Operation, Safety and Maintenance
Contents
1. Supplement Owner s Manual Operation Safety and Maintenance VEHICLE RECORD SHEET CT O ECT II ATA rr E O e e g come O a e oo remsen eee e o o AA CAT SSCS Address SAA men TTT stg sor Samp Table of contents Eayoutiof LPG System Side Vi Wisconsin ala A ase 2 Layout of LPG System Top Viehe a a a aa a aaa aaa a A a aar a aaa aaa a AA A EEEE AES 3 O E A E E E E E nee res 4 Introduction of LPG Safety PreCautions cccccceecceceeeceeeeeeeeeeceeeeeceaeeeeaaeeeeeeceaeeecaaeegeneeseaeeecaaeeeeaaeseeeeeseaeeecaesseaeeseeeeesceeseaeeseneeee 5 e AE ti A A T E E A E E E A E 6 Brief Description of LPG System r a a a sued esd ht vce suse Soca les eaa By eee eased eea raaa aaa Sand a aa Aaa a teas anaE 7 UCI SEISCTOM SWITCH tetitas tata order A 8 Indications Of LED and Beer 9 EPG Electrical Fusen ici a bane aa alla aereos bite ca dad noi o hdd baaa tancia 10 LPG Filler Valve LPG Cylinder LPG Multivalve ooooooonncnnnnnccnncccnnoconnnccnnonccnonrnn narran cnc carr nnrrn 11 Spare Wheel AssomblV tilda tii 12 Compliance to Motor Vehicle rules oooonnnncinnncninncnnnnncnnn conc rc RR nr nn EEaren nanna 13 Periodic Inspection 8 maintenance schedule ocoooonoccccnonocicinnnoccccnononccc nono ccnn narrar cnc 14 Warranty Card viii a A AAA A a 15 Rohan Automotive Service Network ccccocccinnnncnnnccnnccconccnnccnn nc 18 NOTOS iii A A e 21 Layout of LPG System Side View 1 LPG Proof Case2. LAST RETEST DATE CHASSIS No THE LPG INSTALLATION COMPLIES WITH SAFETY REQUREMENTS O OF AIS 026 O INSTALLED BY 13 Periodic Inspection maintenance schedule Kilometer miles or time in months whichever comes first 2 o o o o o o o o o o INSEPECTION s is s sis ie sisis s esis je s sis ieljelis s POINT Slam S NY NR SS 1218181818 2 8 12 8 2 18 1 2 T N a oO o t Y 10 p e N oO 2 8 2 2 e El e al Pa j Ra gt k Pa o sa gt gt a gt gt gt e gt i gt 5 gt E Z gt 5 EAEE E E EE e o j3 9 2 e MOUNTING OF LPG TANK amp KIT l l l l l l l l l l l l l l l l l l l l LEAK CHECKING AT ALL POINTS l l l l l l l l l l l l l l l l l l l l GASEOUS FILTER R R R GAS SOLENOID FILTER R R R R R R REDUCER DIAPHRAM OVERHAULING KIT R R R WIRING HARNESS CLAMPING l l l l l l l l l l l l l l l l l l l l LPG TANK REPLACE TANK AFTER EVERY 15 YEARS Note Statutory Test for Cylinder to be done as per IS 8869 1988 Testing of LPG Cylinder is due after 5 Years from the date of Manufacturing which is available in the Marking Plate on the Tank Inspect these items and their related parts If necessary correct clean replenish adjust rotate or replace R Replace or change 14 Warranty Card Rohan Automotive Equipments Pvt Ltd RAEPL a private limited company incorpora
3. 1 4 2 4 3 4 4 4 5 Use the LPG system as per instructions provided in the manual Ensure inspection of LPG system from time to time Keep the Warranty Card Service Booklet of LPG system in safe place and present it to the GMI RAEPL dealer during your regular maintenance visit and when repair work is needed Please get the vehicle information Card filled up and stamped by the selling GM India Dealer Present the Warranty and Service Booklet to have your vehicle inspected repaired under warranty 5 Disclaimer of consequential damage GMI RAEPL assumes no responsibility for loss of vehicle loss of time inconvenience or any other indirect incidental or consequential damage resulting from the vehicle not been available to the owner because of any defect covered by this warranty 6 Change of Ownership Change of ownership must be duly intimated to GMI dealer if the vehicle is sold within warranty period 17 Rohan Automotive Service Network SE Zone State City Town Branch Address Nameot Dealer s Gontact Contact No no Dealer Address Person Rohan Automotive Equipments 1 East WESTBENGAL Kolkata Pvt Ltd EN61 Sector E 2o PRN 5 Salte Lake Kolkata 91 Rohan Automotive Equipments Pvt Ltd Mr Raju Mob 2 North DELHI Delhi 127 DDA Sheds Okhla Singh q E 9868850081 Industrial Area Phase New Delhi Agar Nagar Road 7 Firozepur M s Prince Mr M
