Page 1
FIATDUCATO
NATURAL POWER
Page 2
The Fiat Ducato Natural Power PetrolMethane version is dealt with in this appendix.
For anything not included in this supplement, please refer to the Fiat
Ducato Owner’s Manual.
FIAT DUCATO NATURAL POWER
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
CO
2
FUEL CONSUMPTION ................................................................................................... 22
2
Page 3
INTRODUCTION
The Fiat Ducato Natural Power version
features two fuel systems, a primary one
for natural gas (methane) and an emergency petrol alternative.
The methane multipoint
injection system
This is an original product from Fiat’s research in the field of alternative fuels that
comes from close co-operation with important 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 designed to run on methane. Petrol functioning 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 optimised 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 correct operating limit, the system automatically 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 only made by the engine control ECU, in a
fully automatic manner.
For this reason there always needs
to be petrol in the tank.
FIAT DUCATO NATURAL POWER
3
Page 4
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 protection against excess flows (if the high pressure system breaks, the flow of methane
is restricted to values that are not dangerous), overheating (fuse pad that allows
the methane to drain off if the temperature exceeds 110 °C) and a pressure calibration device that intervenes if the pressure goes above 300 bar ensuring the
methane escapes in a controlled manner
FIAT DUCATO NATURAL POWER
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.
WARNING
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 chapter should be followed in order to prevent damage to the methane system
parts: ‘Towing the vehicle’.
If there is a problem with the
methane system, only go to an authorised Fiat Dealer.
Do not alter the methane system configuration or components; they are
designed exclusively for the Fiat
Ducato Natural Power. The use of
other components or materials may
lead to malfunctioning and compromise safety.
WARNING
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 safety 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 vehicles or moved in an emergency as a
result of a breakdown or accident.
4
Page 5
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.
FIAT DUCATO NATURAL POWER
Fig. 1
F0N0396m
5
Page 6
CANISTERS
The vehicle has five canisters (total capacity 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 compressed gaseous state (pressure 200 bar
at 15 °C). The methane, stored in the canisters at high pressure, flows through a
dedicated pipe to reach the pressure regulator/reduction unit which supplies the 4
methane injectors at low pressure (about
6 bar).
FIAT DUCATO NATURAL POWER
Certification of the canisters
The methane canisters are certified in accordance with Regulation (ECE) no. 110
The canisters should be inspected, in accordance with Regulation
Procedure (ECE) no. 110, every
4 years from the vehicle registration date or in accordance
with specific regulations in individual countries (see page 13).
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 refill the canisters when the inspection date has expired.
IMPORTANT If the vehicle has
been registered in a country other than Italy, the certification data, identification and inspection
procedures for the methane canisters should conform to the legislation 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.
6
Page 7
SOLENOID
VALVES/SAFETY
DEVICES
The solenoid valves Fig. 2 are bolted directly 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 triggered.
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.
fig. 2
F0N04000m
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 allow it to operate even if the solenoid valve
casing is broken due to an impact.
fig. 3
F0N0393m
4) Manual tap, it is located upstream of
the solenoid valve.
This separates the canister from the
methane system to allow maintenance operations.
The taps can be accessed from outside the
vehicle, and are positioned on the lefthand 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)
FIAT DUCATO NATURAL POWER
7
Page 8
PIPING
METHANE INJECTORS
The methane piping from the filler to the
pressure regulator/reduction unit is made
from galvanised steel and covered in plastic (high pressure) and is located outside
the passenger compartment. The piping
from the pressure regulator/reduction
unit to the methane injectors is in stainless steel.
PRESSURE
REGULATOR/
REDUCTION UNIT
The pressure reduction unit Fig. 4 is installed in the engine compartment.
