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Operation & Maintenance Manual for ECPG

TABLE OF CONTENTS
i.

Introduction ................................................................................................................................................... i-1

1.

Electronic Control Panel with Speed Governor .............................................................................................. 1-1

2.

ECPG Dimensions ....................................................................................................................................... 2-1

3.

Engine Start-up & Adjustments .................................................................................................................... 3-1

4.

Engine Protection ......................................................................................................................................... 4-1

5.

Fault Code Information ................................................................................................................................. 5-1

6.

Troubleshooting ............................................................................................................................................ 6-1

7.

Installation .................................................................................................................................................... 7-1

8.

Appendix ...................................................................................................................................................... 8-1

Operation & Maintenance Manual for ECPG

i-1

Operation & Maintenance Manual for ECPG

SECTION i - INTRODUCTION
Section Contents
Page
About the Manual ................................................................................................................................................... i-2
To the Owner and Operator .................................................................................................................................... i-3
General Safety Instructions .................................................................................................................................... i-4
General Repair Instructions .................................................................................................................................... i-5
Graphic Symbols ................................................................................................................................................... i-6
Electrical Symbols ................................................................................................................................................. i-7
Acronyms and Abbreviations ................................................................................................................................. i-9
Foreword ............................................................................................................................................................... i-10
Important Reference Numbers ............................................................................................................................... i-11
Illustrations ........................................................................................................................................................... i-12

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Operation & Maintenance Manual for ECPG

About the Manual


This manual contains information needed to correctly operate and maintain the ECPG provided
on your engine. Additional service literature (Shop Manual, Troubleshooting and Repair Manual)
can be ordered from Authorised Dealers.
Numerous illustrations and symbols are used to aid in understanding the meaning of the text.
Refer to complete listing of symbols and their definitions. Each section is preceded by a Section
Contents to aid in locating information more quickly.
This manual contains information needed to understand, correctly operate and maintain the
Electronic Control Panel with Governor (ECPG) as recommended by Cummins India Limited.
This manual does not cover base engine maintenance procedures. Refer to the Operation and
Maintenance Manual, Bulletin No. 3243773-03 for the specific engine information. Any base
engine specific changes in the Software Calibration / Features will be covered in separate bulletins
for that particular Engine / Rating.
This manual does not cover generator equipment maintenance or repair procedures. Consult the
generator equipment manufacturer for specific maintenance and repair recommendations.
Both metric and U.S. customary values are listed in this manual. The metric value is listed first,
followed by the U.S. customary in brackets.
This manual does not cover the Installation / Operation of the Service Tool Software. Refer to the
Installation & Operation manual for the ECP-G Service Tool (Bulletin No. 3243816).

Operation & Maintenance Manual for ECPG

To The Owner and Operator


Preventative maintenance is the easiest and least expensive type of maintenance. Follow the
maintenance schedule recommendations outlined in Maintenance Guidelines.
Keep records of regularly scheduled maintenance.
Use the correct fuel, oil and coolant in your engine as specified in Specifications and Torque
Values. Cummins India Ltd. uses the latest technology and the highest quality components to
produce its engines. Cummins recommends using only genuine Cummins parts and ReCon
exchange parts.
Personnel at Cummins Authorized Repair Locations have been trained to provide expert service
and parts support. If you have a problem that cannot be resolved by a Cummins Authorized
Repair Location, follow the steps outlined in the Service Assistance.
NOTE: Discharge of oil or oily waste into or upon water is a direct violation of todays laws.
Violators are subject to a penalty of various monetary charges. Dispose off these substances
properly.

i-3

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Operation & Maintenance Manual for ECPG

General Safety Instructions


Important Safety Notice

WARNING
Read and understand all of the safety precautions and warnings before performing any repair. This list contains the
general safety precautions that must be followed to provide personal safety. Special safety precautions are included
in the procedures when they apply.
Make sure the work area surrounding the product is safe. Be aware of hazardous conditions that can exist.
Always wear protective glasses and protective shoes when working.
Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
Disconnect the battery and discharge any capacitors before beginning any repair work. Disconnect the air
starting motor if equipped to prevent accidental engine starting. Put a Do Not Operate tag in the operators
compartment or on the controls.
Use ONLY the proper engine barring techniques for manually rotating the crankshaft. Do not attempt to rotate
the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property
damage, or damage to the fan blade(s) causing premature fan failure.
If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling system.
Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands
to support the product before performing any service work.
Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related items are
removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that
utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal
injury.
To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or
more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct
capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting
hooks must not be side-loaded.
Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact
with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case
of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY
CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturers instructions to provide complete safety when using these materials. KEEP OUT OF REACH
OF CHILDREN.
To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines, tubes,
and compartments.
Always use tools that are in good condition. Make sure you understand how to use them before performing
any service work. Use ONLY genuine Cummins or Cummins Recon replacement parts.
Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of
less quality if replacements are necessary.

Operation & Maintenance Manual for ECPG

i-5

General Repair Instructions


This engine incorporates the latest diesel technology; yet, it is designed to be repaired using normal repair practices
performed to quality standards.
Cummins India Ltd., does not recommend or authorize any modifications or repairs to engines or
components except for those detailed in Cummins Ser
vice Inf
ormation. In par
ticular
ed
Service
Information.
particular
ticular,, un-authoriz
un-authorized
sonal injur
y. Belo
w is a par
tial listing of components
repair to saf
ety-related components can cause per
Below
partial
safety-related
personal
injury
classified as safety-related:
Air Compressor
Fuel Shutoff Assemblies
Cooling Fan
Fuel Suppl
y Tubes
Supply
Fan Hub Assembly
Lifting Brackets
Fan Mounting Bracket(s)
Throttle Controls
Fan Mounting Capscrews
Turboc
har
ger Compressor Casing
urbochar
harg
Fan Hub Spindle
Turboc
har
ger Oil Drain Line(s)
urbochar
harg
Flywheel
Turboc
har
ger Oil Suppl
y Line(s)
urbochar
harg
Supply
Flywheel Crankshaft Adapter
Turboc
har
g
er
T
urbine
Casing
urbochar
harg
Flywheel Mounting Capscrews
Vibration Damper Mounting Capscrews
Follow All Safety Instructions Noted in the Procedures.
Follow the manufacturers recommendations for cleaning solvents and other substances used during the
repair of the engine. Always use good safety practices with tools and equipment.
Provide A Clean Environment and Follow the Cleaning Instructions Specified in the Procedures
The engine and its components must be kept clean during any repair. Contamination of the engine and
components will cause premature wear.
Perform the Inspections Specified in the Procedures.
Replace all Components or Assemb
lies Whic
h are Dama
ged or Worn Be
yond the Specifications
Assemblies
Which
Damag
Bey
Use Genuine Cummins New or ReCondD Service Parts and Assemblies
The assembly instructions have been written to use again as many components and assemblies as
possible. When it is necessary to replace a component or assembly, the procedure is based on the use
of new Cummins India Ltd. or Cummins ReCon components. All of the repair services described in this
manual are available from all Cummins Distributors and most Dealer locations.
Follow
Disassemblly and Assemb
Assemblly Pr
Procedures
Damag
Follo
w The Specified Disassemb
ocedures to Avoid Dama
ge to the Components.
Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a
Cummins Authorized Repair Location.
ECPG DOS AND DONTS
DONTs
1. DO NOT remove the ECPG connectors A, B and C when +24V supply is conected to ECPG.
2. DO NOT attempt to open the ECPG enclosure.
3. DO NOT attempt to remove or repair any of the ECPG electronic parts (components, cables etc.). There are no
user serviceable parts inside ECPG.
4. Precaution during welding:
i) DO NOT connect ground cable of welding machine to ECPG
ii) DO NOT perform welding near Engine when ECPG harness is conected to ECPG.
5. DO NOT expose ECPG to sunlight, humidity, heat, water while in operation.
6. Servicing of ECPG is to be done by Authorized Cummins Personnel Only.
DOs
1. Precautions during welding :
i) First, disconnect battery cables from battery terminals.
ii) Then, disconnect the connectors A, B, C from the ECPG
2. Contact authorized service personnel in case of ECPG failure.

