for vehicles fitted with lpg fuel system · for vehicles fitted with lpg fuel system lpg cylinder...

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FOR VEHICLES FITTED WITH LPG FUEL SYSTEM

CONTENTS Introduction to LPG ............................................................................................................. 3Safety Precautions (Do's & Dont's) .................................................................................. 3Location of Wagon-R LPG System Major Components ............................................... 4Fuel Modes ............................................................................................................................ 5Selector Switch Position ..................................................................................................... 5Petrol Mode ........................................................................................................................... 5Auto Mode ............................................................................................................................. 6Forced LPG Mode ................................................................................................................ 6LPG Level Indicator (On Dashboard) ............................................................................... 6Automatic Changeover from LPG Mode to Petrol Mode ............................................. 7LPG Filling ............................................................................................................................. 7LPG Cylinder ......................................................................................................................... 8LPG Cylinder Warning Label ............................................................................................. 8Manual Shut off Valve Knob .............................................................................................. 8List of Government Approved LPG Cylinder Testing Stations ................................... 9Jack Removal Procedure .................................................................................................... 9Spare Wheel Location ....................................................................................................... 10Spare Wheel Removal Procedure .................................................................................... 10Instrument Cluster .............................................................................................................. 11LPG Malfunction Warning Lamp ..................................................................................... 12Petrol Tank Capacity ......................................................................................................... 12LPG System Identification ................................................................................................ 12LPG Fuses (Engine Compartment) ................................................................................. 13LPG Fuses (Under Dashboard) ........................................................................................ 13LPG Warning Label ............................................................................................................ 14Periodic Maintenance Schedule ....................................................................................... 14Specifications ...................................................................................................................... 16Fire Extinguisher (if equipped) ....................................................................................... 17Parts Description ................................................................................................................ 18Removal Procedure (from front & rear seat) ............................................................. 18Procedure of Operation .................................................................................................... 19Fitment Procedure .............................................................................................................. 20Refilling Schedules ............................................................................................................ 20

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LPG is a clean, high octane and eco-friendlyfuel. It is basically a mixture of Butane andpropane and is obtained from Natural GasFractionation and Crude Oil Refining.

LPG is a gas at atmospheric pressure, butcan be liquidated when moderate pressureis applied or when the temperature issufficiently reduced.

LPG produces less harmful exhaust gasesas compared to petrol and diesel.

INTRODUCTION TO LPG

In case of any symptom of LPGleakage or releasing noise or anyexternal damage to LPG piping orduring accident, do not panic.• Stop the vehicle and switch off the

engine, roll down the windows andopen all the doors

• Ensure to close manual shut offvalve.

• Contact Maruti Suzuki authorizedworkshop immediatly for furtherassistance.

• Always repair your vehicle at MarutiSuzuki authorised workshop only.

• If engine does not start in LPG mode,start in Petrol mode and get the vehicleinspected by Maruti Suzuki authorisedworkshop.

• Ensure that the Gas tank Cover isalways in closed position and notdamaged. Replace the same as soon asdamage is noticed.

• Ensure that conduit pipes are always ingood condition and secured firmly.Replace in case damage is noticed.

• Get the Auto LPG cylinder checkedperiodically.

• If any Service or body repair is to becarried out, ensure to close Manual shutoff valve on the multivalve. Then removethe Auto LPG cylinder from the vehicle.

• It is recommended to run the vehicle 5-10 Kilometers on Petrol after every 300-500 Kilometers run in LPG mode tokeep the fuel system in good condition.

• Switch "OFF" engine before refilling LPG.

SAFETY PRECAUTIONS (Do's)

• Never install any other gas cylinder inplace of LPG cylinder.

• Do not change/modify the configurationsettings or components from LPGsystem.

• The Auto LPG cylinder should never berepaired under any circumstances, incase of any problem, consult with MarutiSuzuki authorised workshop.

• Never carry inflammable material nearAuto LPG cylinder.

• Never handle LPG system components.In case of replacement of anycomponent, always contact Maruti Suzukiauthorised workshop.

• Do not fill any other type of gas otherthan Auto LPG.

• Do not try to fill more than 22.4 Lts ofLPG.

• Do not use Domestic LPG in yourvehicle.

• Do not press the accelerator pedal tochange from petrol to LPG mode.

