Fiat DUCATO NATURAL POWER Owner's Manual Supplement

Brand: Fiat

Model: DUCATO NATURAL POWER

Type: Owner's Manual Supplement

NATURAL POWER

FIATDUCATO

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 1

FIAT DUCATO NATURAL POWER

The Fiat Ducato Natural Power Petrol-

Methane version is dealt with in this ap-

pendix.

For anything not included in this sup-

plement, please refer to the Fiat

Ducato Owner’s Manual.

CONTENTS

INTRODUCTION ............................................................................................................ 3

FUNCTIONAL SYSTEM DIAGRAM ............................................................................ 5

CANISTERS ....................................................................................................................... 6

SOLENOID VALVES/SAFETY DEVICES ...................................................................... 7

PIPING ................................................................................................................................. 8

PRESSURE REGULATOR/REDUCTION UNIT ....................................................... 8

METHANE INJECTORS ................................................................................................. 8

OIL SEPARATOR FILTER................................................................................................. 8

STARTING THE ENGINE ............................................................................................. 9

PROTECTIVE FUSES ......................................................................................................... 9

FUEL SWITCHING LOGICS ........................................................................................ 10

LIMITATIONS OF USE ..................................................................................................... 11

SYSTEM FAILURE SIGNALLING .................................................................................. 11

AT THE PETROL STATION ......................................................................................... 12

IDENTIFICATION DATA .............................................................................................. 13

MAINTENANCE SCHEDULE ...................................................................................... 14

VEHICLE RAISING POINTS ........................................................................................... 16

ENGINE ............................................................................................................................... 17

ENGINE CODES - BODYWORK VERSIONS............................................................ 18

PERFORMANCE ............................................................................................................... 19

WEIGHTS ........................................................................................................................... 20

CAPACITIES ....................................................................................................................... 21

ENGINE OIL........................................................................................................................ 21

EMISSIONS ............................................................................................................... 21

FUEL CONSUMPTION ................................................................................................... 22

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 2

FIAT DUCATO NATURAL POWER

INTRODUCTION

The Fiat Ducato Natural Power version

features two fuel systems, a primary one

for natural gas (methane) and an emer-

gency petrol alternative.

The methane multipoint

injection system

This is an original product from Fiat’s re-

search in the field of alternative fuels that

comes from close co-operation with im-

portant suppliers in the methane sector.

By adapting the sophisticated electronic

control technology of petrol engines to

meet the specifications of methane, it has

been possible to achieve important results

in terms of driveability, exhaust emissions

and consumption.

Using the methane multipoint injection

system the engine offers the same driving

conditions as running on petrol.

Fiat Ducato Natural Power has been de-

signed to run on methane. Petrol func-

tioning is restricted to situations where

the user has not managed to fill up on

methane prior to having entirely run out.

Engine performance has been opti-

mised to run on methane. When

running on petrol, performance is

limited to guaranteeing the reaching

of the nearest petrol station.

Selecting the type of fuel supply

The Fiat Ducato Natural Power version is

configured to normally run on methane.

When the methane is running out and the

pressure in the canister is close to the cor-

rect operating limit, the system automat-

ically switches to petrol operation.

Fiat Ducato Natural Power is not

equipped with a manual METHANE/

PETROL switch selector, and as such the

change between the two fuel types is on-

ly made by the engine control ECU, in a

fully automatic manner.

For this reason there always needs

to be petrol in the tank.

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 3

FIAT DUCATO NATURAL POWER

Passive safety

The Fiat Ducato Natural Power version

has the same passive safety features as the

other versions.

In particular, the location and mountings

of the canisters have been designed to

pass the impact tests in accordance with

Fiat safety standards. The flow of methane

coming out of the canisters is governed by

a solenoid valve that is only open during

methane operation.

The solenoid valve unit includes protec-

tion against excess flows (if the high pres-

sure system breaks, the flow of methane

is restricted to values that are not dan-

gerous), overheating (fuse pad that allows

the methane to drain off if the tempera-

ture exceeds 110 °C) and a pressure cal-

ibration device that intervenes if the pres-

sure goes above 300 bar ensuring the

methane escapes in a controlled manner

and as quickly as possible.

The solenoid valve is connected to the

Fire Protection System (inertia switch or

fuel cut off switch).

Active safety

The Fiat Ducato Natural Power version

has the same active safety features as the

other versions.

The Fiat Ducato Natural

Power version is equipped

with a high pressure methane system

designed to run at 200 bar.

