TATA Motors Indigo eCS User manual

1
TT
TT
TAA
AA
ATT
TT
TA INDIGO e-CS CNGA INDIGO e-CS CNG
A INDIGO e-CS CNGA INDIGO e-CS CNG
A 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

2
CONTENTS
DESCRIPTION PAGENO.
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 11
7 CylinderManual Shut OFFvalve 12
8 CNGPressure Gauge 12
9 CNGCylinder 13
10 CylinderFillerValve 13
11 SafetyRegulations 15
12 CNGCompliencePlate 15
13 InCase of Blown Fuse 16
14 Fuse Box in Cabin 17
15 SpareWheelRemoval 19
16 TechnicalSpecifications 20
17 Maintenance 21
18 TroubleShooting 21
19 ServiceSchedule-CNG 22

3
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
andtheelectricalparts) in addition to routine maintenance
requiredbythe vehicle.
DO’S:
•Nevercarry outanyrepair workonyour ownorfrom any
other personnel.Always get the car repaired / serviced
at TATA authorized service centre only.
•EnsurethattheBattery Groundterminalisdisconnected
beforestartof any repairs.Re-connectitonce 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
windowsandkeepthedoorsfullyopen forventilation.
b. Turn the ignition switch to ’LOCK’ position.
c. Switch off ignition switch and manual shut off knob
locatedoncylindervalvebeforeservicing/repairing
of any parts in the CNG circuit.

4
e. ImmediatelycontactnearestTATAauthorizedservice
centreforfurtherassistance.
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.
•GetCNGCylindercheckedafterevery 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.
•RemovetheCNG tank during thewelding/brazingwork
ontheCar.
•Check/replace air filter as per service schedule
mentioned.Cleanit 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.
•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
CNG Pressure Gauge in Engine Compartment
d. AlsoensureCNGgaspressure at pressure gauge is
Zero.Fordoingso, we can run vehicle in CNG mode
aftershutting offcylindervalve. Donotrunthevehicle
until leakage is rectified.
CNGcylinder OPEN / CLOSE knob in boot space

5
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.Never placeinflammable,
explosive,corrosivematerialandsharpobjectsnearCNG
cylinder.
•Neverplaceinflammable,explosive, corrosive material
nearCNGcylinder.
•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.

6
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”lampturns“ON”.
•Selectthedesiredfueloperatingmode 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
(PetrolorCNG), your car’s enginewillstartusingpetrol
based on the programmed warming up condition and
laterswitchover automatically to CNG (if CNGmodeis
selected).
•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

7
4. HOW TO SHIFT THE FUELLING MODES
You canswitchfromPETROLtoCNGand
viceversabyoperatingfuelselectorswitch
located on right hand side of dashboard
nearsteeringwheel.Seebelowpicture.
A. PETROL to CNG mode
You can shifttoCNGfuelmode by pressing the fuel selec-
torswitch. The“CNG”lampon theinstrumentclusterstarts
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 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, thisindicates thecompletion
of the transition to the required fuel mode.
•Fastflashingofthe’ CNG’lamponinstrumentcluster
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.

8
INSTRUMENT CLUSTER
5. INSTRUMENT CLUSTER
SET
Knob LCD MODE Selec-
tor
Knob
Fuel
Gauge CNG Lamp
MIL
SIL

9
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 itisinCNGmode thegreen“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

10
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.Thetripmetercanbeused to measure thedistance
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)andIntensity
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

11
ENGINE COMPARTMENT
1. WindshieldWasherFillingCap
2. EngineCoolantTank
3. BrakeFluidContainer
4. EngineOilFillerCap
5. CNGPressureRegulator
6. CNGPressureGauge
7. CNGECU
8. Fuse Box & Relay
9. PetrolECU
10. Battery
11. Air Filter
12. Dip Stick
13. Power SteeringOilContainer
6. ENGINE COMPARTMENT
12 1113
13 4 78910
26
5

