thevehicle in AUTO MODE or PETROL MODEto enhance the engine life.

EXAMPLE

EXAMPLE

EXAMPLE

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FORCED CNG MODE

This is emergency mode and may be usedin cases where there is no petrol in petroltank. In this mode vehicle starts in CNGmode and continues running in CNG mode.With ignition "ON" and engine not running,press and hold the changeover switch tillonly CNG indicator is displayed. In thismode, CNG indicator is displayed and Petrolindicator remains "OFF".

NOTE:It is recommended to keep sufficient amountof petrol in the petrol tank.

CNG LEVEL GAUGE

When the ignition switch is in the “ON”position, this gauge gives an approximateindication of the quantity of CNG in theCNG cylinder. “F” stands for full and “E”stands for empty.

If the indicator gets off the graduation of“E”(not character “E”) refill the CNG cylinderas soon as possible.

The mark (1) indicates that the fuel filler lidis located on the left side of the vehicle.

AUTOMATIC CHANGEOVER FROMCNG MODE TO PETROL MODE

If CNG is finished while the engine isrunning, vehicle will automatically changeover from CNG mode to Petrol mode &CNG malfunction warning lamp will startblinking. Petrol indicator will glowcontinuously and CNG indicator will switchOFF automatically.

To acknowledge this information, press thechangeover switch once. The CNGmalfunction warning lamp will stop blinkingafter the changeover switch is pressed andPetrol indicator will glow continuously.However the CNG malfunction indicator lampwill continue to blink after every subsequentIgnition ON - Ignition OFF condition until thevehicle is refilled with CNG.

NOTE:• It is recommended to keep sufficient

amount of petrol in the petrol tank toprevent engine stalling during automaticchangeover from CNG mode to Petrolmode.

• In case the CNG malfunction warninglamp does not stop blinking afterpressing the changeover switch, take thevehicle to the nearest MARUTI SUZUKIdealer.

EXAMPLE EXAMPLE

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CNG FILLER VALVE

The CNG filler valve is integrated in fuelbox next to petrol filling area.

CNG filler valve (1) can be uncovered bypulling out the filler valve cover (2) and itcan be covered by simply pushing it back.

Filling automatically gets cut off when thecylinder pressure becomes equal todispenser pressure. After CNG filling, ensurethat the filler valve cover (2) and fuel fillerlid (3) is closed.

NOTE:• If the Fuel filler lid (3) is kept open, you

will not be able to start the vehicle.• Engine will stop if the fuel filler lid (3)

is opened in vehicle stationary condition.

CAUTIONDo not place any luggage or loadbetween luggage shelf and cylinder asit may damage the cylinder, pipe,hose, valve etc.

CNG CYLINDER

EXAMPLEEXAMPLE

CNG cylinder (1) is installed in the luggagecompartment below luggage shelf (2).

Luggage shelf (2) above CNG cylinder maybe used for keeping lightweight luggage.

LUGGAGE SHELF

CAUTIONDo not place any heavy luggage orload over luggage shelf as it maydamage it.

EXAMPLE

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Open Close

MANUAL SHUT-OFF VALVE

Manual shut-off valve (1) is located on theleft hand side of the CNG cylinder.

MANUAL SHUT-OFF VALVE OPERATION NOTE:• As per Government regulation, CNG

cylinder needs to be checked andcertified every five (5) years from the dateof initial testing as mentioned on the CNGcylinder identification plate.

• Customer has to present the vehicle toa government approved testing agency.

• Failure to test the cylinder may result indenying of CNG filling by the CNGdispensing stations or may result inconfiscating the vehicle by enforcementauthorities.

CNG supply can be switched off by closingthe manual shut-off valve.

Valve closing: Turn the knob completely inclockwise direction to close the CNG supplyto Engine.

Valve opening: Turn the knob completelyin anti-clockwise direction to open the CNGsupply to Engine.

NOTE:• If the manual shut-off valve is not opened

fully, then the engine may not runproperly.

• If the manual shut-off valve is in closedcondition, it is not possible to fill CNG intothe cylinder.

EXAMPLE

EXAMPLE

CNG CYLINDER WARNING LABEL

You may find this label on the CNGcylinder.

