TATA Motors INDICA eV2 XETA CNG User manual

CNG KIT REGISTRATION CARD (CUSTOMER’S COPY)
Owner name: ...............................................................................................................................................................
Address: ......................................................................................................................................................................
Vehicle Reg. No: .........................................................................................................................................................
Engine No. : ................................................................................................................................................................
VIN: ..............................................................................................................................................................................
Regulator No: .............................................................................................................................................................
Cylinder No : …………………………………………………Cylinder Retesting Date: ................................................
Kms Reading: ................................................................. Date of installation. .........................................................
Dealer Name: .................................................................. Dealer Code ....................................................................
Address: ......................................................................................................................................................................
Seal & Signature of the Dealer

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TT
TT
TAA
AA
ATT
TT
TA INDICA eV2 XETA INDICA eV2 XET
A INDICA eV2 XETA INDICA eV2 XET
A INDICA eV2 XETA CNGA CNG
A CNGA CNG
A CNG
SUPPLEMENT
(This manual should be read in conjunction with
Indica eV2 XETA Owner’s Manual & Service Book)
Passenger Car Business Unit
Pune

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CONTENTS
DESCRIPTION PAGE NO.
1 Introductionto CNG 3
2Safetyprecautions 3
3 Startingtheengine 6
4 Howto shift the fuelling modes 7
5 Instrumentcluster 8
5.1 Fuelgauge 9
5.2Multifunctional LCD,Odometer, 10
Tripmeter& Dimmer
6 Enginecompartment 12
7 CNGfilling 13
8 Safetyregulations 13
9 Incaseofblownfuse 14
10 Sparewheelremoval 17
11 TechnicalSpecifications 18
12 Maintenance 19
13 Troubleshooting 19
14 Warranty policy 19
15 Serviceschedule 20

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1. INTRODUCTION TO CNG :
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-toxicbutinflammable and lighter
than air.
BENEFITS OF CNG :
•CNG is principally comprised of methane. Due to low
density it is compressed at a pressure of around 200
barstoimprovethevehicleon board capacity.
•Lowermaintenancecostswhen vehicles run on CNG.
•Withrisingpetrol costs, CNG hasseenthecompetitive
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
consideredtobeanenvironmentallyviablealternative
topetrol.
INTRODUCTION & SAFETY PRECAUTIONS
2. SAFETY PRECAUTIONS
To get the best out of CNG fuel, the engine must be tuned
andregularlyserviced(bothas regards to the mechanical
andtheelectrical parts) in addition to routine maintenance
requiredbythe vehicle.
DO’S:
•Nevercarry outanyrepairworkonyourownor fromany
other personnel.Always get the car repaired / serviced
at TATA authorized service centre only.
•EnsurethattheBattery Groundterminal isdisconnected
beforestart of anyrepairs.Re-connectit once therepair
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
windowsandkeepthe doorsfullyopenforventilation.
b. Turn the ignition switch to LOCK (0) position.

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c. Switch off ignition switch and manual shut off knob
locatedoncylindervalvebeforeservicing/repairing
ofany partsinthe CNG circuit.AlsoensureCNGgas
pressureat pressure gaugeisZero. For doingso,we
canrunvehicleinCNGmodeaftershuttingoffcylinder
valve.Do not runthevehicle until leakageisrectified.
d. Immediately contact nearest TATA authorized
service centre forfurther 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.
•GetCNGCylinderchecked after every 5 years at Govt.
approved testAgency. Never fill CNG cylinder with air,
LPG or any fuel except CNG.
•Keep the car away from any Fire source.
•Removethe CNG tank duringthewelding/brazingwork
ontheCar.
•Check/replace air filter as per service schedule
mentioned.Clean it during everyservice.
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.
•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
CNGcylinderOPEN / CLOSE knob in boot space
CNG Pressure Gauge in Engine Compartment

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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 /
tamperCNG systemsettings.Neverplaceinflammable,
explosive,corrosivematerialandsharpobjectsnearCNG
cylinder.
•Neverplaceinflammable, explosive, corrosive material
nearCNG cylinder.
•While loading or unloading particulars near boot area,
take extra precaution for preventing any damage to
cylinderand cylinder valve.
•Don’tsmokeinsideor 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.
•Neverusenakedflame/fireto check gas leakages.
•Do not use high pressure washer fluid/water jets at
electrical devices & their connectors during washing.
Thisistopreventmalfunction/failureofelectricalsystem
duetowater ingress.
•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.