4. 2 LPG Filler Valve 3 HIGH Pressure Pipe PVC coated 8 mm 4 LPG Tank 5 Tank Cover 6 Multivalve High Pressure Pipe PVC coated 6 mm Gas Solenoid Reducer Low Pressure Hose Gaseous Phase Filter Change Over Switch 13 14 15 16 17 18 Coolant Hose ECU Injector amp Injector Rail Line Clamp Screw Ducting Hose Earthing Layout of LPG System Top View DIGNO E 42 19 EX Pl ra A pian E 1 LPG Proof Case 7 High Pressure Pipe PVC coated 13 Coolant Hose 2 LPG Filler Valve 6 mm 14 ECU 3 HIGH Pressure Pipe PVC 8 Gas Solenoid 15 Injector Injector Rail coated 8 mm 9 Reducer 16 Line Clamp Screw 4 LPG Tank 10 Low Pressure Hose 17 Ducting Hose 5 Tank Cover 11 Gaseous Phase Filter 6 Multivalve 12 Change Over Switch 3 Specification SPARK LPG Kit Identification Kerb Weight 885 Kg Reducer No Gross Weight 1270 Kg Cylinder No Seating Capacity 5 Person Retest Date Multivalve No LPG Capacity liters ECU ID Number PA FESTIS Vehicle Details Filling Capacity 80 26 20 Liters Engine No Chassis No Note Specifications are subject to change without notice Date of Sale Note To be filled in by the selling dealer Introduction of LPG Safety Precautions Introduction to LPG Auto
5. LPG is a clean high octane and Eco friendly fuel It is basically a mixture of Butane and Propane and is obtained from Natural Gas by fractionation and Crude Oil Refining LPG is in gaseous state at atmospheric pressure but can be liquidated when moderate pressure is applied or when the temperature is sufficiently reduced LPG produces less harmful exhaust gases as compared to petrol amp diesel A CAUTION Always keep approx 10 15 liters petrol in your petrol tank as your vehicle will always start in PETROL mode This will prevent gumming problem in your vehicle fuel system fuel line fuel pump fuel injector etc It will also prevent rust from forming inside the petrol tank Safety Precautions Do s If any minor work or body repairs are to be carried out turn the Multivalve knob to close position prior to commencement of the repair work Get the LPG cylinder checked periodically as per the maintenance chart If the engine does not start in LPG mode switch over to petrol mode and take your vehicle to a Chevrolet authorized service outlet for inspection It is always recommended to start the vehicle in Petrol mode Ensure that conduit pipes are always in good condition and secured firmly Replace in case damage is noticed Don ts e Never fiddle with any of the components in the LPG system e The cylinder should not be repaired under any circumstances In case of any problem consult with a Chevrolet au
6. s glow indicating the level of LPG in the tank If this condition is not present then press the switch As your vehicle always starts in petrol mode the LED on top glows red The vehicle automatically changes over to LPG from petrol after reaching the following conditions 1 In cold start it waits for coolant temperature reach 55 C 2 If coolant temperature is between 55 C to 75 C then it waits for 60secs 3 If coolant temp is more then 75 C it waits for 10sec Upon changing to LPG the LED on top changes to GREEN indicating that your vehicle is now running on LPG Also the solenoid fitted on the LPG tank gets energized making a TAK sound This is a normal and acceptable behavior Indications of LED and Beeper The LED s on the fuel selection switch indicates the level of gas in the cylinder There are six different types of indications of LED Red Petrol Mode Green LPG Mode Push Button to change Fuel Mode Sl Quantity of LPG LED indication on Fuel No in tank selection switch 1 100 85 4 LED s Blinking 2 85 65 4 LED Glowing 3 65 45 3 LED Glowing 4 45 25 2 LED Glowing 5 25 5 1 LED Glowing 6 5 0 1 LED Blinking Beeper indication Your vehicle is also installed with a beeper which is fitted behind the Fuel selection switch This beeper has two different sound patterns which indicate as follows 1 Automatic return to petrol
7. an empty tank it is advisable to fill 26 20 liters of LPG in the tank of your vehicle The tank fitted in your vehicle is of 32 8 liters LPG Cylinder The LPG cylinder is installed in the luggage compartment Regularly inspect for loosening of mounting bolts of Cylinder Mounting A CAUTION Always shut off the engine while refueling the Auto LPG in your vehicle 11 LPG Multivalve The Automatic Shut Off valve is located on the Multivalve of the Auto LPG Cylinder Tank Cover should be placed always on the LPG tank to avoid gas entry into the compartment The knobs of the Tank cover should be hand tightened completely Spare Wheel Assembl For your Spark LPG vehicle the Spare wheel is assembled to the back of your rear seat in the luggage compartment In the tool kit you will find a socket extension tool along with your other regular tools This extension tool needs to be attached to your wheel wrench when assembling or disassembling the spare wheel from your luggage compartment The adjacent figure illustrates the spare wheel assembly operation 12 Compliance to Motor Vehicle rules Your car s LPG tank needs to be recertified every five years as per CMVR AIS 24 25 and 26 Please ensure that it is done by a Chevrolet Authorized Service Outlet and the new date is engraved on the plate LPG COMPLIANCE PLATE LPG CYLINDER No INSTALL DATE ANCE PLATE WATER CAPACITY L