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Operation & Maintenance Manual for ECPG

GRAPHIC SYMBOL
The following symbols have been used in this manual to help communicate the intent of the instructions. When one of
the symbols appears, it conveys the meaning defined below :

WARNING - Serious personal injury or extensive property damage can result if the warning instructions
are not followed.
CAUTION - Minor personal injury can result or a part, an assembly, or the engine can be damaged if
the caution instructions are not followed.
Indicates a REMOVAL or DISASSEMBLY step.
Indicates an INSTALLATION or ASSEMBLY step.
INSPECTION is required.

CLEAN the part or assembly.


PERFORM a mechanical or time MEASUREMENT.
LUBRICATE the part or assembly.
Indicates that a WRENCH or TOOL SIZE will be given.
TIGHTEN to a specific torque.
PERFORM an electrical MEASUREMENT.
Refer to another location in this manual or another publication for additional information.
The component weight 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance
to lift the component.

Operation & Maintenance Manual for ECPG

i-7

ELECTRICAL SYMBOLS
Name

Symbol

Battery

Name
Transfer

Alternator
(Frequency
Source)
Capacitor
Resistor
Fuse
Variable
Resistor
(Potentiometer)

3 Terminal
Device
2 Terminal
Device

Circuit Breaker

Jumper Wire
Terminal Strip
Switches :
(N.O.)
Normally Open

Coil
Magnetic Core

(N.C.)
Normally Closed
Transfer

Transfer
3 position

Transformer

Variable Reluctance
Magnetic Pickup

Relay Contact :
(N.O.)
Normally Open
(N.C.)
Normally Closed

Female Contact

Male Contact

Symbol

i-8

Name

Operation & Maintenance Manual for ECPG

Symbol

Name

Shields:

Earth Safety Ground

Shielded Wire

**

Shielded Pair

**
Crossing of Conductors
(wires) not Connected

Junction of Connected
Conductors (wires)
Grounded
Chassis or Frame
Connection
Conducting connection to a chassis
or frame, or equivalent chassis connection of a printed wiring board.
The chassis or frame (or equivalent
chassis connection of a printed wiring
board) may be at a different potential
than the earth or structure in which
this chassis or frame (or printed
wiring board) is mounted.
Direct Conducting Connection to Circuit
Return.
Conducting connection to a structure
that services a function similar to that
of an earth ground (that is, a structure
such as a frame of an air, space or
land vehicle that is not conductively
connected to earth.)

This symbol may be used in


place of symbol for direct conducting connection to circuit
return to indicate a ground
connection having a specified
protective function (e.g., for
protection against electrical
shock in case of a fault).
Ref. Electrical and Electronics
Graphic Symbols and abbreviated names.

Symbol

Operation & Maintenance Manual for ECPG

i-9

ACR
ONYMS AND ABBREVIA
TIONS
ACRONYMS
ABBREVIATIONS
A

Ampere

Hz

Hertz

AC

Alternating Current

IP53

Ingress Protection - Dust-Protected &

AMF

Auto Mains Failure

AMPS

Amperes

Spraying Water
IP54

Ingress Protection - Dust-Protected &

AWG

American Wire Gage

B+

Battery Positive

In

Inch

Degree Celsius

I/O

Input / Output

CTS

Coolant Temperature Sensor

kg

Kilogram

CW

Clockwise

kPa

Kilopascal

CCW

Counterclockwise

kW

Kilowatt

DC

Direct Current

lb

Pound

ECP

Electronic Control Panel

LED

Light-Emitting Diode

ECP+G / ECPG

Electronic Control Panel with Governor

LLOP

Low Lube Oil Pressure

EMC

Electro-Magnetic Compatibility

mA

Milli-Ampere

EMF

Electro-Motive Force

mW

Milli-Watts

EMI

Electro-Magnetic Interference

mm

Millimeter

EPROM

Erasable Programmable Read Only

MPU

Magnetic Pickup

Memory

N-m

Newton-meter

E-STOP

Emergency Stop

O/M

Owner-Operator Manual

Splashing Water

ESS

Engine Speed Sensor

OEM

Original Equipment Manufacturer

Degree Fahrenheit

OPS

Oil Pressure Sensor

FSOV

Fuel Shutoff Valve

OS

Over Speed

ft (FT)

Foot

PC

Personal Computer

GND

Ground

P-P

Peak to Peak

GOEM

G-Drive Original Equipment

P/N

Part Number

Manufacturer

psi

Pounds Per Square Inch

H2O

Water

rpm (RPM)

Revolutions Per Minute

HCT

High Coolant Temperature

PWM

Pulse Width Modulator

HE

Heat Exchanger

Volts

Hg

Mercury

PT

Pressure Time

hp

Horsepower

MS

Military Standard

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Operation & Maintenance Manual for ECPG

Foreword
This manual contains information for the correct operation and maintenance of your Cummins engine. It
also includes important safety information, engine and systems specifications, troubleshooting guidelines.
Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new owner.
The information, specifications, and recommended maintenance guidelines in this manual are based on
information in effect at the time of printing. Cummins India Limited reserves the right to make changes at
any time without obligation. If you find differences between your engine and the information in this manual,
contact your local Cummins Authorized Dealer.
The latest technology and the highest quality components were used to produce this engine. When
replacement parts are needed, we recommend using only genuine Cummins or ReCon exchange parts.
These parts can be identified by the following trademarks:

Operation & Maintenance Manual for ECPG

i-11

Important Reference Numbers


Fill in the part name and number in the blank spaces provided below. This will give you a reference whenever
service or maintenance is required.

ECPG Sr. No.

____________________

Engine Model

____________________

Engine Serial Number

____________________

Engine Control Parts List (CPL) Number

____________________

Engine Oil Type and Viscosity


Fuel Pump Part Number

SAE grade 15 W 40
____________________

Filter Part Numbers:


Air Cleaner Element

____________________

Coolant (C-Series)

____________________

Lubricating Oil

____________________

Fuel

____________________

Belt Part Number (Alternator)

____________________

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Operation & Maintenance Manual for ECPG

Illustrations
Some of the illustrations throughout this manual are
generic and will not look exactly like the engine or parts
used in your application. The illustrations can contain
symbols to indicate an action required and an acceptable
or not acceptable condition.

The illustrations included in this manual are intended to


illustrate procedures performed or location of particular
items.
ECPG
The procedure performed or location of the item described
will be the same even though the illustrations may vary.

Illustrations showing connector contact positions for


connections to the Electronic Control Panel and Governor
are shown as viewed looking at the connector on the
ECPG, not the interfacing connector of the wiring harness.

ECPG Connector A

Illustrations showing connector contact positions for


connections to the in-line connectors of the wiring
harnesses are viewed looking at the corresponding
connector on the factory supplied engine or extension
wiring harness, not the connector of the interfacing
harness.

Connector Fuel Actuator

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Operation & Maintenance Manual for ECPG

SECTION 1
ECPG GENERAL INFORMATION
Page
Electronic Control Panel with Speed Governor ...................................................................................................... 1-2
Description ................................................................................................................................................... 1-2
Theory of Operation ...................................................................................................................................... 1-2
Introduction to Parts .............................................................................................................................................. 1-3
ECPG Front Panel ........................................................................................................................................
Harness ........................................................................................................................................................
Extension Harness (Option) ..........................................................................................................................
Inputs ...........................................................................................................................................................
Outputs ........................................................................................................................................................

1-5
1-5
1-5
1-6
1-6

Sensors ................................................................................................................................................................
Magnetic Pick-up ..........................................................................................................................................
Coolant Temperature Sensor ........................................................................................................................
Intake Air Temperature Sensor .....................................................................................................................
Lube Oil Pressure Sensor .............................................................................................................................
Coolant Level Sensor ...................................................................................................................................
Actuator and Actuator Housing .....................................................................................................................