It is dangerous to force the system

with higher pressures. When towing

or lifting the vehicle, the instructions

in this booklet at the end of the chap-

ter should be followed in order to pre-

vent damage to the methane system

parts: ‘Towing the vehicle’.

If there is a problem with the

methane system, only go to an au-

thorised Fiat Dealer.

Do not alter the methane system con-

figuration or components; they are

designed exclusively for the Fiat

Ducato Natural Power. The use of

other components or materials may

lead to malfunctioning and compro-

mise safety.

When oven painting, the

canisters should be removed

from the vehicle and later carefully

refitted by a Fiat Dealer. Although the

methane system has numerous safe-

ty features, it is advisable to close the

manual taps for the canisters every

time the vehicle is not in use for a

long period, transported on other ve-

hicles or moved in an emergency as a

result of a breakdown or accident.

WARNING

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 4

FIAT DUCATO NATURAL POWER

FUNCTIONAL SYSTEM DIAGRAM

Description of the system functional diagram Fig. 1

1 Methane canisters - 2 Methane repressurising filler - 3 Methane piping - 4 Pressure regulator/reduction unit - 5 Methane injector

carrier manifold - 6 Petrol tank - 7 Oil separator filter.

F0N0396m

Fig. 1

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 5

FIAT DUCATO NATURAL POWER

The plates handed over by the Dealership

with the documentation contain the date

for the first inspection of the canisters.

Those responsible for the methane

supply are not authorized to re-

fill the canisters when the in-

spection date has expired.

IMPORTANT If the vehicle has

been registered in a country oth-

er than Italy, the certification da-

ta, identification and inspection

procedures for the methane can-

isters should conform to the leg-

islation in that country. In any

case, it should be remembered

that the life of the canisters is 20

years from the production date

as set out in Regulation (ECE) no.

110.

CANISTERS

The vehicle has five canisters (total ca-

pacity about 218 litres) located under the

floor of the vehicle and protected by two

special guards. The canisters are the tank

that contains the methane in the com-

pressed gaseous state (pressure 200 bar

at 15 °C). The methane, stored in the can-

isters at high pressure, flows through a

dedicated pipe to reach the pressure reg-

ulator/reduction unit which supplies the 4

methane injectors at low pressure (about

6 bar).

Certification of the canisters

The methane canisters are certified in ac-

cordance with Regulation (ECE) no. 110

The canisters should be inspect-

ed, in accordance with Regulation

Procedure (ECE) no. 110, every

4 years from the vehicle regis-

tration date or in accordance

with specific regulations in indi-

vidual countries (see page 13).

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 6

FIAT DUCATO NATURAL POWER

2) Mechanical excess pressure device

(Burst Disk), in the event of excess pres-

sure (above 330 bar), it ensures that the

methane escapes as quickly as possible in

a controlled manner.

3) Excess flow, it intervenes if the piping

is broken limiting the flow of methane to

values that are not dangerous.

The flow restrictor valve is located to al-

low it to operate even if the solenoid valve

casing is broken due to an impact.

SOLENOID

VALVES/SAFETY

DEVICES

The solenoid valves Fig. 2 are bolted di-

rectly onto the methane canisters with the

main function on interrupting the flow of

methane to the supply circuit.

The solenoid valves are open when:

❒ t

he pressure in the canister is sufficient

for operation;

❒

the engine is running;

❒

the inertia switch has not been trig-

gered.

The solenoid valve assembly is equipped

with the following safety devices:

1) Fuse pad, in the case of overheating

(temperature above 110 °C), it totally

eliminates the danger of excess pressure

making the methane in the canister flow

out as quickly as possible in a controlled

manner.

4) Manual tap, it is located upstream of

the solenoid valve.

This separates the canister from the

methane system to allow maintenance op-

erations.

The taps can be accessed from outside the

vehicle, and are positioned on the left-

hand side.

To close the taps A - Fig. 3: turn the knob

in the direction (1) shown by the arrow

(clockwise OFF)

To open the taps A - Fig. 3: turn the knob

in the direction (2) shown by the arrow

(anti-clockwise ON)

fig. 2

F0N04000m

fig. 3

F0N0393m

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 7

FIAT DUCATO NATURAL POWER

PIPING

The methane piping from the filler to the

pressure regulator/reduction unit is made

from galvanised steel and covered in plas-

tic (high pressure) and is located outside

the passenger compartment. The piping

from the pressure regulator/reduction

unit to the methane injectors is in stain-

less steel.

PRESSURE

REGULATOR/

REDUCTION UNIT

The pressure reduction unit Fig. 4 is in-

stalled in the engine compartment.