8. defective within the warranty period Free service will be provided to the kit during warranty period only within the limits where GMI RAEPL has its service network Please visit your nearest Chevrolet authorized service outlet for all types of services for your car This warranty shall be null and void if the car is subject to abnormal use such as rallying racing or participation in other competitive sports This warranty shall not apply to any repair or replacements as a result of accident or collision 15 3 6 3 7 3 8 3 9 3 10 3 11 3 12 3 13 3 14 3 15 This warranty is expressly in lieu of all warranties whether by law or otherwise express or implied and other obligations or liabilities on our part and we neither assume nor authorize any person to assume on our behalf any other liability arising from sale of the kit or any agreement in relation thereto Any claim arising from this warranty shall be recognized only if it is notified in writing to us without any delay soon after such defects as covered and ascertained under this warranty The decision taken by GM India RAEPL will be final and binding on all matters arising out of the new kit Warranty The owner should preserve with them the original Invoice for the necessary verification and produce the same as and when required This warranty is issued at Changodar Tal Sanand Dist Anmedabad Gujarat and competent court shall have exclusive Juri
9. ik Mob 19 Pvt Ltd Oza 151 Brick Factory Compound Opp Dreamland Bungalows Shastrinagar Mulund W Mumbai 400 052 9870041699 13 Rohan Automotive Equipments Pvt Ltd 7 Parvati Industrial Estate Mr Parag Opp Adinath Society Pune Shah Satara Road Pune 411 009 West MAHARASHTRA Pune Mob 9822064101 14 Parvatinagar 3 A Shyamal Row Houses Mr Hemal Satellite Road Shah Ahmedabad 380 015 West GUJARAT Ahmedabad Mob 9879788280 Rohan Automotive Head office 5 Ashwamegh Industrial Estate Changodar Taluka Sanand Dist Ahmedabad 382213 Ph 02717 251900 www rohanauto com 20 za CHEVROLET General Motors India Pvt Ltd All information illustrations and specifications contained in this Owner s Manual are based on the latest production information available at the time of publication The right is reserved to make changes at any time without notice Regd Office Chandrapura Industrial Estate Halol 389 351 Dist Panchmahals Gujarat India Phone 91 2676 221000 Customer Assistance Center Plot No 15 Echelon Institutional Area Sector 32 Gurgaon 122 001 Haryana India Tel 91 124 3080000 Part No 95225501 Works A 16 MIDC Talegaon Industrial Area Phase ll Revision No 00 Near Floriculture Park Talegaon Navlakh Umbhre Village Road Tehsi Maval Revision Date Pune 410 507 Maharash
10. ob Sa JENON PUNJAB Luchiana Motors ese Opp Taranjitsingh 9815020203 Restaurant Ludhiana 122 735 M s Shastri Nagar Mr Sumit Mob 4 North U P Kanpur The Next Chain Factory Khanna 9918801053 Generation Compound Kanpur Rohan Automotive Equipments Pvt Ltd Mr Parivesh Mob a a Phiwara Opp Ashoka Hotel Sabun Dad 9829047894 Marg Bhilwara 311 011 18 Rohan Automotive Equipments Pvt Ltd Mr Rakesh No 11 R 0 B Main Mob 6 Jr South TAMIENADY Chennai Road Nr TVS Petrol Bunk snah 9884028186 Whites Road Royapetta Chennai 600 014 Rohan Automotive Equipments Pvt Ltd Mr Mahesh Mob Be eee e Secunderabad 4 7 4121 19 182 Putli bowl Kotak 9885019832 Hyderabad 95 Rohan Automotive Equipments Pvt Ltd Mob 8 South KERALA Thrissur 50 116 Kanjany Road Mr Jose 9846032927 Chungum P O Ayyanthole 9847033260 Thrissur 03 Rohan Automotive Equipments Pvt Ltd Mr Ajayz Mob q E aS I Bangalore 131 3 Lalbagh Main Road Pasha 9886098140 Banglore 560 027 406 143 Nova WS an rene Mr Dilip Mob 10 west GOA Pardoz eL Auto dorio resort Manwani 9326101419 Service Provorim Bardez Goa Rohan Automotive Equipments Pvt Ltd Mr Ajay Mob 11 West M P Indore 4 A Victory Chambers Ratlam Mehta 9826030899 Kothi Nr Gita Bhavan Square A B 12 West MAHARASHTRA Mumbai Rohan Automotive Equipments Mr Kaush