1-6
1-6
1-7
1-7
1-7
1-7
1-8

Connector Details ..................................................................................................................................................


Connector-A .................................................................................................................................................
Connector-B .................................................................................................................................................
Connector-C .................................................................................................................................................
Data Link Connector (9 Pin) ..........................................................................................................................

1-9
1-9
1-9
1-9
1-9

ECPG Hardwired Interconnections ...................................................................................................................... 1-10

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Operation & Maintenance Manual for ECPG

Electronic control panel with speed


governor
Description
The Electronic control panel (ECPG) with built in governor
is used on engines for governing engine speed,
monitoring engine parameters and protecting the engine
in catastrophic conditions. The ECPG with built in
governor comprises of, ECPG with software to govern
the engine speed, actuator mounted in an aluminum
housing, mounting par ts, cable harness for
interconnection, engine sensors. This ECPG eliminates
the conventional electronic fuel controller (EFC) and the
related harness. The ECPG is used on PT type fuel
system.

ECPG

ECPG

The primary function of the ECPG is to govern the engine


speed in isochronous or droop mode. The ECPG hardware
and software provides the following additional features :

Engine Speed Governing


Operator Control Interface
Engine Monitoring
Engine Protection
System Fault Diagnostics.
Electronic Service Tool

Theory of operation
The magnetic pickup senses the engine speed at the
flywheel ring gear and generates an AC voltage with its
frequency proportional to the engine speed. The signal is
sensed by the ECPG and is used as a speed feedback.

ECPG

The actuator mounted in the actuator housing is used to


control the fuel flow from the fuel pump to the injectors.
Actuator valve (with no current flowing in the actuator
coil) is normally closed. Actuator opens depending upon
the current through the actuator coil.
The ECPG compares the electrical signal from the
magnetic pickup with a preset speed reference point (for
e.g. 1500 RPM). If there is a difference in the two signals,
the controller will change the amount of current flowing
through to the actuator coil.
A change in the amount of current to the actuator coil
makes the actuator shaft to linearly open/ close the fuel
outlet port, and controls the amount of fuel flow to the
engine. This in turn controls the engine speed.
The ECPG controls the engine speed at the set reference
speed (for e.g. 1500 RPM) from No load to Full load (For
Isochronous operation). It also provides programmable
speed droop function. It requires no special settings as
the software in the ECPG controls the engine speed.

ECPG

Operation & Maintenance Manual for ECPG

1-3

INTRODUCTION TO PARTS
The ECPG enclosure is made of glass reinforced plastic
and is divided into two halves, the front enclosure and
the rear enclosure.

&&&&

These two enclosures are sealed by a rubber seal.


Six M5 x 0.5, 50mm length Phillips head screws are used
for mounting it.

The ECPG comprises of two sub assemblies (printed


circuit boards) :
a. I/O board (Analog board)
b. CPU board (Digital board)
These boards are housed in the glass reinforced, plastic
enclosure. The CPU board is mounted on the front and
the I/O board is mounted on the rear half of the enclosure
respectively.

The CPU board processes the input signals received from


the I/O board and performs the calculation and displays
the measured data on the digital display. It also checks
for various safety limits and shuts off the supply to the
fuel shut off valve if one of the engine parameters exceeds
the set safety threshold. The CPU board also calculates
the engine running time and displays it.

CPU Board

The I/O Board interfaces with the engine sensors and


OEM connections, through three connectors called as
Connector A (19-pin), Connector B (10-pin), and Connector
C (7-pin). The CPU board interfaces with the service
tool through D-type connector called as datalink
connector.

I/O Board

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Operation & Maintenance Manual for ECPG

The Connector A interfaces with the engine sensors and


actuator.
Connector A is a male 19 position MS shell connector.
It mates with female connector on the engine harness
through a 19 position receptacle socket.
Connector B is a male 10 position MS shell connector.
It interfaces with customer connections through 10
position MS shell receptacle socket.
The following customer features are accessible via
hardwired connections to Connector B :

CONNECTOR-A

Alternate Frequency Switch


Overspeed (OS) alarm relay driver
High coolant temperature (HCT) alarm relay driver
Low lube oil pressure (LOP) alarm relay driver
Remote start
Remote stop
Raise contact
Lower contact.
Intake air temperature alarm relay driver.
Customer Selection Output Alarm relay driver : Not
ready to start, Engine running, Common warning,
Common shutdown.
Speed bias input.

CONNECTOR-B

Connector C is for future expansion.


The datalink connector is 9 pin D type connector
interfacing with PC based service tool.
The data link is intended to be used to connect single or
multiple ECPGs to a host computer acting as a supervisor
for facilitating data acquisition and logging using a PC
based service tool.
There are many features of the ECPG that are configured
using the service tool. Electronic service tool is a
packaged software application that installs on a IBM
compatible PC. The Service Tool is available as a Kit
(Part No. 4105287) on a CD. The Service PC, running
the ECP-G Tool is connected to the ECP-G via a RS-232
serial communication cable. The enclosed figure
illustrates the method used to connect the Service PC
via the engine harness to the ECP-G. The data link uses
two wire RS-485 serial communication standard. A RS485 to RS-232 convertor (Part No. 4071717) is required
for connecting the data link to a PCs RS-232 serial
communication port.
The configurable features will be discussed in this manual,
however, all functions of Service Tool are not covered.
Refer to the Service Tool manual (Part No. 3243816) for
more detailed information about using Service Tool. Note
that the PC that has the Service Tool software installed
requires a separate service cable to communicate with
the ECPG through the RS-485 service datalink connector
on the Engine Harness.

DATA LINK
CONNECTOR

CONNECTOR-C
4105287
ECPG
Service Tool

4073853
ECPG to data-link adapter
cable, adapter side stub

4071851
PC to data-link
adapter cable

4071935
ECPG

4071717
Data-link Adapter

4071852
ECPG to data-link
adapter cable ECPG
side stub

SERVICE TOOL

Operation & Maintenance Manual for ECPG

1-5

ECPG front panel


The front operator interface panel comprises of the
following:
(i) Four digit 7 Segment Display, to indicate the
scanned engine parameters.

8 GREEN
LEDs

&&&&

Three Position
Key Switch

Idle/Rated
Toggle Switch

8 RED
LEDs

(ii) A column of green LEDs on the left hand side with


legends to indicate the parameter being selected for
display.
(iii) A column of red LEDs on the right hand side with
legends to indicate the fault condition.
(iv) Scan Push button: The display is toggled between
All Parameters and Single Parameter scan mode
by the momentary pressing of the scan button. It is
mounted on the front plate of the ECPG.
(v) Three position key switch : The key switch on the
front panel is used to Wake up ECPG and start/
stop the engine. It is used to turn the 24 V DC battery
ON/OFF and thus start the engine. Refer Section ECPG Features, Power down mode.
(vi) Idle / Rated Toggle switch : The engine mode is
toggled between idle and rated using this switch.

Harness
The outputs from all the sensors are connected to the
ECPG through the engine harness. This harness is
connected to the ECPG through Connector A.
The other harness, which is the OEM harness connects
the OEM outputs like remote start, remote stop and alarm
relay drivers through Connector B.
Extension Harness (Option)
The Extension Harness provides the means for mounting
the ECPG off the engine, such as generator set or some
other remote location. This is accomplished by extending
the circuits from the engine harness connector to the
ECPG mounting location. The maximum length of
extension harness is 10 meters.
CA
UTION
CAUTION
No attempt should be made to bypass/tap
existing engine sensors, actuators or to operate
the engine using 3rd party governor control
systems.

Following inputs / outputs are connected to the ECPG

ENGINE
HARNESS

OEM
HARNESS

Scan Push
Button

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Operation & Maintenance Manual for ECPG

by two harnesses at the rear of the ECPG.