It has the task of reducing the pressure

of the methane from the value in the can-

ister to the supply value for the methane

injectors (about 6 bar) and keeping it con-

stant in all operating conditions.

METHANE INJECTORS

There are 4 dedicated injectors for the

methane gas A - Fig. 5, fitted on the in-

take manifold near the cylinder head, one

for each intake duct; they are supplied at

a constant pressure (about 6 bar) and op-

erated by the electronic control unit.

OIL SEPARATOR FILTER

The oil separator filter Fig. 6 is installed

in the vehicle underbody.

It has the task of separating the excess oil

in the methane.

fig. 5

F0N0401m

fig. 4

F0N0398m

fig. 6

F0N0397m

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 8

FIAT DUCATO NATURAL POWER

❒

METHANE canister empty - petrol

tank not empty

–

start-up is forced to petrol, with no

switch to methane until such time

as the methane canister is filled. At

the same time, the reserve warning

light turns on and the instrument

panel display shows the message

‘REFUELLING REQUIRED‘;

❒

METHANE canister not in reserve -

petrol tank empty

– start-up always takes place in

methane mode.

Fusebox in engine compartment

USERS FUSE AMPERES

Methane fuse solenoid valves F27 10

Methane relay solenoid valves T21 20

STARTING THE

ENGINE

The following describes the various dif-

ferent ways in which the engine is started,

depending on vehicle conditions:

❒

METHANE canister not in reserve -

petrol tank not empty

– start-up always takes place in

Methane mode.

PROTECTIVE FUSES

The table below contains a list of the pro-

tective fuses with reference to the

petrol/methane version. For all the other

fuses, consult the Owner’s Handbook that

this supplement comes with.

If the methane has run out, the control

unit automatically manages the switch to

running on petrol.

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 9

FIAT DUCATO NATURAL POWER

FUEL SWITCHING

LOGICS

Management of switching between the

two different fuel supplies is fully auto-

matic, and carried out by the engine con-

trol unit.

When the residual amount of methane

goes below 1/5 of the capacity of the can-

isters, the CNG logo and the lowest lev-

el Fig. 7 flash to indicate the reserve and

notify the need to refuel.

If the methane has run out, switching to

petrol takes place automatically: the K in-

dicator near the CNG symbol Figs. 8-9

lights up in the instrument panel display.

Having reached the reserve

methane pressure threshold, and

completely filled the methane tank,

the system forces the switch to

petrol for 5 seconds, with the aim of

keeping the petrol fuel supply system

fully efficient.

fig. 7

F0N0402m

The general recommendation is to

avoid emptying the petrol tank com-

pletely, as this may lead to a risk for

the driver:

❒

after having gone below the

METHANE reserve level, the vehicle

continues running on petrol until this

runs out;

❒

in a previous mission, the vehicle ran

out of petrol, and during METHANE

functioning reached the reserve

METHANE pressure threshold: in this

case, the system forces the switch to

petro, and the vehicle turns off whilst

moving.

fig. 9

F0N0404g

fig. 8

F0N0403g

N.B. Ensure that the key is set to the OFF

position when refilling with methane. If the

system had already forced the switch to

petrol, and you fill with methane with the

key in the ON position, following refu-

elling, the vehicle will continue running on

petrol, until next start-up.

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 10

FIAT DUCATO NATURAL POWER

LIMITATIONS OF USE

The passage from running on methane to

petrol involves the immediate insertion of

the maximum speed limit to 90 Km/h. As

such, after the first methane reserve warn-

ing, refuel as quickly as possible, and in any

case prior to the second warning that the

gaseous fuel (two beeps), in order to avoid

‘risk’ conditions, such as, for example,

overtaking at high speeds on the motor-

way.

Petrol function is for emergency purpos-

es only. In order to guarantee good inde-

pendence, even where there is limited

tank capacity, performance is limited such

as speed or, as for take-off, acceleration

(particularly uphill).

As such, before embarking on demanding

journeys and/or routes, in terms of load

or road conditions, it is advisable to en-

sure that the gaseous fuel canister is full.

SYSTEM FAILURE

SIGNALLING

With the multifunction display, any system

failure is signalled through a dedicated

messages and, at the same time, by the

CNG logo and the four methane levels

flashing (with solid bars). In this case, go

to a Fiat Dealership as quickly as possi-

ble.

With the reconfigurable multifunction dis-

play, any system failure is signalled by the

dedicated message and, at the same time,

by the

symbol coming on and the four

methane levels going out. In this case, go

to a Fiat Dealership as quickly as possi-

ble.

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 11

FIAT DUCATO NATURAL POWER

fig. 10

F0N0392m

The profile of the filler for refilling is the

universal type compatible with Italian and

NGV1 standards.