12
CNG FILLING
7. CYLINDER MANUAL SHUT OFF VALVE / KNOB :
Amanual shutOFFknobis fittedtocylindervalve. Cylinder
valveismounted on CNG cylinder.
Manual shut OFF Knob Operation:
CNG supply can be cut OFF by closing the manual shut
OFFvalve/ 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-clock-
wise direction to open the CNG supply to Engine.
8.CNG PRESSURE GAUGE :
CNG pressure gauge indicates the high pressure in the
system. It is located in Engine compartment.
CNGcylinder OPEN / CLOSE knob in boot space CNG Pressure Gauge in Engine Compartment

13
CNG CYLINDER & CNG FILLER VALVE
9.CNG CYLINDER:
TheCNGcylindersarelocatedinbootspace.CNGisstored
inahighpressure cylinder at a pressure of 200 bar (work-
ingpressure).
Themaximum storage pressureofCNGin cylinder isupto
260 bar (i.e. cylinder test pressure).
CNG cylinderin boot space
10. CNG FILLER VALVE :
CNGfillervalve is used tofillCNGinthecylinder.Itisfitted
nearpetrolfillinglocation. CNG should be filled by gas fill-
ing nozzle at filling station.
CNG tank capacity : 60 liters of Water capacity
1
2
1. CNG Filler Cap 2. Petrol Filler Cap
3. Microswitch with LED
3

14
IMPORTANT:
•KeeptheIgnition switch in“OFF”conditionduring CNG
refilling.
•Donotuse your mobilephoneswhenyou are atafilling
station.
•After filling the CNG, if the filler valve is kept open, you
will not be able to start the vehicle. Always close the
fillervalve/ receptaclecapproperly,in order tostartthe
vehicle
For filling the CNG, follow the below procedure.
•Rotate the filler valve / receptacle cap in anticlockwise
direction.
CNG FILLER VALVE
•Openthefillervalve/receptaclecap.
•Now CNG can be filled by gas filling nozzle at
fillingstation.
•Close the cap properly once the CNG gas is filled.
NOTICE
•Whenthe fillervalve/receptacle capisopened(or not
inplace),theLEDontheCNGrefuelingsensorstarts
glowing(RED colour), and when the capis closed (in
place)theLEDgoes off.
•Incasethevehicleisnotcranking/starting,checkfor
the LED on the sensor. If it’s glowing, the filler valve /
receptaclecap should be tightened properly.

15
11. SAFETYREGULATION:
FIREEXTINGUISHER :
Afireextinguisherisprovidedonthecarnear 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.
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.
12.CNG COMPLIENCE PLATE:
CMVR(Compliance to Motor Vehicle Rules) plate is fitted
near to filler valve with CNG kit identification and installa-
tion details.
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 aTATAAuthorizedServicecentreandthe
newdateisengravedontheplate.
Location of Fire Extinguisher
CMVR Plate
SAFETY REGULATION & CNG COMPLIENCE PLATE

16
13. 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.
•Removetheblownfuseandreplacewith 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

17
FUSE BOX
14. FUSE BOX IN CABIN

18
Sr. Function Fuse
No. Rating
1 STARTER PROTECTION CIRCUIT 5A
2 FRONT AND REAR FOG LAMP 20A
3 FUEL PUMP 15A
4 LPG/CNG POWER RELAY 15A
5 POSITION LAMP-RH 5A
6 POSITION LAMP-LH 5A
7 BLOWER + W/W + HORN RELAY COIL 5A
8 INDICATOR LAMPS 10A
9 MUSIC SYSTEM & CHIME KEY IN 5A
10 A/C CONTROLS 10A
11 HEAD LAMP LOW BEAM RELAY 15A
12 HEAD LAMP HIGH BEAM RELAY 15A
13 WASH & WIPER 25A
14 INSTRUMENT CLUSTER FUEL CUT-OFF 10A
15 REVERSE LAMP, CLOCK & CIG.LIGHTER 20A
16 STARTER RELAY 20A
17 MUSIC SYSTEM, CLOCK & INST. CLUSTER 15A
18 ROOF,ENGINE,LOAD AREA LAMP 5A
19 - -
20 C.D.L & IMMOBILISER 30A
21 STOP LAMP & HMSL 10A
22 VENTILATION MOTOR 30A
FUSE BOX
2. FUSE BOX - NEAR FIRE WALL- CNG