Inputs
1. Battery Supply Voltage
2. Coolant Temperature sensor
3. Intake Air temperature sensor (only on KTA50G8 and
KTA38G5 engine models)
4. Lube Oil Pressure sensor
5. Engine speed sensor i.e. magnetic pickup
6. Low coolant level sensor
7. Scan push button
8. Key switch
9. Remote start
10. Remote stop
11. Idle / Rated switch
12. Alternate Frequency switch
13. Speed bias input
14. Battery charging failure indication
SENSOR FEEDBACK

15. Raise

AIR INTAKE TEMPERATURE

16. Lower
Outputs
1. Fuel shut-off valve
2. Starter magnetic switch

MAGNETIC
PICK-UP

ECP-G

FUEL PUMP
LOP

3. High coolant temperature alarm relay driver


ENGINE

4. Low lube oil pressure alarm relay driver

FUEL SHUTOFF VALVE,


FUEL ACTUATOR

5. High Intake air temperature alarm relay driver

OEM
INTERFACE

6. Engine overspeed relay driver


7. Fuel actuator
The figure shows how various parts are functionally
connected. Following major parts are included in the
ECPG.
SENSORS
a. Magnetic pickup
The magnetic pickup is an electromagnetic device. It is
mounted on the flywheel housing. It senses the engine
speed at the flywheel ring gear and generates AC voltage
with its frequency proportional to the engine speed. A
Two pin MS connector is provided to connect the magnetic
pick up to the engine harness.
The magnetic pickup is connected between pin B
(RPM ) and T (RPM +) of Connector A through engine
harness.

ECPG

Operation & Maintenance Manual for ECPG

1-7

b. Coolant temperature sensor

COOLANT TEMPERATURE SENSOR

A coolant temperature sensor is mounted on the


thermostat housing.
The sensor is fitted in an adapter. A two-pin connector
is provided to connect the coolant temperature sensor to
the engine harness.
The sensor is connected between pin P and N of
Connector A through the engine harness.

c. Intake Air temperature sensor

Intake Air
Temperature Sensor

The intake air temperature sensor is used to monitor the


low temperature aftercooler performance for two-pump
two-loop system only.
The intake air temperature sensor is mounted on the
aftercooler housing for the KTA 38- G5 and KTA-50-G8
engines. A two-pin connector is provided to connect the
intake air temperature sensor to the engine harness.
The sensor is connected between Pin S and U of
Connector A through the engine harness.

d. Lube oil pressure sensor


LUBE
OIL
PRESSURE
SENSOR

Lube oil pressure sensor is mounted on the engine block


oil gallery. A three-pin connector is provided to connect
lube oil pressure sensor to the engine harness.
The sensor is connected between pin J, Pin G and
Pin H of Connector A through the engine harness.

COOLANT LEVEL
COOLANT
LEVELINDICATOR
SENSOR

e. Coolant level sensor


The coolant level sensor is a switch type sensor. It
is used to detect the coolant level of the engine. The
sensor is connected at Pin-R of Connector A to the
engine harness.

Note : The sensor locations shown in the figures are


of VTA-28 engine as an example.

1-8

f.

Operation & Maintenance Manual for ECPG

Actuator and actuator housing

The actuator is a linear proportional valve. The actuator


is housed in the aluminum housing. This assembly is
used as a valve for controlling the speed and horsepower
of the engine by controlling the fuel flow. The actuator is
connected between Pin-F and Pin-M of Connector A to
the engine harness.
Actuator

Actuator is closed when no current is flowing through the


actuator coil. When current is passed through the actuator
coil, the actuator port opens proportional to the actuator
current.

Housing

Operation & Maintenance Manual for ECPG

CONNECTOR DETAILS
Connector-A
Sr. No.

PIN

Description

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V

Battery (24 VDC) Negative


Engine speed sensor return
Not Connected
Fuel shut off valve output
Starter magnetic switch output
Fuel actuator output
Lube oil pressure sensor supply
Lube oil pressure sensor signal (output)
Lube oil pressure sensor return
Datalink start output relay driver (future expansion)
Battery (24 VDC) Positive
Fuel actuator return
Coolant temperature sensor signal
Coolant temperature sensor signal
Coolant level sensor signal
Intake Air temperature sensor signal
Engine speed sensor signal
Intake Air temperature sensor signal
Battery charging failure signal

Connector-B
Sr. No.

Letter

1
2
3
4
5
6
7
8
9
10

A
B
C
D
E
F
G
H
I
J

Description
Battery (24 VDC) Negative
Speed raise / Alternate Frequency
Speed lower
Remote Start
High intake air / Engine overspeed alarm relay driver
Low lube oil pressure alarm relay driver
High coolant temperature alarm relay driver
Customer selectable output
Speed bias signal
Remote stop

Data Link Connector (9 pin)


Sr. No.

Letter

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9

Description
Data link positive
Data link negative
Not connected
Not connected
Not connected
Not connected
Not connected
Not connected
Not connected

Connector - C (Future use)


Sr. No.

Letter

1
2
3
4
5
6
7

A
B
C
D
E
F
G

Description
Electrical STC valve return
Not connected
Not connected
Fuel rail pressure sensor signal (output)
Fuel rail pressure sensor supply
Fuel rail pressure sensor return
Electrical STC valve output

1-9

1-10

ECPG Hardwired Interconnections


Data Link
Connector
Service Tool
Interface
Connector A
Engine Sensors

Speed
Coolant Temperature
Intake Air Temperature
Lube Oil Pressure
Coolant Level
FSO valve
ECPG Power & Ground
Fuel Actuator
Starter magnetic S/W

Connector C
Future Scope

ECPG Rear Vie


w
View

ECPG Fr
ont Vie
w
Front
View

Remote Start
Remote Stop
Speed bias
Switch Input
Raise
Lower
Alternate frequency
Lamp / Relay Driver
Low lube oil pressure alarm
Coolant Temperature Alarm
Air intake temperature/
Over Speed Alarm
Customer O/P

OFF / RUN /
START
Mode

Idle / Rated
mode

Single
Parameter /
All parameters
Scan mode

Operation & Maintenance Manual for ECPG

Connector B

Operation & Maintenance Manual for ECPG

2-1

SECTION 2
ECPG DET
AILS
DETAILS
Page
ECPG Dimensions ................................................................................................................................................ 2-2
ECPG Electronic Interfaces .................................................................................................................................. 2-3
ECPG Features .................................................................................................................................................... 2-4
Power Down Mode ........................................................................................................................................
Key Switch and Starter Protection ................................................................................................................
Over Cranking Prevention .............................................................................................................................
Parameter Selection Push Button .................................................................................................................
Idle / Rated Mode Selection .........................................................................................................................
Engine Running Hours ..................................................................................................................................
FSO Supply / Fuel Actuator Command .........................................................................................................
Alarm Relay Drivers .....................................................................................................................................
Remote Start ................................................................................................................................................
Remote Stop ................................................................................................................................................
Battery Voltage ............................................................................................................................................
Battery Charging Indication ...........................................................................................................................

2-4
2-4
2-5
2-5
2-6
2-6
2-6
2-6
2-7
2-7
2-7
2-7

2-2

Operation & Maintenance Manual for ECPG

ECPG DIMENSIONS (PART DESCRIPTION)

7
263.9

6
5
313.9

3875362

4071721

4084285

504975
4

4084219
3

4084218

4083975

REF. NO.

97.3

21

1
PLATE,COOLER

SWITCH,PUSH BUTTON

SWITCH,TOGGLE

SWITCH, IGNITION

PANEL BACK

1
PANEL DISPLAY

SEAL,FRONT COVER

ITEM DESCRIPTION
ITEM NO.

QTY.

The ECPG measures 314 x 264 x 118 mm including the heat-sink. Refer to the section Installation for details and cautions
before selecting a location for mounting the ECPG.