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3. STARTING THE ENGINE
NOTE:
Your Engine can start either in gas mode or in petrol
mode but it is always advisable to start in petrol mode
and then switch to gas mode.
• To start, turn the ignition key to “IGN” position. Ensure
the“MIL”lampturns“ON”.
• Selectthedesiredfueloperating mode by pressing the
FuelSelectorSwitch.
• Keep the clutch pedal fully pressed and crank the
engine.DOnot press the accelerator pedal.
• If the engine cranks but fails to start then repeat the
aboveprocedure.Releasethekeyassoonastheengine
starts. Ensure that the “MIL” lamp is “OFF”.
NOTE:
• Irrespective of the position of the fuel selector switch
(Petrolor CNG), your car’senginewillstartusing petrol
when the engine / coolant temperature is below 10°C
(especially in cold winter) and later switch over
automaticallytoCNG(ifCNGmodeisselected).Once
theengine warms up, yourcar’s engine will start using
CNG, if CNG mode is selected.
• Duringnormalambient(summerandothermonths),you
car’senginewillstartin CNG,ifCNGmodeisselected.
• StartingtimeinCNGwillbelongerthan inpetrol (approx
1seclongerthanpetrolstartingtime) dueto thephysical
characteristics of the fuel.
• Ensurethatyour car has sufficient petrol in the tank as
petrol is used for starting until the engine warms up.
• Ensure that you run your car in “PETROL” mode for at
least10kmsforevery300kmscoveredin“CNG”mode
toensure proper working of petrol fuel supplysystem.
STARTING THE ENGINE

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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 se-
lector switch. The “CNG” lamp on the instrument cluster
starts flashing during the changeover to CNG mode and
glows permanently after changing to CNG mode indicat-
ing that the car is running on CNG.
B. CNG to PETROL mode
Similarly you can switch to PETROL fuel mode by press-
ing 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.
FUELLING MODES & CNG LAMP
CNG LAMP :
This lamp glows when you select the CNG
fuel mode. This lamp will not glow when you
selectpetrolfuel 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
lampglows permanently,this indicates thecompletion
of the transition to the required fuel mode.
•Fastflashingofthe’CNG’ lamp oninstrumentcluster
indicates the fault in CNG system. Car will
automatically switch to Petrol mode. Get the car
checked / repaired at the nearestAuthorized TATA
servicecenter.
•Very Slow flashing of the’ CNG’ lamp indicates the
emptytank / NO CNG supply (loss of pressure). Get
the CNG tank re-filled.

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INSTRUMENT CLUSTER
5. INSTRUMENT CLUSTER
SET
Knob LCD MODE Selec-
tor
Knob
Fuel
Gauge CNG Lamp
MIL

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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
levelof petrolandwhen itisinCNG modethegreen “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(ambercoloured) comes ‘ON’ indicating the fuel
level is low. Refill the fuel tank at the earliest.
Sr. No. CNGpressure (bar) Fuel gauge
indication
1 15 Empty low
2 100 1/2
3 150 3/4
4 200 Full
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.
Fuel
Gauge CNG Lamp
Low Fuel
Warning Indicator
FUEL GAUGE

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MULTIFUCTIONAL LCD
5.2 MULTIFUNCTIONAL LCD, ODOMETER,
TRIPMETER AND DIMMER:
The speedometer indicates the car speed in km/hr. The
odometer records the total distance the car have been
driven.Thetripmetercanbe used to measurethedistance
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
TripmeterA,TripmeterB,CNG MASS(inkg)and Intensity
level of panel illumination.
The selection and control of functions are done through
‘MODE’and ‘SET’ pushbuttons (knobs) providedoneither
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.
Odometer
Tripmeter / CNG MASS /
Intensity level of
illumination

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LCD DISPLAY
DISPLAY SELECTION BY “MODE” AND “SET” KNOBS:
Sr. No. Indication on LCD With “MODE” knob pressed With “SET” knob pressed
1 ODOMETER Display changes to TRIP ‘A’ ————
2 TRIPA Display changes to TRIP ‘B’ Resets TRIP ‘A’ distance
3 TRIPB Display changes to CNG MASS Resets TRIP ‘B’ distance
4 CNG MASS Display changes to DIMMER ————
5 DIMMER Display changes to ODOMETER Adjusts dimming level