11. pletely exhausted the vehicle will switch over to petrol mode automatically without stopping Fuel mode can be changed without stopping the vehicle Fuel Selection switch Changeover switch ROUND LED PUSH BUTTON FOR FUEL i SELECTION i 4 Selection of Fuel is done through the change over switch You can select either LPG as fuel or petrol A CAUTION Forced Starting in LPG mode can be used for only 5 times After that user take his vehicle to a Chevrolet authorized service outlet to extend this mode for another 5 times A CAUTION Please ensure that the gear shift is in Neutral position before starting the engine in either mode Forced Petrol Mode When the push button is pressed on the switch vehicle runs on petrol and the round LED on top glows RED and all four levels LED turn off Forced start in LPG MODE Not recommended If there is no petrol available in your petrol tank while starting you may start your vehicle in LPG mode To start your vehicle in LPG mode please follow these directions e Turn on your Ignition Key e Your fuel mode indicator on your fuel selection switch glows red indicating petrol mode e Press and hold fuel selection switch for 5 seconds until fuel mode LED changes to green e Now crank your engine by turning your ignition key and your vehicle will start in LPG mode LPG Mode When the switch is in LPG mode the top LED is RED and the level gauge LED
12. right and pull the pin 3 Press the lever 4 Direct discharge at base of flame with rapid sweeping motion 5 Recharge the fire extinguisher after use Brief Description of LPG System The brief description of sequential injection system is as under Sequential Injection System can assure higher performances without compromising the simplicity of the installation From the functional amp performance point of view Sequent Injection System has the following advantages e Reduced power loss e No gas air mixer e Very small reducer e No backfire risk e Reduced pollution levels Sequential Injection is obtained by using an electronic injector in each cylinder A high precision of gas dosage is obtained using this system Auto Diagnosis on ECU inlet outlet is protected against short circuit Spark LPG Vehicle comes fitted with bi fuel option and can be driven on auto LPG or Petrol An auto LPG storage tank has been installed in the trunk compartment and can store up to a maximum of 26 20 Liters of auto LPG An auto LPG manual shut off valve is available on the multivalve in the LPG cylinder in case gas supply to the engine needs to be cut off A selection switch is provided on the HLD Switch This switch helps in selecting the fuel mode for the vehicle Fuel selection switch also indicates the amount of LPG in the storage tank A separate indicator is also provided on the tank itself In case the gas is com
13. sdiction of courts of Anmedabad alone to the exclusion of all other courts Warranty shall be null or void if any vehicle on which parts or accessories not approved by RAEPL has been used any vehicle which has been adjusted repaired by other than a GMI RAEPL Dealer or Service Engineer Installation or usage of domestic LPG or LPG Cylinder Failure to have regular periodic inspection and service of the kit Improper or wrong maintenance and in deviation with the guidelines given in service booklets any modification alteration made in the Vehicle thereby affecting the functioning of the kit fitted on the vehicle Failure to use genuine parts fluids oil coolant Auto LPG and or other accessories consumables recommended or approved by GMI RAEPL Damage caused by driving the vehicle under severe conditions such as un pliable or water logged roads in race or rallies Damaged caused by natural disasters like earthquake floods fire etc Damage due to water or other foreign matters in the fuel system and or illegal use of domestic LPG damage to the kit while driving the vehicle in water logged conditions or entry of water into the kit fitment area No warranty repair shall be made if it is found that the vehicle identification number like chassis engine Odometer LPG Reducer LPG fuel tank Multifunction valve LPG ID plate or the warranty and service booklet have been tampered with 16 4 Warranty responsibilities of the owner 4
