Use and maintenance booklet of gas equipment
Contents
1. ITALIAN DISTRIBUTION NETWORK Dealers network amounts today to more than 2000 LPG stations and roughly 600 CNG stations and it is growing a lot EUROPEAN DISTRIBUTION NETWORK Dealers network amounts today to more than 14 000 LPG stations in 26 Countries and roughly 1 700 CNG stations in 25 Countries PARKING In Italy CNG vehicles are not submitted to restrictions concerning the underground parking while LPG vehi cles can only park in the outside floors and in the first underground floor of garages Please check the laws in force in your Country about this matter or ask your GFI installer REFUELLING ADAPTER Before moving to a foreign country we suggest to check if your refuelling point is the suitable one for the country where you are going to Please ask your installer for further information EQUIPMENT DISASSEMBLY Eventual disassembly must be carried out by a GFI authorised workshop Please check if a new test is necessary in your Country after this operation CONSUMPTION LPG consumption shows roughly a 20 increase in comparison with petrol one but the general featu re of this information percentage comes from the average between high and low powered vehicles makes a specific analysis of any single case necessary 7 Maintenance schedule A regular maintenance is essential to keep gas sy stem in safety and low costs conditions Besides the traditional care for a petrol vehicle your LPG or CNG equipment ought2. CNG system mechanical components LJ Inspection and replacement of LPG or CNG SV filter if needed LI Air filter cleaning LI Inspection of spark plugs cables and ignition system LI Inspection of connection clamping LI Inspection of water gas clamps tightening LJ Inspection of carburation with GFI special instrument LI Inspection cleaning possible repl of LPG filter cartridge Other inspections ritira GFI workshop s stamp and signature SCHEDULED MAINTENANCE COUPON after 15 000 km from installation ia Vemde ian LE ecn ili LJ Inspection of LPG or CNG system mechanical componentso LJ Inspection and replacement of LPG or CNG SV filter if needed LI Air filter cleaning LI Inspection of spark plugs cables and ignition system L Inspection of connection clamping LI Inspection of water gas clamps tightening LJ Inspection of carburation with GFI special instrument LJ Inspection cleaning possible repl of LPG filter cartridge if needed LI Inspection and cleaning of Apache IG1 injectors LI Inspection and adjustment of valves gap UHNEFINSPECONS ria GFI workshop s stamp and signature SCHEDULED MAINTENANCE COUPON after 30 000 km from installation E IRA RESORT VEN ana Dale cicca Mi LI Inspection of LPG or CNG system mechanical componentso LJ Inspection and replacement of LPG or CNG SV filter if needed LI Air filter cleaning LJ Inspection of spark plugs cables and ignition system LI Inspection of connect
3. pollution caused by fuels burning Especially it has low content in carbon a big advantage in order to reduce carbon oxides emissions Petrol and diesel vehicles pollute less today but it is diffusely acknowledged that the main polluting elements nitrous oxides and particulate dust micro scopic particles including a mix of chemical elements still are the big problem to face Even if diesel engines have been strongly improved to reduce carbon oxides new vehicles equipped with Common Rail devices still emits a big quantity of nitrous oxides and parti culate dust compared with new vehicles powered by petrol or converted to LPG In most of cases LPG vehicles pollute a 90 less than diesel ones in terms of nitrous oxides and particulate dust CNG is a gaseous mix made up of hydrocarbons mainly composed by methane and in less quantity ethane propane and higher hydrocarbons Inert ga ses such as nitrogen and carbon dioxide can be pre sent too CNG is an excellent fuel for controlled ignition engi nes along with suitable engine control and supply technology it can easily mix with air into the combu stion chamber giving many benefits e excellent distribution of air fuel mixture e oexcellent air fuel ratio control in thermal cold en gine and dynamic during acceleration tip in and for absence of liquid fuel film into intake ducts e stoichiometric air fuel ratio can be maintained du ring the whole engine worki