SAFETY PRECAUTIONS (Dont's)

CAUTION

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LOCATION OF WAGON-R LPG SYSTEM MAJOR COMPONENTS

1 LPG Refilling Valve2 High Pressure Pipe3 Multivalve Assy.4 LPG Tank5 High Pressure Pipe

6 Vent Hose7 Pressure Regulator LPG8 Low Pressure LPG Hose9 High Pressure LPG Filter10 Low Pressure LPG Filter

11 Low Pressure & Temp. Sensor12 LPG Injector Rail13 Coolant Hose14 Change Over Switch/Fuel Level

Indicator15 LPG Controller

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FUEL MODES

NOTE:

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

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

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

• Stop cranking the engine immedi-ately after the engine has started orthe starter 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 for about 15 seconds beforetrying again.

CAUTION

wwwww WARNING

(1)

SELECTOR SWITCH POSITION PETROL MODE

In this mode vehicle starts in petrol andcontinue running in petrol mode. In thismode, petrol indicator glows continuously inORANGE color and LPG indicator (GREEN)will remain "OFF".

When the vehicle is running in this mode,it can be shifted to LPG mode by pressingthe changeover switch.

LPG

PRESS

PETROL LED(ORANGE) "ON"

LPG LED(Green)"OFF"

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AUTO MODE

LPG

LPG LED(GREEN) blinks

Petrol LED(ORANGE) "ON"

FORCED LPG MODE

This is emergency mode and may be usedin cases where there is no petrol in petroltank. In this mode vehicle starts in LPG andcontinues running in LPG mode. Withignition "ON" and engine not running, pressand hold the changeover switch till LPGindicator glows continuously. In this mode,LPG indicator glows continuously in GREENcolor and Petrol indicator (ORANGE)remains "OFF".

NOTE:• It is recommended to keep sufficient

amount of petrol in the petrol tank.

• The vehicle will not start in Forced LPGmode if the coolant temperature is belowzero deg C.

LPG

LPG LED(GREEN) "ON"

Press

Petrol LED(ORANGE) "OFF"

In this mode engine starts in petrol modeand then automatically changes to LPG afterreaching programmed warming up condition.With ignition switch ON and vehicle startedin “AUTO MODE”, LPG indicator blinks(Green Color), and PETROL indicator glows(Orange color) continuously. Afterchangeover to LPG, LPG indicator will glowcontinuously and Petrol indicator switchesoff automatically.

NOTE:• It is always recommended to start the

vehicle in AUTO MODE or PETROLMODE to enhance the engine life.

• The fuel changeover to LPG will nothappen if the vehicle is started at the timewhen the coolant temperature is belowzero deg. C.

LPG LEVEL INDICATOR(On Dashboard)

LPG level indicator is built into thechangeover switch. It consists of four greenand one red LEDs, which indicatesapproximate amount / level of remainingLPG in the cylinder. Red LED of LPG levelindicator glows when reaches to reservequantity.

LPGMaximum

LPG Levelindicator

Reserve LPGlevel Indicator(RED)

Minimum

NOTE:

• When LPG reserve level indicator glows,refill LPG as soon as possible.

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LPG filler Valve is installed on left hand sideof your vehicle. LPG Filling will stopautomatically once cylinder is filled upto80% of the capacity.

The cylinder fitted in your vehicle is of 28litres water capacity. When filling an emptycylinder, it is advised to fill maximum 22.4litres of LPG in the tank of your vehicle. Incase, filling is being done after removal and/or fitment of Auto LPG cylinder, for testingthe LPG cylinder as per govt. regulation,have the joints checked for leakage byapplying soap solution or leak detector byMaruti Suzuki authourized workshop.

LPG FILLINGAUTOMATIC CHANGEOVER FROMLPG MODE TO PETROL MODE

When Auto LPG is emptied while the engineis running, vehicle automatically changesfrom LPG mode to Petrol mode and LPGmalfunction warning lamp starts blinking.Petrol indicator (ORANGE color) glowscontinuously and LPG indicator (GREENcolor) gets switched OFF automatically.

To stop this alert, press the changeoverswitch once. LPG malfunction warning lampwill stop blinking and Petrol indicator(ORANGE color) will glow continuously.However, LPG malfunction warning lamp willcontinue to blink after every subsequentIgnition ON - Ignition OFF condition, untilthe vehicle is refilled with atleast 8 liters ofLPG.

