1. INTRODUCTION TO CNG: CNG (COMPRESSED NATURAL GAS) is principally constituted of Methane. CNG is a colourless, odourless and non-toxic gas. For detection in case of leakage, odorants are added to give it a distinctive, pungent smell. But, it is inflammable and lighter than air. Due to its low density, CNG is compressed to up to around 200 bar to increase storage capacity. CNG has the following benefits. CNG is a clean burning fuel and has lesser tail • pipe emissions than compared to gasoline. CNG offers lower running and maintenance • costs compared to gasoline. CNG does not contaminate and dilute the • crankcase oil during combustion and hence oil in the engine does not lose its properties which can lead to early wear and tear of engine parts. 2. SAFETY INSTRUCTIONS To get the best out of CNG fuel, the vehicle must be serviced as per the service interval given in this manual. Following should be kept in mind before working or handling CNG components. DO’S Always disconnect the Battery Ground terminal • before start of any repairs. Re - connect it only after the repair activity is completed. Natural Gas is highly inflammable. Park the • vehicle in open space away from any heat source. Keep all fire sources (ignition \ spark \ flame) • out of work area. Before starting any work on CNG system, turn • off the manual valve on the cylinder valve. Start the engine and run on CNG mode at idle until all the fuel (CNG) in the system is depleted. Remove the CNG cylinders before any • welding/brazing work on the Car. After working on gas system components, open • the manual service shut off valve. Check all components connections for gas leak using electronic leak detector or non-corrosive foaming agent like Snoop® or Collins® (refer gas leak detection procedure section) before cranking the engine. All fasteners should be tightened to specified • torque. If either over tightened or left loose, it will result in leakage at joints and damage to the parts threads. It will also adversely affect the performance of the parts/systems because various clearances/bearing plays in the aggregates are governed by the tightening torques of the fasteners. Before tightening, clean the threads. If the vehicle has to be kept/parked in a • confined space, close both the manual valve on the cylinders valve. If you smell CNG or if you hear a hissing sound of leakage, follow these directions: a. Do not panic. Park the 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 off ignition c. Switch off the gas supply by putting both manual shutoff knob to ‘OFF’ position. The Manual shut off knob is located on Cylinder valves fitted on CNG cylinders inside the boot. Do not run the vehicle until leakage is rectified. DONT’S Do not install an LPG, Propane or any other • cylinder in place of CNG cylinders. It is illegal and unsafe. Never fill CNG cylinders with air, LPG or any • fuel except CNG. Never alter CNG system configuration. Do not • adjust / tamper CNG system settings. Never place inflammable explosive, corrosive • material or sharp objects near CNG cylinders. Don’t smoke inside or near the CNG vehicle • NOTE In case of gas leakage in low pressure • circuit, 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. Leakage in high-pressure line from CNG • Tank to High-pressure regulator will not be monitored/ detected. It is essential to have enough of petrol at all • times to ensure trouble free operation in case of empty CNG tank. 1.2L REVOTRON CNG PHASE-2 ENGINE 94
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