It has the task of reducing the pressure
of the methane from the value in the can-
FIAT DUCATO NATURAL POWER
ister to the supply value for the methane
injectors (about 6 bar) and keeping it constant in all operating conditions.
fig. 4
fig. 5
There are 4 dedicated injectors for the
methane gas A - Fig. 5, fitted on the intake manifold near the cylinder head, one
for each intake duct; they are supplied at
a constant pressure (about 6 bar) and operated by the electronic control unit.
F0N0398m
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.
F0N0401m
fig. 6
F0N0397m
8
Page 9
STARTING THE
ENGINE
The following describes the various different 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.
Fusebox in engine compartment
❒
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.
PROTECTIVE FUSES
The table below contains a list of the protective 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.
USERS FUSE AMPERES
Methane fuse solenoid valves F27 10
Methane relay solenoid valves T21 20
FIAT DUCATO NATURAL POWER
9
Page 10
FUEL SWITCHING
LOGICS
Management of switching between the
two different fuel supplies is fully automatic, and carried out by the engine control unit.
When the residual amount of methane
goes below 1/5 of the capacity of the canisters, the CNG logo and the lowest level 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
FIAT DUCATO NATURAL POWER
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 completely, 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. 8
fig. 9
F0N0403g
F0N0404g
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 refuelling, the vehicle will continue running on
petrol, until next start-up.
10
Page 11
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 warning, 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 motorway.
Petrol function is for emergency purposes only. In order to guarantee good independence, 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 ensure 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 possible.
With the reconfigurable multifunction display, any system failure is signalled by the
dedicated message and, at the same time,
by the Rsymbol coming on and the four
methane levels going out. In this case, go
to a Fiat Dealership as quickly as possible.
FIAT DUCATO NATURAL POWER
11
Page 12
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 single-acting valve, prevents the methane
from flowing back to the filler.
To access the filler, undo the cap A - Fig.
10.
FIAT DUCATO NATURAL POWER
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
3
(different pressure) nozzles, to measure the
residual pressure in the canister, the single-acting valves must be undone supplying a small amount of methane.
The other plates (handed over with the
vehicle documentation) contain the date
for the first inspection of the canisters.
fig. 10
F0N0392m
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.
12
Page 13
IDENTIFICATION DATA
IMPORTANT If the vehicle has been
registered in a country other than
Italy, the certification data, identification and inspection procedures for
the methane canisters should conform to the legislation 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 ECE Regulation 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);
E
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);
(–N)
(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 accordance with ECE Regulation Procedure
no. 110, every 4 years from the vehicle
registration date or in accordance with
specific regulations in individual countries.
FIAT DUCATO NATURAL POWER
13
Page 14
MAINTENANCE SCHEDULE
Additional operations to the Maintenance Schedule in the Owner’s Handbook.
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
FIAT DUCATO NATURAL POWER
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
Thousands of kilometres
40 80 120 160 200
●●●●●
●●●●●
●●●●●
●●●●●
●●●●●
●●●●●
●●
●●●●●
●●●●●
●●●●●
●●●●●
●●●●●
●●●●●
14
(*) or every 12 months
Page 15
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)
40 80 120 160 200
●●●●●
●●
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
●●●●●
●●●●●
●●●●●
●●●●●
●●●●●
●●●●●
●
●●●●●
●●
●●●●●
FIAT DUCATO NATURAL POWER
15
Page 16
VEHICLE RAISING POINTS
Arrange the jack near the lift support closest to the wheel to be replaced at the points
shown in fig. 12.
FIAT DUCATO NATURAL POWER
16
fig. 12
F0N0399m
Page 17
ENGINE
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
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;
Fuel
kW
Nm
3
2999
100
136
3500
350
35,6
1500
NGK IFRF-D;
NGK BKR7E
Methane
FIAT DUCATO NATURAL POWER
17
Page 18
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
FIAT DUCATO NATURAL POWER
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
18
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
Page 19
PERFORMANCE
Top speed in km/h
Running
on petrol: 90
Running
on methane: Version MH1 159
Version MH2 155
Version LH3 153
ATTENZIONE
Modifications or repairs to
the fuel feed system that are
not carried out properly or do not
take the system’s technical specifications into account can cause malfunctions leading to fire risk.