4. valve necessary for LPG refuelling is generally situa ted in the vehicle rear side To refuel it is necessary to unscrew the plastic protection cap if existing and connect the refuelling gun cng refuelling point equipped with a non return valve necessary for CNG refuelling is generally situa ted in the vehicle front side engine compartment To 3 recharge CNG cylinders it is necessary to remove the quick coupling protection on which the refuelling gun will be inserted As soon as the refuelling flow stops the non return valve automatically come back in its closing position obstructing so the body central hole and allowing the gun disconnection without any con siderable gas leakage DIRECTIONS TO FOLLOW DURING THE REFUELLING You are recommended to follow directions and pre cautions suggested at the filling stations During the refuelling it is necessary to follow some simple safety norms LPG CNG switch the engine off LPG CNG turn all board lights and radio equipment off CNG get out of your car and go to the suitable sta tion areas Authorised personnel generally carry out refuelling operation STARTING UP AND CHANGEOVER Vehicles converted with injection systems in gaseous phase are equipped with a push button changeover switch with acoustic indicator Buzzer on which a gas level indicator is integrated consisting of 4 green LEDs Changeover called One Touch is a one position switch Fue
5. I Inspection and adjustment of valves gap Other inspections ritira GFI workshop s stamp and signature SCHEDULED MAINTENANCE COUPON after 105 000 km from installation ia Vemde ian LE ecn ili LJ Inspection of LPG or CNG system mechanical components LJ Inspection and replacement of LPG or CNG SV filter if needed LI Air filter cleaning LI Inspection of spark plugs cables and ignition system L Inspection of connection clamping LI Inspection of water gas clamps tightening LJ Inspection of carburation with GFI special instrument LJ Replacement of LPG filter cartridge or filter if needed LI Inspection and cleaning of Apache IG1 injectors LI Inspection and adjustment of valves gap UHNEFINSPECiOs rina GFI workshop s stamp and signature SCHEDULED MAINTENANCE COUPON after 120 000 km from installation E IRA RESORT VEN ana Dale cicca Ki sissies L Inspection of LPG or CNG system mechanical components LJ Inspection and replacement of LPG or CNG SV filter if needed LI Air filter cleaning LI Inspection of spark plugs cables and ignition system LI Inspection of connection clamping LI Inspection of water gas clamps tightening LJ Inspection of carburation with GFI special instrument LJ Replacement of LPG filter cartridge or filter if needed LJ Overhauling of Apache IG1 injector I Inspection and adjustment of valves gap DIMEFIMSPECHDNS iii GFI workshop s stamp and signature www gficontro
6. LJ Replacement of LPG filter cartridge or filter if needed LJ Overhauling of Apache IG1 injector LI Inspection and adjustment of valves gap UHNEFINSPECiONS ria GFI workshop s stamp and signature SCHEDULED MAINTENANCE COUPON after 75 000 km from installation E IRA RESORT VEN ana Dale cicca Ki sissies L Inspection of LPG or CNG system mechanical components LJ Inspection and replacement of LPG or CNG SV filter if needed LI Air filter cleaning LI Inspection of spark plugs cables and ignition system LI Inspection of connection clamping LI Inspection of water gas clamps tightening LJ Inspection of carburation with GFI special instrument LJ Replacement of LPG filter cartridge or filter if needed LI Inspection and cleaning of Apache IG1 injectors I Inspection and adjustment of valves gap DIMEFIMSPECHDNS iii GFI workshop s stamp and signature SCHEDULED MAINTENANCE COUPON after 90 000 km from installation i P RARE VENICE Rain ea LL RESPIRO E SER RETTA LJ Inspection of LPG or CNG system mechanical components LJ Inspection and replacement of LPG or CNG SV filter if needed LI Air filter cleaning LI Inspection of spark plugs cables and ignition system LU Inspection of connection clamping LI Inspection of water gas clamps tightening LJ Inspection of carburation with GFI special instrument LJ Replacement of LPG filter cartridge or filter if needed LJ Overhauling of Apache IG1 injector L
7. Propane mixed in a not standard way sometimes vehicle can change over to petrol during acceleration for lower tank gas pressure due to a smaller propane percentage Only using LPG complying with the European re gulation EN589 assures the right working of gas equipment Performances powers speed pick up and consumptions are slightly lower if compared to the petrol mode both in LPG and in CNG mode 3 Guarantee conditions The system good working guarantee relating to its correct installation adjustments and maintenance is issued and charged to the installer s workshop to whom you can address to for any further information The producer issues the good working guarantee of every single product bearing the GFI trademark in accordance with norms and general guarantee condi tions in force at the moment of installation 4 Gas system components Information about equipment dislocation characte ristics and instructions for use is merely indicative Before picking up your vehicle please ask your GFI installer for more information We reserve our right to modify the following chapters without notice LPG TANK CNG CYLINDERS It is the biggest and heaviest additional element and it s installed in the rear side of the vehicle strongly fixed to the car body lpg there are two kinds of tanks cylindrical housed in a part of the luggage compartment or ring sha ped housed in the spare wheel compartment In both ca