NOTE:

• It is recommended to keep atleast 5 litresof petrol in the petrol tank to preventengine stalling while automatic change-over from LPG mode to Petrol mode.

• In case the LPG malfunction warninglamp does not stop blinking after pressingthe changeover switch, have the vehicleinspected at the nearest MARUTI SUZUKIdealer.

• In case LPG is refilled in an empty tank,ensure that minimum 8 liters of LPG isfilled as it is required for system tochangeover from Auto mode to LPGmode. In case less than 8 liters of LPGis filled in an empty tank, vehicle maycontinue to run on Petrol mode only.

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LPG CYLINDER WARNING LABEL

You may find this label on the LPG cylinder.

MANUAL SHUT OFF VALVE KNOB

The Manual shut off valve knob (Yellow incolour) is located on Multivalve, on the AutoLPG cylinder. The knob should always bein open position to allow the flow of LPGto engine. In the close position of the lever,LPG supply to the engine is stopped.

The manual shut off valve knob must beclosed in case of any repair in the LPGsystem parts or any symptoms of leakage.

NOTE:

• If the manual shut off valve is not openedfully, then engine may not run properly.

• If the manual shut off valve is in closedposition, it is not possible to fill LPG intothe cylinder.

LPG CYLINDER MULTIVALVE

LPG cylinder (1) is installed below theluggage floor carpet in the luggagecompartment.

NOTE:

• Do not load sharp and heavy objects inthe rear luggage area.

LPG CYLINDER

(1)

• Do not fill more than 22.4 litres ofLPG in tank.

• Usage of Domestic LPG is legallyprohibited and can cause seriousdamage to the vehicle.

CAUTION

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wwwww WARNING• Never remove the Multi-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 multivalve, once itis replaced / removed from cylinderassembly, during re-certification ofLPG tank, without changing gasketand multivalve screw.

• Even if the LPG from the cylinder isconsumed till engine stops, someamount of LPG will be left out in thetank under pressure.

JACK REMOVAL PROCEDURE

Jack (1) is located below the luggage floorcarpet.

NOTE:To access the JACK it is NOT required totake out luggage floor carpet completely.Flap is provided separately for easy accessof tool Kit.

(1)

LIST OF APPROVED LPG CYLINDERSTESTING STATIONS

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

NOTE:• As per Government regulation, LPG

cylinder needs to be checked andcertified every five (5) years from the dateof last retest as mentioned on the LPGcylinder identification plate.

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

• Failure to test the cylinder may result indenying of LPG fill ing by the LPGdispensing stations or may result inconfiscating the vehicle by enforcementauthorities.

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

• As per Government regulation, LPGcylinder has to be discarded at 15 yearsfrom the date of initial testing asmentioned in the LPG 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.

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SPARE WHEEL REMOVALPROCEDURE

(a) Remove spare wheel cover (1) bylifting upside.

(b) Take out the wheel wrench (2) fromutility box by just rotating/lifting the flap,provided in the luggage floor carpet.

NOTE:To access the utility box it is NOT requiredto take out luggage floor carpet completely.Flap is provided separately for easy accessof tool Kit.

(2)

Spare wheel is located behind the rear lefthand Seat, fitted on a bracket and tightenedwith help of a locking knob.

SPARE WHEEL LOCATION

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1) Speedometer2) Odometer / Tripmeter3) Odometer / Tripmeter selector knob4) LPG malfunction warning Indicator lamp5) Fuel Indicator6) Warning and Indicator lights (if equipped)

INSTRUMENT CLUSTER

EXAMPLE

(c) Engage the notch provided end withscrew & rotate in anticlock-wisedirection as shown.

(d) Take out the spare wheel in thedirection as shown in figure.

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Your vehicle is fitted with petrol tank of 35litres capacity.

NOTE :

The tank should always have sufficientquantity of petrol.

PETROL TANK CAPACITY

PETROLFILLERCAP

PETROLTANK

LPG SYSTEM IDENTIFICATION

LPG cylinder Identification number and LPGkit installation date is located near the LPGfiller valve.

LPG

AUTO LPG TANK ID NO.