Operation & Maintenance Manual for ECPG

2-3

ECPG ELECTRONIC INTERFACES

(OEM Scope of
Supply)

2-4

Operation & Maintenance Manual for ECPG

ECPG FEA
TURES
FEATURES
a. Power do
wn mode
down
Unswitched 24 VDC volts is connected to the ECPG
through Connector A.
When the key switch is turned to Run position :
-

ECPG wakes up from sleep mode and executes


hardware check where the LEDs and Displays are
checked. ECPG then enters into all parameters scan
mode and is ready to start the engine.

When the key switch is turned to OFF position/key S/W


is in run position and engine is not running.
-

ECPG will not turn off immediately but the power


down mode will be enabled. ECPG will turn Off after
the set power down time, thus minimising the battery
drain during engine off condition.



Power down mode can be disabled temporarily using


the service tool as per the attached illustration.

b. Key switch and starter protection


The key switch on the front panel is used to turn on or off
the 24 volts DC battery supply to the ECPG. The key
switch is a three-position switch which controls the three
modes as off, run, start.
i)

OFF

Off mode :
The key switch in off mode disconnects the
supply to the FSOV and fuel actuator, resulting
in engine shut down. It also transits the ECPG
to power down mode.

ii)

Run mode :
When the key switch is turned to Run position,
the controller wakes up. Carries out self check
and is ready to start the engine.
RUN

iii) Start mode :


Turn and hold the key switch to Start position,
for controller to energize the starter magnetic
switch.
A built in software mechanism disengages the
supply to the starter magnetic switch after six
seconds and prevents the starter from damage.
The controller also ramps up the engine speed
from crank to idle/rated mode in a predetermined
time period.
Note : For Amf application, key switch should always
be in R
UN position to star
RUN
startt the engine
through remove start input.

START

Operation & Maintenance Manual for ECPG

2-5

c. Over cranking prevention


Starter disengage speed

> 300 RPM

Engine Speed

300

Starter
solenoid condition

Fail
to
start
/
crank
6 sec.
ON

6 sec.
ON

ON
6 sec.
OFF

6 sec.
OFF

Crank
Speed

When the key switch is held in Start position, the starter


magnetic switch will turn on, causing the starter to engage
to the flywheel ring gear teeth and rotate the engine. As
the engine picks up speed, the starter magnetic switch
is de-activated by the ECPG automatically.
This disengages the starter from the flywheel ring gear,
preventing the starter from Over cranking.
As long as the engine is running, taking the key switch
to Start position will not activate the starter key switch.
This prevents starter damage that can be caused by an
attempt to engage the starter with flywheel ring gear when
an engine is already running.

OFF

TIME (seconds)

There is a built in timer mechanism which prevents starter


damage due to over cranking. After six seconds from the
instant the key switch is turned to Start position, the
starter magnetic switch will automatically de activate and
remain de activated for six more seconds even if the key
is in start position.



The starter protection is based on engine speed and not


on lubricating oil pressure.
Releasing the key switch from Start position will reset
the starter engage/disengage time.
OFF

d. Scan push button


The scan push button is used to select the following
display scan modes :
(a) Single parameter scan mode
(b) All parameters scan mode.


The parameter selection switch acts as a toggle to select


these two modes. These two modes are toggled by
momentarily pressing and releasing the parameter scan
push button.
PARAMETER
SELECTION

All
parameters
scanned
sequentially



In all parameters scan mode, all the parameters are


scanned sequentially and the corresponding green LED
for the parameter on the left hand column, glows and the
value of the parameter is displayed on the 7-segment
digital display. The value of the parameter is displayed
for two seconds after which the next parameter is
scanned.
The user can toggle to the Single Scan Mode from the
All Parameters Scan mode by momentarily pressing and
releasing the scan push button.

Toggle
between
Single scan /
all parameters
scan mode.

The value of the selected parameter is displayed


continuously on the 7-segment digital display.

2-6

Operation & Maintenance Manual for ECPG

e. Idle / Rated Mode Selection


The idle / rated switch is used to select the base running
speed of the engine. When the idle / rated switch is in
Idle Position, Idle speed is selected. Whereas Rated
speed is selected if the switch is in Rated Position.
For e.g.
Idle speed
= 1100 rpm (Idle position)
Rated speed = 1500 rpm (Rated position)
Note : For AMF application, Idle/Rated switch should
al
wa
ys be in RA
TED position so that on
alwa
ways
RATED
Remote Start, engine goes to rated speed.
f.

Engine Running Hours

The hour meter shows the number of hours for which the
engine has been running at Rated Speed.


The reading is refreshed after every hour on the display.

g. FSO supply / Fuel actuator command


The percentage duty cycle of the actuator PWM command
is indicated on the front display. This fuel actuator
command is proportional to the current flowing through
the actuator.

RUN

The supply to the fuel shut off valve is turned on the


moment the key switch is set to Run position, and
remains ON continuously till the engine trips because of
a fault condition or the user stops the engine manually or
the controller receives a Remote Stop command.



RUN

h. Alarm Relay Drivers


Relays are connected between point E or F or G or H and
point A of the OEM harness for alarm indication.
Use suitable relays as shown in OEM connector wiring
diagram OR use suitable interface circuits to make use
of the alarm relay driver outputs..
Refer Section 8-2 for specification of relays to be used.

HCT ALARM
G

LLOP ALARM
OS/HIGH IMT ALARM
CUSTOMER
SELECTION
OUTPUT
OEM INTERFACE PANEL

H
I

A
B

A1;

J
E

OEM CONNECTOR "B


ON CONTROLLER

Operation & Maintenance Manual for ECPG

OEM "B" CONNECTOR

J
C

F
D

Remote start

Note that the Starter magnetic switches (2 Nos. in case


of KV engines) draw current from this 24 V source. The
cables and the contact must therefore be appropriately
rated. Recommend 10 amps capability. It also includes
starter protection and over cranking preventation.

PIN D

N/O
CONTACT

i.

Applying +24 volts DC (with respect to engine battery


negative) through an external contact at Pin D of the
Connector B, would start the engine with this remote start
command. +24 volts DC should be applied continuously
at this input till engine starts.

2-7

+ 24 V D C (+24)

Note : Use potential free contact for this input.


j.
OEM "B" CONNECTOR

H
I

Note : Applying +24 volts DC to Remote Start and


Remote Stop inputs at the same time shall not start
the engine.

J
C

F
E

On applying 24 volts DC is externally applied to pin J of


the Connector B, the supply to the fuel shut off valve is
removed and fuel actuator is closed the engine is shut
down remotely.

+ 24 V DC

Remote stop

PIN J
N/O
CONTACT

Note : Use potential free contact for this input.


CAUTION
Do not connect +24V from battery to pin A (ground)
of OEM connector
connector..
k. Battery voltage
 "

A 24V battery is connected to power up the ECPG. This


battery voltage is measured and displayed on the digital
display.

Battery
Voltage

l.



Battery
Charging
failure

Battery Charging Indication

With no charging current flowing to the battery from the


charging alternator, the charging failure LED glows . Hence
this LED glows when the engine is not running.
As the engine starts running and the charging alternator
starts supplying charging current to the batteries, the
LED turns OFF.
If this LED glows when the engine is running, it indicates
that the charging alternator is not generating voltage.

2-8

Operation & Maintenance Manual for ECPG

NOTES
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

Operation & Maintenance Manual for ECPG

3-1

SECTION 3
ENGINE STARTUP AND ADJUSTMENTS
Page
Engine Startup and Adjustments ........................................................................................................................... 3-2
Governor Gain Adjust ................................................................................................................................... 3-2
Droop Adjust ................................................................................................................................................ 3-2
Isochronous Mode ........................................................................................................................................ 3-3
Frequency Adjust ......................................................................................................................................... 3-3
Raise/Lower Switches .......................................................................................................................... 3-3
Speed Bias Input ................................................................................................................................. 3-3
Alternate Frequency ............................................................................................................................. 3-4

3-2

Operation & Maintenance Manual for ECPG

ENGINE STARTUP AND ADJUSTMENTS

Service Tool
Configurable
Feature

a. Governor gain adjust


The governor gain can be set by changing the value using
the PC based service tool.
Caution
Improper configuration or adjustment of governor
gain feature can cause unstable engine operation.
The customer is responsible for performing the
necessary system tests to ensure that the feature is
properly configured.