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ENGINE COMPARTMENT
1. WindshieldWasherFillingCap
2. EngineCoolantTank
3. BrakeFluid Container
4. EngineOilFillerCap
5. CNGPressureGauge
6. CNGECU
7. Fuse Box & Relay
8. PetrolECU
9. Battery
10. Air Filter
11. Dip Stick
12. Power Steering Oil Container
6. ENGINE COMPARTMENT
11 1012
13 4 56789
2

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7. CNG FILLING :
CNGfiller valve is used tofillCNGinthe cylinder. It isfitted
nearpetrolfillinglocation.CNGshouldbefilledbygasfilling
nozzle at filling station.
CNG tank capacity: 60 liters of Water capacity
IMPORTANT:
•Keep the Ignition switch in “OFF” condition during
CNG refilling.
•Do not use your mobile phones when you are at a
Fillingstation.
8. SAFETY REGULATION :
FIREEXTINGUISHER :
Afireextinguisherisprovidedonthe car near driver seat
Method of operation :
1. Checkifthepressuregaugeneedlein green zone.
2. Holdupright,pullthepinand press the lever.
3. Direct discharge at base of flame with rapid sweeping
motion.
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.
CNG FILLING & SAFETY PRECAUTIONS
CNG
Filler
Cap
PETROL
Filler
Cap
Location of Fire Extinguisher

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9. IN CASE OF BLOWN FUSE
Your car’s CNG system is protected against short circuit /
overloadby a fuse (15A)fitted in the fuse box.
To replace a blown fuse:
•Openfuse box cover.
•Identifyblownfusefromits melted wire.
•Removetheblownfuseand replace with one of similar
amperage.
Take your car to a TATAAuthorized service centre to find
out the reason for the fuse to blow & repair the problem.
NOTE:
Fuse replacement should preferably be done only at
TATAAuthorized 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.
WARNING:
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 TATAauthorized service centre.
IN CASE OF BLOWN FUSE
CNG KIT / CMVR NUMBERING PLATE :
CMVR (Compliance to Motor Vehicle Rules) plate is
installed near to filler valve with CNG kit identification and
installationdate.
Your car’s CNG cylinder needs to be recertified every five
years as per CMVR (AIS 24, 25 and 26). Please ensure
thatitis done by aTATAAuthorizedServicecentre and the
newdateisengravedontheplate.
CMVR Plate

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FUSE BOX
FUSE BOX IN CABIN

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Fuse Function Fuse
No. Rating
F1 Starter protection circuit 5A
F2 Front and rear fog lamp 20A
F3 Fuel pump 15A
F4 CNG power relay 15A
F5 Position lamp RH 5A
F6 Position lamp LH 5A
F7 Blower + W/W + Horn relay coil 5A
F8 Indicator lamps 10A
F9 Music system and chime key in 5A
F10 A/C controls 10A
F11 Head lamp low beam relay 15A
F12 Head lamp high beam relay 15A
F13 Wash & wipers 25A
F14 Instrument cluster 10A
F15 Reverse lamp, clock and 20A
cigarette lighter
F16 Blank
F17 Music system, clock and 15A
instrument cluster
F18 Roof, engine and load area lamp 5A
F19 Blank
F20 C.D.L. and Immobilizer 30A
F21 Stop lamp and H.M.S.L. 10A
F22 Ventilation motor 30A
FUSE BOX

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10. 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.
•Unscrewsparewheel mounting nut.
•Once this nut is removed, the wheel can be lifted and
taken out.
SPARE WHEEL REMOVAL
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.

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TECHNICAL SPECIFICATIONS
11. TECHNICAL SPECIFICATIONS
ENGINE (Bi-fuel: Petrol + CNG)
Model TATA475 SI 70
Type Watercooled, Multi Point Injection, Single overhead camshaft Engine
No. of cylinders 4inline
Bore X Stroke 75 mm x 67.5 mm
Capacity 1193 cc
Max. Engine output CNG Mode : 55 Ps at 5000 rpm
Max. Torque CNG Mode : 90 Nm at 2600 rpm
Compression ratio 10 : 1
Firing order 1 - 3 - 4 - 2
Fuel system Sequential Injection with close loopAir / Fuel control
Emission compliance BS IV
Cooling system capacity 6.0 Liters
ELECTRICALSYSTEM
System Voltage 12Volts-ve earth
Battery 12V,DIN55
Alternator 90A
FUELTANKCAPACITY
Fuel Tank Capacity PETROL : 37 Litres / CNG : 60 LITRES of WATER CAPACITY