LPG

AUTO LPG TANK ID NO.

When the ignition switch is turned “ON”, thisLPG malfunction warning lamp comes onbriefly, to check that the LPG system istroublefree.

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

• If LPG malfunction warning lamp blinksduring engine running, it means there issome problem in LPG system in whichvehicle cannot continue running on LPGand automatically switchover to petrolmode. Have your vehicle checked atMaruti Suzuki authorized workshop.

LPG MALFUNCTION WARNING LAMP

LPG

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LPG FUSES (Engine Compartment) LPG FUSES (Under Dashboard)

6) LPG VLV Relay -

15) LPG VLV Fuse 7.5A

7) LPG Fuse 7.5A

Always be sure to replace a blownfuse with the fuse of correctamperage. Never use a substitutesuch as aluminium foil or wire toreplace a blown fuse. If you replacea fuse and the new fuse blows in ashort period of time, have your vehicleinspected immediately by your MarutiSuzuki authorised workshop.

wwwww WARNING

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LPG WARNING LABEL

Rear Right door

Front Driver door

LPG warning label is located on front andrear Right side doors.

NOTE :

The interval should be judged by odometerreading. Over and above the regularmaintenance schedule described in the mainowner's manual (supplied with the vehicle)following has to be checked only by MarutiSuzuki authorised workshop.Check Auto LPG cylinder every five yearsat Government approved LPG cylinderstesting agency.For periodic maintenance refer next page.

PERIODIC MAINTENANCE SCHEDULE

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PERIODIC MAINTENANCE SCHEDULE

Kms (1 X 1000) 1 5 10 20 30 40 50 60 70 80 90 100

Month 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

Low Pressure LPG Filter Cartridge with O-Rings - - R R R R R R R R R R

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

High Pressure LPG Filter Cartridge of LPG Regulator

with O-Rings - - R R R R R R R R R R

LPG Pressure Regulator Overhauling:- Diaphragmreplacement with O-Rings & solenoid plunger Cleaning - - - - - R - - - R - -

All Fasteners Torque values for Bracket,LPG Pressure Regulator, LPG Filter, LPG Tank & T T T T T T T T T T T Tall LPG Pipe joints.

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 the same intervals respectively.

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

• For relays and fuse of Petrol system refer “Inspection & Maintenance” section in main Owner’s Manual.

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SPECIFICATIONS

NOTE:Specifications are subject to change without notice.

ITEM: Mass (weight) UNIT:Kg LPG

Curb mass (weight) 895-925

ITEM: Wheel and Suspension LPG

Tyre size, front and rear 145/80R13

Rim size 13 x 4J

Tire pressures Front 2.3 Kg/cm² (32.7psi)

Rear 2.3 Kg/cm² (32.7psi)

ITEM: Steering LPG

Toe-in Each wheel 3 min ± 5 min

Total wheel 6 min ± 5 min

ITEM: Capacities (approx.)

Fuel tank (Petrol) 35 L

LPG Tank (water filling capacity) 28 L (LPG can be filled to 80% of total tank capacity i.e. 22.4 L)

13A

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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 LPG mode to keep fuel system

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

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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). Immediatelycontact the fire extinguisher manufactureras per the information provided on the fireextinguisher.

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.

Fire extinguisher is located below co-passenger's seat.

5. Refill the fire extinguisher immediatelyafter use.

Don't• Do not use water for cleaning fire

extinguisher. (Use clean cloth forremoving dust)

• Do not rely on used or discharged fireextinguisher.

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1) Fire extinguisher cylinder

2) Seal3) Safety Pin

4) Lever

5) Nozzle

PARTS DESCRIPTION REMOVAL PROCEDURE (from front seat)

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

REMOVAL PROCEDURE (from rear seat)

Hold the body of fire extinguisher (1) and liftit up in order to disengage it from clamp (2)as shown. Pull it out towards yourself.

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PROCEDURE OF OPERATION

1. Hold the fire extinguisher (1) upright.

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

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

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

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.

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FITMENT PROCEDURE

Insert the body of fire extinguisher (1) in tothe clamp (3) and place the nozzle (2)carefully downwards, on the clamp

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.

for vehicles fitted with lpg fuel system · for vehicles fitted with lpg fuel system lpg cylinder...

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