Data Link
Convertor

To ECPG

Feature = Governor
Trim
= Governor Gain Adjust

b. Droop adjust
The droop can be set by changing the value electronically
using the PC based service tool.

Service Tool
Configurable
Feature

Caution
Improper configuration or adjustment of Droop
feature can cause unstab
le engine operation. The
unstable
customer is responsible for performing the necessary
system tests to ensure that the feature is properly
configured.

Data Link
Convertor

Feature
Trim

= Reference Speed
= Droop

To ECPG

The amount of droop can be calculated using the


formula.
Droop engine gensets which are set to 50 Hz operation
at full load, need to have the engine no load governed
speed adjusted to:
51.5 Hz (1545 RPM) for 3 % Speed droop
52.5 Hz (1575 RPM) for 5 % Speed droop

(No. Load Speed - Full Load Speed)


% Droop = x 100
Full Load Speed

If the rated kW is not available, use the available kW to


get the engine speed, as computed by the formula :
3 % DROOP

Note : The default Droop is factory set to 3%.

51.50
51

FREQUENCY (Hz)

Available kW load
S = NLS x (NLS - FLS)
(Rated kW load)
Where,
S
= Speed at available load
NLS = No load speed (Same as high idle speed)
FLS = Full load speed
(Rated speed normally 1500 RPM)

50
49

0%

50 %

LOAD

100%

Operation & Maintenance Manual for ECPG

3-3

c. Isochronous mode

ISOCHRONOUS SPEED MODE

FREQUENCY (Hz)

For Isochronous speed operation, the droop setting needs


to be set at 0 %.
51

The droop setting can be adjusted using the service tool.


50
49

0%

50 %

100%

LOAD
OEM B CONNECTOR

d. Frequency Adjust
The Frequency adjust can be effected through Speed
Raise to Speed Lower Inputs, or through Speed bias
Input one of these sources can be selected through PC
Based tool settable trim.

SPEED RAISED

i)

Two switch input contacts called as Speed Raise


and Speed Lower are provided on the Connector B
to adjust the generator set frequency. The frequency
is adjusted within +/- 4 Hz of rated operating
frequency.

SPEED LOWER
(+) 24 VDC

OEM / CUSTOMER PANEL

The customer can implement the frequency adjust


feature by connecting the speed Raise / speed Lower
push buttons on the Connector B to (+) 24 Volts.

Service Tool
Configurable
Feature

The engine speed will increase or decrease at a pre


programmed rate depending upon the switch
selected. The Raise / Lower ramp rate can be
programmed through the service tool as shown in
the enclosed figure..
Data Link
Convertor

Feature
Parameter

= Reference Speed
= Speed Adjust Source

Note : Use potential free contacts for these inputs.


ii) Speed Bias input

To ECPG

Service Tool
Configurable
Feature

Feature
Parameter

Raise / Lower Switches

The speed bias input can be implemented by


connecting a 0 5 Volts analog input at pin number
I Connector B with reference to engine battery
negative.
Note : The speed bias signal and the signal return
conductors must be protected from EMI by using a
twisted, shielded cable. One end of the shield must be
connected at Pin A of Connector B at the ECP-G end
and the other end to be left open.

= Reference Speed
= Speed Adjust Ramp Rate

Data Link
Convertor

Caution

To ECPG

The Voltage input must not exceed 5 Volts DC for the


speed bias input. Improper configuration or
adjustment of speed bias input feature can cause

3-4

Operation & Maintenance Manual for ECPG

unstable engine operation. The customer is


responsible for performing the necessary system
tests to ensure that the feature is properly configured.
The Speed bias Trim feature can be enabled using the
service tool as described in the enclosed figure.

OEM "B" CONNECTOR

ANALOG OUTPUTS

(0 - 5 V D C )

J
C

F
E

e. Alternate Frequency Input (50/60 Hz)


An alternate frequency input is provided for selection
between one of the two generator set frequency settings
(50 Hz or 60 Hz).

OEM / CUSTOMER PANEL

This feature can be set through the service tool as shown


in the enclosed figure.
Note : The alternate frequency selection feature is only
enabled for engines rated for dual speed operation. For
engines rated for single speed operation, the alternate
frequency input is non operational and no service tool
related settings need to be made.
If the frequency selection using the alternate frequency
input changes for dual speed engine operation while the
engine is running, the selected frequency setting will not
take effect until the engine is shut down and restarted.
The frequency adjust feature using Speed Raise / Speed
Lower inputs is ineffective for dual speed operation.
All software calibrations in the ECP-G shipped out of the
factory have a default setting of 50 Hz ONLY operation.
Separate software calibration(s) needs to be downloaded
into the controller if the genset is to be operated @ 60 Hz
ONLY or 50 Hz / 60Hz (Dual speed operation).
Note : For the Dual speed operation (50 Hz or 60 Hz)
the Raise / lower feature(s) are disabled in the software
calibration.
Note : Alternate frequency feature can be used for
single g
enset application onl
y.
genset
only

Service Tool
Configurable
Feature

Data Link
Convertor

Feature
Parameter

= Reference Speed
= Genset Operating Mode

To ECPG

Operation & Maintenance Manual for ECPG

4-1

SECTION 4
ENGINE PROTECTION
Page
Engine Protection .................................................................................................................................................. 4-2
Fault Diagnosis ............................................................................................................................................ 4-2
Fault Codes .................................................................................................................................................. 4-2
Service Tool ................................................................................................................................................. 4-3
Alarm Relay / Lamp Drivers .......................................................................................................................... 4-4
Fault Acknowledge / Reset ........................................................................................................................... 4-4

4-2

Operation & Maintenance Manual for ECPG

ENGINE PROTECTION
The engine protection parameters shown on the right can
be configured within preset limits using the service tool.
The service tool does not allow to set the values of the
parameter beyond the minimum and maximum limits. The
service tool does not allow the setting of parameter
values beyond the minimum and maximum limits.

Engine Speed
Coolant Temperature
Lube Oil Pressure
Air Inlet Temperature
Coolant Level

a. Fault Diagnosis
There are eight red colour LEDs on the front display of
the ECPG. These LEDs light up individually when a
fault is reported active by the ECPG.

#

Fault diagnosis is displayed next to the LED which is


illuminated.

Individual
LED
glow
when
fault is
detected.

Note : Only active faults are displayed on ECPG digital


display. ECPG service tool shall be used to view all
active as well as inactive faults.
b. Fault Codes
The ECPG can record and report certain detectable
diagnostic conditions. These conditions are recorded as
fault codes. These can be used to assist in trouble
shooting engine and controller failure. Refer to the fault
code list and trouble shooting tree in the manual for further
details.

#

If fault
condition is
detected,
ECPG
Fault Code
detected
LED glows

Fault codes recorded in the ECPG can be accessed in


following way :
1) ECPG Front Panel.
When a fault is detected by the ECPG, the red LED on
the right hand side row ECPG Fault detected lights up.
The user can use the scan push button to view all the
active faults detected by the ECPG displayed in
sequence.

#

LED
glow
when a
fault
occurs.

Operation & Maintenance Manual for ECPG

4-3

Fault Code Viewing :

All
parameters
scanned
sequentially

Procedure for viewing fault code varies slightly depending


on whether user is in Single parameter or continuous
scan mode.
#

Single Parameter Mode :

Toggle
between
Single scan /
all parameters
scan mode.

Example : Consider that user is monitoring Coolant


Temperature and Green LED for Coolant temperature is
glowing with value of coolant temperature displayed on
Digital display.
If a fault occurs at this time,
1. Red LED will glow next to the fault condition.
2. RED LED will glow next to ECP fault code detected
and Fault code will be stored in ECPG memory.
3. Push the scan push button to invoke continuous scan
mode until scan reaches ECP fault code. Push and
release the scan push button, at this position to
select ECP fault code.
4. The display will show at fault codes stored in memory
sequentially.
Continuous Scan Mode :
If a fault occurs at this time,
5. Red LED will glow next to the fault condition.
6. Red LED will glow next to ECP fault code detected
and Fault code will be stored in ECPG memory.