8. ion clamping LI Inspection of water gas clamps tightening LJ Inspection of carburation with GFI special instrument LJ Replacement of LPG filter cartridge or filter if needed LJ Overhauling of Apache IG1 injector I Inspection and adjustment of valves gap DIMEFIMSPECHDNS iii GFI workshop s stamp and signature SCHEDULED MAINTENANCE COUPON after 45 000 km from installation i P RARE VENICE Rain enna LL RESPIRO E SER snes LI Inspection of LPG or CNG system mechanical components LJ Inspection and replacement of LPG or CNG SV filter if needed LI Air filter cleaning LI Inspection of spark plugs cables and ignition system LI Inspection of connection clamping LI Inspection of water gas clamps tightening LJ Inspection of carburation with GFI special instrument LJ Replacement of LPG filter cartridge or filter if needed LI Inspection and cleaning of Apache IG1 injectors LI Inspection and adjustment of valves gap Other inspections ritirare GFI workshop s stamp and signature SCHEDULED MAINTENANCE COUPON after 60 000 km from installation ia Vemde ian LE ecn ili LI Inspection of LPG or CNG system mechanical components LJ Inspection and replacement of LPG or CNG SV filter if needed LI Air filter cleaning LI Inspection of spark plugs cables and ignition system L Inspection of connection clamping LI Inspection of water gas clamps tightening LJ Inspection of carburation with GFI special instrument
9. l change gas or petrol is recognised every time the push button is pressed ECU recognises and records the fuel state gas or pe trol when you switch off the vehicle in order to repro pose the same state at the next switching on A Petrol mode The red round LED turned on informs user of this state gas level information disappears that s to say that the four green level LEDs are turned off B Gas Mode In this state vehicle starts in petrol mode Red round LED is on and gas level LEDs are on in a number depending on the tank gas level Vehi cle changes automatically over to gas mode when program changeover settings are reached The round LED by becoming first orange and then green in forms user that changeover has been done C Gas petrol automatic changeover GFI systems are able to recognize when it s not possible to supply the engine correctly because of the end of gas or of the gas supply low pressure In this situation with switch in gas position vehicle automatically changes over from gas to petrol in this case vehicle can work in petrol mode for short periods System can automati cally come back to gas mode if it recognizes the possi bility to supply engine correctly Otherwise if system realises it cannot supply engine with gas anymore it informs user by means of a repetitive buzzing and of the switch red LED turned on Buzzer can be switched off by putting the switch in petrol position Now it s necessary
10. l quan tity corresponding to 1 4 or 1 2 of the tank and periodically refill it WARNING Vehicles with On Board Computer on some vehicles during the gas mode information about autonomy and consumptions given by the on board computer and by the petrol level indi cator must not to be considered You can have the real petrol level only when you start the vehicle up After the changeover to gas you could per ceive a petrol level decrease proportionally to the kilometres made After switching the vehicle off and only after some minutes since the vehicle starting you can try again to detect the real petrol level WARNING A strategy can be activated with some systems in order to allow short periods of petrol working not indicated by the changeover switch Please check with your installer if this strategy has been enabled 6 Useful references LPG TANK OVERHAULING In Italy LPG tank must be replaced 10 years after its fi nal test Please check the laws in force in your Country about this matter CNG CYLINDERS TEST In Italy at the moment of the installation vehicle is equipped with a plastic tag coloured in blue light green showing important data about cylinders in stalled on the vehicle Please check the procedure provided for your Country VEHICLE PERIODICAL OVERHAULING In Italy every car after its fourth year of life must be submitted to overhauling Please check the laws in force in your Country about this matter
11. lsystems eu GFI Alternative Fuel Systems MTM srl Societ Unipersonale Via La Morra 1 12062 Cherasco CN Italy Phone 39 0172 486 81 Fax 39 0172 488 237