EXAMPLE

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wwwww WARNING

LIST OF APPROVED CNG CYLINDERSTESTING STATIONS

To obtain testing stations infromation visitthe following internet website address :“www.peso.gov.in”

JACK REMOVAL(For CNG vehicles)

• Even if the CNG from the cylinderis consumed till engine stops, someamount of CNG will be left out inthe tank under pressure.

The tyre changing tools are stowed in theright side of the luggage compartment.

To remove the jack, turn its shaft counter-clockwise and pull the jack out of thestorage bracket.

To stow the jack, place it in the storagebracket and turn the shaft clockwise untilthe jack is securely held in place.

Pull the strap (1) on the side of the luggageflap (2) to make space for removal of thecover (3).

EXAMPLE

EXAMPLE

• All the expenses for CNG cylinder testinghas to be borne by the customer.

• As per Government regulation, CNGcylinder has to be discarded at 20 yearsfrom the date of initial testing asmentioned in the CNG cylinderidentification plate.

• Customer has to discard the cylinder athis / her expense through governmentapproved scrap agencies.

• No person shall refill any cylinder, whichhas been repaired under sub-rule (2) withany gas unless a full report on the repairsand test carried out on the cylinder,accompanied by the repairer's certificateof testing are furnished to the ChiefController and his permission is obtainedfor its refilling.

wwwww WARNING• Never remove the cylinder valve

from the cylinder assembly. For anyassistance consult Maruti Suzukiauthorized workshop.

• Never try to clean the cylinder. Incase of any problem, contact MarutiSuzuki authorized workshop.

• Do not reuse the cylinder valve,once it is replaced / removed fromcylinder assembly.

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CNG MALFUNCTION WARNING LAMP

When the ignition switch is turned "ON", thisCNG malfunction warning lamp comes onbriefly, to check that the CNG malfunctionlamp is troublefree.

• If CNG malfunction warning lamp glowscontinuously, with ignition "ON" there issome problem with the CNG system.Immediately get your vehicle checked byMaruti Suzuki authorized workshop.

• If CNG malfunction warning lamp blinksduring engine running, it means there issome problem in CNG system in whichvehicle cannot continue running in CNGMODE and automatically switchover topetrol mode. Have your vehicle checkedat Maruti Suzuki authorized workshop.

NOTE:With ignition switch "ON" and engine notrunning, blinking of CNG lamp indicates thatfuel lid is open. Vehicle will not start in thiscondition. Close the lid in order to start thevehicle.

1) Speedometer2) Tachometer (if equipped)3) Fuel gauge (Petrol)4) Fuel gauge (CNG)

INSTRUMENT CLUSTER (WITH TACHOMETER)

EXAMPLE

5) Information display6) Trip meter selector knob7) Indicator selector knob8) Warning and indicator lights9) CNG malfunction warning Indicator lamp

Note:• At the time engine is running on Auto mode or Forced CNG mode, Instantaneous fuel

consumption, Average fuel consumption and Driving range information will not bedisplayed on information display (5).

• If CNG mode is changed to Petrol mode, Instantaneous fuel consumption will appearafter few second, whereas Average fuel consumption and Driving range will appearimmediately, depending on the display selected.

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1) Speedometer2) Tachometer (if equipped)3) Fuel gauge (Petrol)4) Fuel gauge (CNG)

INSTRUMENT CLUSTER (WITHOUT TACHOMETER)

EXAMPLE

5) Information display6) Trip meter selector knob7) Indicator selector knob8) Warning and indicator lights9) CNG malfunction warning Indicator lamp

Note:• At the time engine is running on Auto mode or Forced CNG mode, Instantaneous fuel

consumption, Average fuel consumption and Driving range information will not bedisplayed on information display (5).

• If CNG mode is changed to Petrol mode, Instantaneous fuel consumption will appearafter few second, whereas Average fuel consumption and Driving range will appearimmediately, depending on the display selected.

HIGH ENGINE COOLANTTEMPERATURE WARNING LIGHT(RED COLOR)

When the ignition switch is turned to the“ON” position, this light comes on briefly soyou can check that the light is working. Ifthis light blinks while driving, it means theengine is running hot. Avoid drivingconditions that may lead to actualoverheating. If the light stays on withoutblinking, then the engine is overheating.Follow the instructions in the “If the EngineOverheats” of “EMERGENCY SERVICE”section.

CAUTIONContinuing to drive the vehicle whenengine overheating is indicated canresult in severe engine damage.