All
parameters
scanned
sequentially

7. Wait until scan reaches ECP fault code. Push and


release the scan push button, at this position to
select ECP fault code.

#

8. The display will show all fault codes stored in memory


sequentially.
Toggle
between
Single scan /
all parameters
scan mode.

Service Tool
Configurable
Feature

When ECP fault code is selected for display, any new


fault code will be displayed, when it is registered in the
ECPG. When engine has shut down as a response to
fault, ECPG may power down in the stipulated time before
the user has viewed the fault code. In this case, fault
codes can be viewed even at next power ON the ECPG
following the above procedure.
c. Ser
vice Tool
Service
The engine protection parameters and the fault codes
are available to the user using the service tool.

Data Link
Convertor

Feature
Trim

= Reference Speed
= Droop

To ECPG

4-4

Operation & Maintenance Manual for ECPG

d. Alarm Relay / Lamp Drivers


Four (4) output drivers are provided to annunciate the
specific engine protection alarm conditions that have
occurred. Individual output of these drivers can be used
to drive either a lamp or a relay. Following relay / lamp
drivers are provided :
Engine Warning conditions :
(1) High Coolant Temperature
(2) Low Lube Oil Pressure
(3) Engine Overspeed / High Intake Air Temp.
shutdown
(4) Customer output.

HCT ALARM
G

LLOP ALARM
OS/HIGH IMT ALARM
CUSTOMER
SELECTION
OUTPUT
OEM INTERFACE PANEL

H
I

A
B

A1;

J
E

OEM CONNECTOR "B


ON CONTROLLER

Each relay / lamp driver is capable to handle a rated


maximum continuous voltage equal to Battery (+) and
80mA sink Current.
The recommended Relay for the Relay driver is O/E/N
57 DP-12-106 coil : 12 Volts / 150 ohms.
Refer to the ECPG Fault Response threshold table for
the Warning and Shutdown.
Note : Intake Air Temperature Sensor is pr
ovided ffor
or
pro
specific engine models only for these engine High
Intake Air Temp. Alarm and Engine o
ver
speed alarm
over
verspeed
are provided on a common output.
(Connector B-Pin E).
FAULT ACKNOWLEDGE

e. Fault Acknowledge / Reset


The ECPG does not have a separate fault reset switch.
All the faults which are detected active by ECPG will
be displayed on the digital display. The ECPG will not
shut off the engine for faults with a response of Warning.
It will shut off the engine for faults with response of
Shutdown.
If ECPG powers off with active faults, the fault codes
will be displayed at next ECPG startup.
If the engine trips because of a fault with a response of
Shutdown, it can be restarted immediately. If the fault
condition persists, the engine will be shutoff again.
All the active faults are stored in the ECPG non volatile
memory. They are retained permanently, in the nonvalatile memory of ECPG.

Turn key switch to


OFF position.

5-1

Operation & Maintenance Manual for ECPG

SECTION 5
ECPG - FAULT CODE INFORMATION
Page
ECPG Fault Code Information ............................................................................................................................... 5-2
ECPG Fault Response Threshold ......................................................................................................................... 5-5

5-2

Electronic Control Panel + Governor (ECPG)


Fault Code Information
Engine
Protection/
System Fault

Default
Fault Response

Fault Description

Effect (Only when fault is active)

135

System

Warning

Engine Lube Oil Pressure sensor signal is


shorted high

No engine protection for Lube Oil Pressure.


No effect on engine performance.

141

System

Warning

Engine Lube Oil Pressure sensor signal is


shorted low

No engine protection for Lube Oil Pressure.


No effect on engine performance.

143

Engine
Protection

Warning

Engine Lube Oil Pressure has dropped below the


warning threshold for Low Lube Oil Pressure

Low Lube Oil Pressure warning relay driver is


energized. No effect on engine performance.

144

System

Warning

Engine Coolant Temperature sensor signal is


shorted high

No engine protection for Coolant Temperature.


No effect on engine performance.

145

System

Warning

Engine Coolant Temperature sensor signal is


shorted low

No engine protection for Coolant Temperature.


No effect on engine performance.

146

Engine
Protection

Warning

Engine Coolant Temperature has exceed the


warning threshold for High Coolant Temperature

High Coolant Temperature warning relay driver is


energized. No effect on engine performance.

151

Engine
Protection

Shutdown

Engine Coolant temperature has exceed the


shutdown threshold for high Coolant Temperature

Engine will shutdown.

153

System

Warning

Engine Intake Air Temperature sensor signal is


Shorted high

No engine protection for Intake Air Temperature.


No effect on engine performance.

154

System

Warning

Engine Intake Air Temperature Sensor signal is


shorted low

No engine protection for Intake Air Temperature.


No effect on engine performance.

Operation & Maintenance Manual for ECPG

Fault
Code

Fault
Code

Engine
Protection/
System Fault

Default
Fault Response

Fault Description

Effect (Only when fault is active)

155

Engine
Protection

Warning

Engine Intake Air Temperature has exceed the


warning threshold for High Intake Air Temperature

High Intake Air Temperature warning relay driver


is energized. No effect on engine performance.

234

Engine
Protection

Shutdown

Engine Speed Signal indicates that engine speed


is greater than Overspeed threshold

Engine will shutdown. Fuel Shut-Off Valve


(S.D. Coil) is de-energized (valve closed).
Overspeed shutdown relay driver is energized.

235

Engine
Protection

Shutdown

Engine Coolant Level has dropped below the


shutdown threshold for Low Coolant Level.

Engine will shutdown.

359

System

Warning

Engine cranked but failed to start

No effect on engine performance

415

Engine
Protection

Shutdown

Engine Lube Oil Pressure has dropped below the


shutdown threshold for Low Oil Pressure

Engine will shutdown.

441

System

Warning

Low voltage has been detected for battery


during engine crank.

Engine may not crank. Possible loss of ECPG


functionality.

1411

System

Warning

Speed Bias Analog Input signal is shorted high

The Speed Bias Analog Input signal feature will


be disabled. Possible loss of engine
performance.

1416

System

Warning

Engine fail to shutdown

Engine failed to stop even after a stop command


was issued by the system. No engine
protection feature.

Operation & Maintenance Manual for ECPG

Electronic Control Panel + Governor (ECPG)


Fault Code Information

5-3

5-4

Electronic Control Panel + Governor (ECPG)


Fault Code Information
Engine
Protection/
System Fault

Default
Fault Response

Fault Description

Effect (Only when fault is active)

1438

System

Warning

Engine fail to crank

No effect on engine
performance.

3111

System

Warning

Speed Bias Analog Input signal is shorted low

The speed bias analog input signal feature will be


disabled. Possible loss of engine
performance.

3112

System

Warning

Speed Raise Switch is shorted high

The Speed Raised Switch feature will be disabled.


Possible loss of engine performance.

3113

System

Warning

Speed Lower switch is shorted high

The Speed Lower Switch feature will be disabled.


Possible loss of engine performance.

3115

System

Shutdown

Speed signal was lost while engine running.

Engine will shutdown.

3116

System

Warning

Fuel Actuator PWM signal is close to maximum


for long enough time due to possibly stuck
actuator or insufficient fuel supply.

Possible loss of engine performance at


higher loads.

3118

System

Warning

Powerdown hardware within ECPG malfunctioning.

1) No effect on engine performance.


2) ECPG will not powerdown. Potential
battery drain.