12. ms 1 Introduction Dear customer we would like to congratulate you on choosing our GFI gas conversion system This booklet wants to get you used to the new system so please read it carefully before driving your car to avoid any misunderstanding The use of gas offers many important advantages First of all gas refueling cost is considerably lower than the petrol and diesel one Exhaust emissions of a gas vehicle are cleaner than the petrol and diesel ones With every journey you can help thus in reducing the emission of C02 responsible for the greenhouse effect and other harmful substances such as nitrous oxide Have a pleasant journey with your new GFI system 2 What are LPG and CNG LPG LPG is the international acronym for Liquefied Petroleum Gas It is a crude refining product and a Natural Gas coming from the oilfields LPG is a complex hydrocarbon mainly made up by propane and n butane together with isobutane propylene ethane buthene and pentane in diffe rent forms Used in motor traction LPG is a mixture of propane and butane with chemical and physical features giving vehicles excellent performances in terms of power flexibility and engine good working It burns without leaving carbon residuals into the en gine preventing so an early engine wear extending the life of spark plugs valves and pistons and keeping engine oil features unchanged for longer LPG diffu sion could strongly contribute in reducing
13. ng This means that a good combustion can be obtained allowing excellent performances low consumption very low polluting emissions almost total absence of carbon residuals into the engine and engine low noise Thanks to its molecular structure CNG has a high detonation resistance level over 120 octane allowing to use high compression levels over than 12 1 with no need to add chemical additives such as for petrol increasing so energetic efficiency and reducing consumptions Thanks to its oxidation resistance high level CNG is the best fuel for internal combustion engines be cause combustion occurs with a flame coherent with spark plugs allowing high steadiness and low noise level a very important aspect for our cities GAS QUALITY The fuel for auto traction called CNG is a gas mixture that can show some differences according to the ge ographical zone and to other uncontrollable factors depending on distribution network manager or sup plier Methane is the main component of Natural Gas with a quantity between the 84 and the 99 5 The presence of many gases reduces calorific value of CNG for auto traction and consequently vehicle perfor mances and autonomy Also using LPG the autonomy of the vehicle changes a lot because it depends on driving and maintenance conditions but also on gas composition which can change from season to sea son but from filling to filling too LPG is in fact a gas composition Butane and
14. orized GASEOUS PHASE FILTER It has the important task of retaining any gas impuri ty preserving in this way the injectors working In the LPG systems it s situated downstream the reducer vaporizer and in the CNG ones at the reducer inlet RAIL AND INJECTORS We called Rail the element on which gas injectors are housed It allows the uniform distribution of gas fuel to all injectors Injector is an electromechanical injector to all intents and purposes with the task of supplying dosed gas fuel quantity in pressure and inject it in the intake manifold A pressure and tempe rature sensor situated on the Rail or near it provides to the ECU all information necessary for managing flow and for automatic petrol gas and gas petrol changeover ECU It is the brain of the whole system and allows perfor ming different kinds of operations in accordance with the equipment installed from the simple changeover to some sophisticated carburation controls from the diagnosis to the emission control and so on All ECUs are equipped with Safety Car function that closes solenoid valves in case of engine accidental switching off even with key contact being on in order to pre vent any possible gas leakage CHANGEOVER SWITCH Situated in a comfortable position inside the passen ger compartment it allows choosing vehicle powe ring gas or petrol 5 Instructions REFUELING lpg refuelling point equipped with a non return
15. ses it s made of heat treated HT steel and is tested up to 30 bar pressures that s to say over the normal working pressure ranging from 2 to 15 bar Every tank is submitted to the hard tests provided for the Land Transports Department Moreover in order to preserve tank and to increase safety the law orders the 80 filling limitation limitation automatically managed by the multivalve cng the seamless single piece cylinders are tested at a pressure more than twice the working one CNG cylinders amply conform to the stringent internatio nal laws about crash testing and flash point stan dards TANK CYLINDER VALVE lpg situated on the tank multivalve manages many functions such as refuelling filling limitation level indication LPG taking with interception solenoid val ve Safety valve and excess flow It is equipped with a manual tap allowing its closing cng every single CNG cylinder is equipped with a special valve performing different functions First of all it allows the cylinder closing separating its con tents from the rest of the equipment Cylinder valve also carries out a breather function in case of acci dental overpressures As a good rule it s better to turn off the tap situated on the cylinders before starting any operation or in case of accident REFUELLING POINT pg refuelling point equipped with a non return valve is outside the vehicle in a protected and hid den position on the rear b