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 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 motorway.
Petrol function is for emergency purposes
only. In order to guarantee good independence, 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
ensure that the gaseous fuel canister is full.
FIAT DUCATO NATURAL POWER
19
Page 20
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)
FIAT DUCATO NATURAL POWER
Maximum permitted load on the roof:
❒) In the presence of optional equipment the unladen weight increases and, as a result, the payload decreases in relation to the max-
(
(❍) Loads not be exceeded. The user is responsible for arranging goods in the luggage compartment and/on load carrying platform
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
imum permitted loads.
within the maximum permitted loads.
20
Page 21
CAPACITIES
ENGINE OIL
CO2EMISSIONS
Petrol
Petrol . . . . . . . . . . . . . . . . . litres 14.5
– including a reserve of . . . litres 8
Methane
- Methane (*). . . . . . kg (approx.) 36
- Methane range. . . . . . . . . . . . . . 400 km
(*) The amount of methane depends on
the outside temperature, the supply pressure, the quality of the gas and the type
of refuelling system. The total volume of
the canisters is about 220
litres (218.5 nominal) for all version.
IMPORTANT It should be remembered
that when using a fuel such as methane the
range is very variable because as well as
the driving conditions and vehicle maintenance it also depends on the temperature
of the gas in the canister.
The methane actually heats up during the
refuelling and cools down whilst driving,
undergoing variations in pressure that reduce the quantity that can be used.
The engine oil used is SELENIA K P.E.
(Contractual Technical Reference
N° F603.C07): SAE 5W-40 ACEA C3
grade synthetic base lubricant, FIAT
9.55535-S2 certification.
The CO2emission figures in the table below refer to combined fuel consumption.
CO
emissions according to Direc-
2
tive 2004/3/EC (g/km)
Methane . . . . . . . . . . . . . . . . . . . . . 239
FIAT DUCATO NATURAL POWER
21
Page 22
FUEL
CONSUMPTION
N.B. The trip computer data concerning
range, average consumption and instantaneous consumption are not available for
this version.
The fuel consumption figures given in the
table below are determined on the basis
of the homologation tests laid down by
specific European Directives.
The procedures below are followed for
measuring consumption:
- urban cycle: cold starting followed by driving that simulates urban use of the vehicle;
- extra-urban cycle: frequent accelerations
in all gears, simulating extraurban use of
the vehicle: speed varies between 0 and
120 km/h;
- combined consumption: determined
through a weighting of about 37% of the
urban cycle and 63% of the extra-urban
cycle.
IMPORTANT The type of route, traffic
conditions, weather conditions, driving
style, state of the vehicle in general, trim
level/equipment/accessories, use of the climate control, vehicle load, presence of a
roof rack and other situations that adversely affect the aerodynamics, may lead
to consumption figures that differ from
those measured (see ‘Saving fuel’ in
the ‘Starting and driving’ chapter in
the booklet).
It should also be pointed out that whilst
the vehicle is being run in (up to around
3000 km) the fuel consumption may be
higher than the figures given.
FIAT DUCATO NATURAL POWER
Fuel consumption according to Directive 2004/3/EC
Urban 16,7 10,9
Extra urban 11,4 7,5
Combined 13,4 8,8
(*) Consumption in kg x 100 km in accordance with the calculation of the molecular mass.
(**) Fuel consumption according to Directive 2004/3/EC.
22
Methane Methane
(m3x100 km) (**) (kg x 100 km) (*)
Page 23
NOTES
FIAT DUCATO NATURAL POWER
23
Page 24
Fiat Group Automobiles S.p.A. - Customer Services - Technical Services -
Service Engineering - Largo Senatore G. Agnelli, 5 - 10040 Volvera - Torino (Italia)
Print no. 603.83.954 - 03/2009 -1 Edition
Loading...