In some European countries adaptors are

considered ILLEGAL (e.g. in Germany).

In the case of service stations with m

(dif-

ferent pressure) nozzles, to measure the

residual pressure in the canister, the sin-

gle-acting valves must be undone supply-

ing a small amount of methane.

The other plates (handed over with the

vehicle documentation) contain the date

for the first inspection of the canisters.

Those responsible for the

methane supply are not

authorized to refill the

canisters when the

inspection date has expired.

The single-acting valve prevents the

methane from flowing back to the

filler.

AT THE FILLING

STATION

METHANE GAS FILLER

The methane filler is located near the

petrol one Fig. 10.

It is comes complete with a ‘single-acting’

valve: inserted into the filler itself the sin-

gle-acting valve, prevents the methane

from flowing back to the filler.

To access the filler, undo the cap A - Fig.

10.

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 12

FIAT DUCATO NATURAL POWER

IDENTIFICATION DATA

IMPORTANT If the vehicle has been

registered in a country other than

Italy, the certification data, identifi-

cation and inspection procedures for

the methane canisters should con-

form to the legislation in that coun-

try. In any case, it should be re-

membered that the life of the can-

isters is 20 years from the produc-

tion date as set out in ECE Regula-

tion no. 110.

Marking the canisters

Each methane canister is identified in the

factory with a stamp on the nose of the

actual canister.

fig. 11

F0N0405m

The stamp includes:

CNG ONLY (type of gas designed for:

compressed natural gas only);

DO NOT USE AFTER





(canister expiry date: month-year);

FABER (name of canister manufacturer);







(canister regis-

tration number);



L (nominal canister capacity in litres);



KG (weight of canister kg: specific

for each canister);

20.0MPa15°C (operating pressure at

15°C);

30.0MPa (canister test pressure);



110R-



(ECE homologa-

tion number);

ECE R 110 (manufacturing regulations);

CNG-1 (type of canister);





(canister manufacture test

date: month/year);

USE ONLY FABER-APPROVED

PRD (PRD safety device warning);

(

–

(ENI stamp).

The other plates (handed over with the

vehicle documentation) contain the date

for the first inspection of the canisters.

SYSTEM INSPECTION

The canisters should be inspected, in ac-

cordance with ECE Regulation Procedure

no. 110, every 4 years from the vehicle

registration date or in accordance with

specific regulations in individual countries.

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 13

FIAT DUCATO NATURAL POWER

MAINTENANCE SCHEDULE

Additional operations to the Maintenance Schedule in the Owner’s Handbook.

Thousands of kilometres

Replace oil separator filter

Replace spark plugs

Visually inspect the condition of: methane pipes and connectors, renew if necessary (*)

Check pressure regulator heating piping seal

Check pressure regulator and replace internal filter (*)

Check correct assembly of injectors (positioning clip holding)

Check tightening torque of canister fastening bands

Check electrical connections and that engine wiring is intact

Check tyre conditions/wear and adjust pressure if required

Check light system operation (headlights, direction

indicators, hazard lights, boot lights, instrument panel warning lights, etc.)

Check windscreen wiper/washer operation and adjust

nozzles, if required

Check windscreen blade position/wear

Check disk brake pad conditions and wear and front and rear disk brake

pad wear indicator operation

(*) or every 12 months

40 80 120 160 200

●●●●●

●●

●●●●●

●●●● ●

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 14

FIAT DUCATO NATURAL POWER

40 80 120 160 200

●●●● ●

●●

●●●● ●

●

●●●● ●

●●

●●●● ●

Thousands of kilometres

Sight inspect conditions and soundness:

Sight inspect the conditions of: bodywork, underbody protection, pipes

and hoses (exhaust - fuel - brakes) - Rubber parts (boots - sleeves - bushes, etc.)

- Brake and fuel system hoses

Sight inspect accessory drive belt conditions/tension

(excluding engines provided with automatic tighteners)

Check and adjust handbrake lever stroke, if required

Check exhaust emissions

Check cleanness of locks and lever cleanness and lubrication

Change engine oil and oil filter

Replace air cleaner cartridge (▼)

Top up fluids

(engine coolant - brakes - power steering - windscreen washer - etc.)

Replace accessory drive belt

Check engine control system operation (through diagnosis socket)

Change brake fluid (or every 2 years)

Change pollen filter (or every 2 years)

(▼) If the vehicle is equipped with a specific air filter for dusty areas:

- Every 20,000 Km check-up and filter cleaning

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 15

FIAT DUCATO NATURAL POWER

VEHICLE RAISING POINTS

Arrange the jack near the lift support closest to the wheel to be replaced at the points

shown in fig. 12.