16. to be submitted to maintenance by the authorised workshop that installed it Preventive maintenance of gas system components has a vital importance for its good right working Products ageing is a gradual process but by doing some simple scheduled maintenance checks you could keep low costs and high safety on your vehicle First car service The first car service should be carried out by the au thorized workshop that installed your LPG or CNG system It must be made after the first 1 000 1 500 km covered in gas mode If you had your car serviced 5 by a workshop different from the installer s one some costs of labour may be charged Scheduled maintenance BRC chargeable scheduled maintenance is based on car service coupons to be carried out 10 000 20 000 km after the installation and then every 20 000 km in order to always assure the vehicle and gas system right working For doing car service you need to go to your installer and ask for the stamp application on the suitable coupon These operations will assure the equipment right working and the Guarantee validity NOTE Costs of labour for GFI components replace ment will be charged to the customer even if covered by builder s guarantee if replacement operations will be carried out by a workshop different from the in staller s one SCHEDULED MAINTENANCE COUPON after 1 000 km from installation i P RARE VENICE Rain ea LL RESPIRO E SER RETTA LJ Inspection of LPG or
17. to refuel to obtain again the vehicle normal gas working Gas petrol changeover strategy can be also adopted in some special conditions and for a few seconds in order to optimise vehicle working D Error indication In case of possible gas system wor king anomalies systems informs user by turning on the two blinking green level LEDs in the middle and by the round orange LED blinking too In this situa tion changeover switch doesn t work anymore and ECU records the fuel mode you had before the error indication If vehicle was in gas mode the mode re mains the same idem for petrol mode If ECU recorded the gas mode but meanwhile the fuel ends passage to the petrol mode will be automatic and without any acoustic indication LEVEL INDICATOR FOR INJECTION AND CARBURETTOR VEHICLES Changeover switch also works as level indicator thanks to its LEDs Normally changeover switch has 4 green LEDs showing gas quantity inside the tank 4 LEDs 4 4 3 LEDs 3 4 2 LEDs 2 4 1 LEDs 1 4 Fuel reserve indication is given by the first green LED blinking NOTE LEDs indication is purely indicative It can change from a refueling to another as such as change suddenly because of vehicle movements We suggest to always use the partial odometer in order to control vehicle autonomy In some changeover switches a suitable red LED indicates the fuel reserve WARNING Avoid that petrol tank is completely empy It s necessary to always keep a petro
18. umper or near the petrol filler inside the fuel little door In the former case to refuelling the car you have to simply unscrew the cap and connect the gun while in the latter one it may be necessary to screw the suitable gun adapter cng it is a normal non return valve having refuel ling function and it s normally situated in the engine compartment You can recognize it thanks to a red protection cap or to a black screw cap As a good rule it s better to check the refuelling point cap closing to avoid possible impurities might compromise its right working SOLENOID VALVE Housed in the engine compartment it s the device that allows the automatic opening and closing of the gas flow from the tank to the engine It can be provi ded with a filter for impurities that ought to be perio dically replaced It carries out several safety functions such as gas flow closing in case of engine accidental switching off even with key contact switched on REDUCER It is an important device situated in the engine com partment Traditional system reducers need periodic overhauling and adjustment not always necessary on reducers of the gaseous injection systems lpg LPG reducers vaporizers allow reducing pressure to the working values and provide the heat exchange necessary for the complete LPG evaporation cng CNG reducers allow reducing pressure to the optimal working values CNG is in gaseous state so it doesn t need to be vap
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