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CNG cylinder identification number and CNGkit installation date is located inside the fuelfiller lid.

CNG WARNING LABEL

Front Driver Door

EXAMPLE

CNG KIT IDENTIFICATION

CNG warning label is located on front rightdoors.

FUSE BOX

26) CNG Valve 7.5A

31) Blank

32) Blank

33) CNG 7.5A

34) Blank

For other fuses, refer "Inspection andmaintenance" section in the main owner'smanual.

EXAMPLE

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PERIODIC MAINTENANCE SCHEDULE

Kms (1 x 1000) 1 5 10 20 30 40 50 60 70 80 90 100Month 1 6 12 24 36 48 60 72 84 96 108 120

All Joints (Gas leakage) I I I I I I I I I I I I

Coolant Hoses(Leakage, Damage) I I I I I I I I I I I I

All Fasteners Torque values T T T T T T T T T T T T

CNG low pressure filtercartridge with O-Ring - - - R - R - R - R - R

Spark Plug(Clean and adjust the gap) - - I R I R I R I R I R

CNG cylinder leak testing andcertification Every 5 years from the date of initial testing by govt. approved testing agency

CNG filler receptacle O-Ring Replace every 4 years or 300,000 Km, whichever comes earlier

T ........Tighten to Specified Torque

I ......... Inspect and correct or replace if necessary

R ....... Replace

Note:

• This table includes services as scheduled up to 100,000 km mileage. Beyond 100,000 km, carry out the same services at thesame intervals respectively.

• For other maintenance details refer “Inspection & Maintenance” section in main Owner’s Manual.

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NOTE:1) It is recommended to run the vehicle on petrol mode for 5~10 kms after every 300~500 km run in CNG mode to keep fuel system

in good condition.2) Always keep minimum 5 litres of petrol in your petrol tank.

SPECIFICATIONS

NOTE:Specifications are subject to change without notice.

Mass (Weight) (Kgs)

Kerb Weight 1230-1245 Kgs

Gross Weight 1820 Kgs

Seating Capacity 7 persons

Fuel Capacity (litres)

Petrol 45 L

CNG (Water Filling Capacity) 60 L

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FIRE EXTINGUISHER (if equipped)Do's and Don'ts

Do's1. Check pressure gauge periodically. Max

charging pressure is 15Kgf/cm2 (in greenzone (2)).

2. When pressure drops, indicator needle(1) will shift to the red zone (3).Immediately contact the fire extinguishermanufacturer as per the informationprovided on the fire extinguisher.

3. Get the fire extinguisher serviced onlythrough the manufacturer service centre.Refer the information provided on the fireextinguisher to locate the nearest servicecentre.

4. Ensure that the Fire extinguisher isalways kept at its prescribed position inthe vehicle.

5. Refill the fire extinguisher immediatelyafter use.

Fire extinguisher is located below 2nd rowseat.

LOCATION

PARTS DESCRIPTION

1) Fire extinguisher cylinder

2) Seal

3) Safety Pin

4) Lever

5) Nozzle

REMOVAL PROCEDURE

Lift Lever (1) of fire extinguisher slightlyupwards and pull the fire extinguisher in thedirection as shown in the figure, in orderto disengage it from clamps (2).

Don't• Do not use water for cleaning fire

extinguisher. (Use clean cloth forremoving dust)

• Do not rely on used or discharged fireextinguisher.

EXAMPLE

EXAMPLE

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FITMENT PROCEDURE

3. Pull Safety pin (3)

4. Squeeze lever (4) and direct the jet fromnozzle (5) towards the near edge of thefire with a rapid (fast) sweeping motion.

5. Drive the fire towards the far edge untilflames are extinguished.

Insert the body of fire extinguisher (1) in tothe clamps (3) and place the nozzle (2)carefully downwards.

NOTE:Ensure that the nozzle of fire extinguisheris properly seated on the clamp.

REFILLING SCHEDULES

1. Refilling is necessary after every use.

2. Fire extinguisher needs refilling afterevery 3 years even if it is not used.

PROCEDURE OF OPERATION

1. Hold the fire extinguisher (1) upright.

2. Break seal (2) by rotating the safety pin(3).

NOTE:Fire extinguisher is only meant for small firecaused in vehicle by external source only.

EXAMPLE

EXAMPLE

introduction to cng - welcome to sparsh automobiles€¦ · contents introduction to cng ... manual...

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