14. ted under the companies Act 1956 and having its office at 5 Ashwamegh Industrial Estate Changodar Tal Sanand Dist Anmedabad 382 213 warrants that the new LPG kit fitted on your vehicle is free from any material and or workmanship defects subject to your compliance with the terms and conditions mentioned hereunder and other kit maintenance norms as suggested in the service manual Under the warranty period only a Chevrolet authorized service outlet as mentioned in the Owner s Manual will carry out necessary repairs using new re conditioned or re manufactured parts with a view to correcting any defect covered by this warranty 1 Warranty Terms The LPG Kit fitted on your vehicle has a warranty of 3 years or 1 00 000 Kms whichever is earlier 2 Warranty Obligation Our obligation under this warranty shall be limited to repairing or replacing free of charge such parts of the LPG system which are found defective in our inspection on the car being brought to Chevrolet authorized service outlet within the warranty period The parts so repaired or replaced shall also be warranted for quality and workmanship till the vehicle warranty 3 Warranty Limitation 3 1 3 2 3 3 3 4 3 5 Any part which is found to be defective and be replaced under the warranty shall become the property of GM India Liability of GM India RAEPL under the warranty is limited to the value of the service repair replacement of parts found to be
15. thorized service outlet e Do not adjust setting of LPG system e Do not install domestic LPG or any other gas cylinder in place of OE fitted cylinder e Do not carry inflammable material near the LPG cylinder e Do not try to fill more than 26 20 liters of auto LPG e Do not use domestic LPG or any other gas in your vehicle A CAUTION After washing cleaning please ensure that the LPG tank compartment is completely dry before starting your vehicle Safet In Case of Gas Leakage Maintenance e Do not panic Check pressure on the gauge every week The needle should e The ECU automatically switches off the LPG supply from remain in green zone If it comes to red zone please send the the tank unit for recharging The Fire Extinguisher is to be refilled e As a Safety precaution close the manual shut off valve every three years even if it is not used provided on the Multifunction valve located on the LPG tank Ensure that the tank cover is properly fitted e Roll down all the windows and keep the doors fully open e The ECU will automatically switch the fuel mode to Petrol e The ECU will not allow you to switch to LPG mode until the leakage is rectified e Contact the nearest Chevrolet Authorized service station and get car repaired Fire Extinguisher One fire extinguisher is located below the front passenger seat Method of operation 1 Check that the pressure gauge needle is in green zone 2 Hold up
16. tra India Tel 91 2114 663939 11 2010 2 000 24 Hr Helpline at 30308080 Notes
17. when your LPG is over When the auto LPG in your LPG tank is over the fuel mode is automatically changed over to petrol A buzzer will begin to beep every 1 second to indicate this automatic changeover to petrol mode The driver needs to acknowledge this by pressing your fuel selection switch and the buzzer will stop beeping 2 Diagnostic errors Whenever there is a diagnostic error your buzzer will make 3 beeps every 20 seconds At this point please press the fuel selection switch to change over to petrol mode Please get your vehicle inspected repaired at nearest Chevrolet authorized service outlet LPG Electrical Fuse The LPG system is protected against short circuit overload using 15A fuse fitted as shown in the figure The changing of fuse should be done only at Chevrolet Authorized Outlet A CAUTION Always be sure to replace blown fuse with fuse of correct amperage Never use a substitute such as aluminum foil or wire to replace a blown fuse Have your vehicle inspected immediately by Chevrolet Authorized Service Outlet 10 LPG Filler Valve LPG Cylinder LPG Multivalve LPG Filler valve Auto LPG Refueling valve is located at rear right side below tail lamp Plastic cap on the Filler Valve should be closed completely after refueling Filling is stopped automatically once the tank is filled up to 80 of the capacity As a safety precaution partial filling should be avoided as far as possible When filling
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