F0N0399m

fig. 12

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 16

FIAT DUCATO NATURAL POWER

GENERAL FEATURES

Engine identification code F1CE0441A

Cycle Eight

Number and layout of cylinders 4 in line

Number of valves per cylinder 4

Piston bore and stroke mm 95.8 x 104

Total displacement cm

2999

Compression ratio 12,5 ± 0,5:1

Max. EEC power HP

corresponding speed rpm

Max. EEC torque kgm

at a speed of rpm

Spark plugs Champion RC7BYC;

NGK IFRF-D;

NGK BKR7E

Fuel

ENGINE

100

136

3500

350

35,6

1500

Methane

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 17

FIAT DUCATO NATURAL POWER

ENGINE CODES - BODYWORK VERSIONS

Key: 250 A A M F A AX

MODEL

PAYLOAD

ENGINE

ENGINE TRANSMISSION/AXLES

BODYWORK

WHEELBASE

VERSION

PAYLOAD

A 3000 kg

B 3300 kg

C 3500 kg LIGHT

D 3500 kg HEAVY

E 4005 kg

ENGINES

A 100 Multijet

C 120 Multijet

D 160 Multijet

E 130 Multijet

G 140 Natural Power

TRANSMISSION

M Manual gearbox

A Automatic gearbox

BODYWORK

A Chassis cab frame

B Platform frame without drive cab

C Platform chassis cab

D Flatbed truck

E Primary school bus

L Middle school bus

F Van

G Long cab trailer

H Long cab frame

M Minibus

P Panorama

R 6/9 seater crew cab

U Platform frame without

‘platform’ drive cab

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 18

FIAT DUCATO NATURAL POWER

PERFORMANCE

Top speed in km/h

Modifications or repairs to

the fuel feed system that are

not carried out properly or do not

take the system’s technical specifica-

tions into account can cause mal-

functions leading to fire risk.

ATTENZIONE

N.B. The passage from running on

methane to petrol involves the immediate

insertion of the maximum speed limit to

90 Km/h. As such, after the first methane

reserve warning, refuel as quickly as pos-

sible, and in any case prior to the second

warning that the gaseous fuel (two beeps),

in order to avoid ‘risk’ conditions, such as,

for example, overtaking at high speeds on

the motorway.

Petrol function is for emergency purposes

only. In order to guarantee good indepen-

dence, even where there is limited tank ca-

pacity, performance is limited such as speed

or, as for take-off, acceleration (particu-

larly uphill).

As such, before embarking on demand-

ing journeys and/or routes, in terms of

load or road conditions, it is advisable to

ensure that the gaseous fuel canister is full.

Running

on petrol: 90

Running

on methane: Version MH1 159

Version MH2 155

Version LH3 153

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 19

FIAT DUCATO NATURAL POWER

WEIGHTS

Weights (kg) for versions

Kerb weight

(with supplies, spare wheel, tools and

accessories):

Payload including the driver (❒):

Maximum permitted loads (❍)

– front axle:

– rear axle:

– total:

Towable loads

– braked trailer:

– non braked trailer:

Maximum load on tow hitch(trailer with brakes)

Maximum permitted load on the roof:

Van Van Van Panorama Combined Van Van

3500 Light 3500 Light 3500 Heavy 3500 Light 3500 Heavy 3500 Heavy 3500 Heavy

MH1 MH2 MH2 M1 M1 LH2 XLH2

2285 2310 2350 2685 2485 2400 2445

1215 1190 1150 815 1015 1100 1055

1850 1850 2100 1850 2100 2100 2100

2000 2000 2400 2000 2400 2400 2400

3500 3500 3500 3500 3500 3500 3500

2500 2500 3000 2500 3000 3000 3000

750 750 750 750 750 750 750

100 100 120 100 120 120 120

150 150 150 150 150 150 150

(

❒) In the presence of optional equipment the unladen weight increases and, as a result, the payload decreases in relation to the max-

imum permitted loads.

(❍) Loads not be exceeded. The user is responsible for arranging goods in the luggage compartment and/on load carrying platform

within the maximum permitted loads.

603_83_954 Ducato Nat Power GB 25-03-2009 15:03 Pagina 20

Page is loading ...

Fiat DUCATO NATURAL POWER Owner's Manual Supplement

Fiat DUCATO NATURAL POWER Owner's Manual Supplement

Fiat DUCATO NATURAL POWER Owner's Manual Supplement

Related papers

Other documents