Operation & Maintenance Manual for ECPG

Fault
Code

Operation & Maintenance Manual for ECPG

5-5

ECPG FAULT RESPONSE THRESHOLD


Engine Parameter

Fault Response (default values)

Threshold (default values)

Engine Overspeed

Shutdown

110% of rated RPM for 1500 RPM


110% of rated RPM for 1800 RPM

Warning

90oC (194 oF)


93oC (199 oF)

Shutdown

96oC (205 oF)

High Intake Manifold Temperature


Warning

Warning

75oC (167 oF)

Low Lube Oil Pressure Warning

Warning

RPM
0
500
1100
1500

Threshold (bar)
0
0.5
1.0
2.7

Low Lube Oil Pressure Shutdown

Shutdown

RPM
0
500
1100
1500

Threshold (bar)
0
0.3
0.6
2.4

Low Coolant Level

Shutdown

Low Coolant Level

High Coolant Temperature Warning

High Coolant Temperature Shutdown

5-6

Operation & Maintenance Manual for ECPG

NOTES
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Operation & Maintenance Manual for ECPG

6-1

SECTION 6
TROUBLESHOOTING
Page
Fault Code 135 ...................................................................................................................................................... 6-2
Fault Code 141 ...................................................................................................................................................... 6-3
Fault Code 143 ...................................................................................................................................................... 6-4
Fault Code 144 ...................................................................................................................................................... 6-6
Fault Code 145 ...................................................................................................................................................... 6-7
Fault Code 146 ...................................................................................................................................................... 6-8
Fault Code 151 .................................................................................................................................................... 6-10
Fault Code 153 .................................................................................................................................................... 6-12
Fault Code 154 .................................................................................................................................................... 6-13
Fault Code 155 .................................................................................................................................................... 6-14
Fault Code 234 .................................................................................................................................................... 6-15
Fault Code 235 .................................................................................................................................................... 6-16
Fault Code 359 .................................................................................................................................................... 6-17
Fault Code 415 .................................................................................................................................................... 6-18
Fault Code 441 .................................................................................................................................................... 6-20
Fault Code 1411 .................................................................................................................................................. 6-21
Fault Code 1416 .................................................................................................................................................. 6-22
Fault Code 1438 .................................................................................................................................................. 6-23
Fault Code 3111 .................................................................................................................................................. 6-24
Fault Code 3112 .................................................................................................................................................. 6-25
Fault Code 3113 .................................................................................................................................................. 6-26
Fault Code 3115 .................................................................................................................................................. 6-27
Fault Code 3116 .................................................................................................................................................. 6-28
Fault Code 3118 .................................................................................................................................................. 6-29

6-2

Operation & Maintenance Manual for ECPG

TR
OUBLESHOO
TING
TROUBLESHOO
OUBLESHOOTING
Fault Code
135

Reason
Engine Lube Oil Pressure sensor signal is shorted high.

Cause

Lube Oil Pressure sensor


short

OK

Engine harness defective

OK

ECPG Malfunctioning

Effect (Only when fault code is


active
Warning
No engine protection for Lube Oil
Pressure. No effect on engine
performance.

Correction
Inspect the sensor for damaged,
corroded, bent, broken, expanded or
pushed back pins. If sensor pins are
found damaged, replace the sensor.
Also inspect the sensor for dirt,
debris, moisture in or on the sensor
pins.
If observed, flush the dirt, debris,
moisture from the sensor pins.
Check the lube oil pressure sensor
as per sensor specification. If it is
not as per sensor specification,
replace the sensor.
Check the sensor supply voltage
between pin G and pin J of engine
harness. If no sensor supply voltage
is observed, check the engine
harness for continuity.
Check supply voltage = 5V if the lube
oil pressure sensor signal wire
(pin H) is shorted to + 5V sensor
supply wire pin G in the engine
harness. If short is observed in the
harness, repair the wires, that have
short circuits or replace the engine
harness.
Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code
141

Reason
Engine Oil pressure sensor signal is shorted low.

Cause

Lube Oil Pressure sensor


open

OK

Engine harness defective

OK

ECPG Malfunctioning

6-3

Effect (Only when fault code is


active)
Warning
No engine protection for Lube Oil
Pressure. No effect on engine
performance.
Correction
Inspect the sensor for damaged,
corroded, bent, broken, expanded or
pushed back pins. If sensor pins are
found damaged, replace the sensor.
Also inspect the sensor for dirt,
debris, moisture in or on the sensor
pins.
If observed, flush the dirt, debris,
moisture from the sensor pins.
Check the lube oil pressure sensor
as per sensor specification. If it is
not as per sensor specification,
replace the sensor.
Check the sensor supply voltage
between pin G and pin J of engine
harness. If no sensor supply voltage
is observed, check the engine
harness for continuity.
Check supply voltage = 5V if the lube
oil pressure sensor signal wire
(pin H) is shorted to + 5V sensor
supply wire pin G in the engine
harness. If short is observed in the
harness, repair the wires, that have
short circuits or replace the engine
harness.
Replace the ECPG.

6-4

Operation & Maintenance Manual for ECPG

Fault Code

Reason
Engine Oil Pressure has dropped below the warning
threshold for low lube oil pressure.

143

Cause
Insufficient lube oil in engine

Effect (Only when fault code is


active)
Warning
Low lube oil pressure warning relay
driver is energized.
No effect on engine performance.
Correction
Check the dipstick calibration.
Check the oil level in the engine.
Add oil if level below dipstick mark.

OK

Lube Oil Pressure sensor


not at correct location on
engine

Check the mounting location of lube


oil pressure sensor on engine. Refer
to engine specification. If location is
incorrect, relocate sensor and
check operation.

OK

Lube oil diluted with fuel or


coolant

OK

Full flow lube oil filter(s)


plugged

Check for fuel or coolant


contamination in the lube oil.
If contaminated, remove the cause.
Drain all the oil in engine and fill the
fresh lube oil in the engine.

Replace lube oil filter(s).

OK

Lube oil suction tube broken


or tube seals leaking

Remove oil sump. Inspect/replace


the suction tube.

OK

Malfunction lube oil pressure


regulator in lube oil filter
head.

Remove oil sump. Inspect/replace


suction tube.

OK

Lubricating oil pump


malfunction

Inspect lubricating oil pump. repair


or replace the pump if necessary.

Operation & Maintenance Manual for ECPG

Fault Code

Reason
Engine Oil Pressure has dropped below the warning
threshold for low lube oil pressure.

143
Contd.

Cause

Lube oil pressure sensor


defective

6-5

Effect (Only when fault code is


active)
Warning
Low lube oil pressure warning relay
driver is energized.
No effect on engine performance.
Correction
Check the lube oil pressure sensor
as per sensor specification. If it is
not as per specification, replace the
sensor.

OK

Sensor getting + 5 V supply

Check the sensor supply voltage


between pin G and pin J of engine
harness. If not, check the engine
harness.

OK

Engine harness defective

OK

ECPG Malfunctioning

Check the continuity between


connector A and engine harness
(pin G, pin H or pin J). If no
continuity is observed, repair the
wires that have short circuits or
replace the engine harness.

Replace the ECPG.

6-6

Operation & Maintenance Manual for ECPG

Fault Code

Reason

144

Engine coolant temperature sensor signal is shorted high.

Cause
Coolant Temperature
sensor short

OK

Engine harness defective

OK

ECPG Malfunctioning

Effect (Only when fault code is


active
Warning
No engine protection for coolant
temperature. No effect on engine
performance.
Correction
Check the Coolant Temperature
sensor resistance as per sensor
specification. If it is not as per
sensor specification, replace the
sensor.

Check the Coolant Temperature


sensor signal wire (pin N) shorted
to + 24 V battery supply in the
engine harness. If short is observed,
repair the wires that have short
circuits, or replace the engine
harness.
Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code

Reason

145

Engine Coolant Temperature sensor signal is shorted low.

Cause
Coolant Temperature
sensor open

OK

Engine harness defective

OK

ECPG Malfunctioning

6-7

Effect (Only when fault code is


active
Warning
No engine protection for coolant
temperature. No effect on engine
performance.

Correction
Check the Coolant Temperature
sensor resistance as per sensor
specification. If it is not as per
sensor specification, replace the
sensor.

Check the Coolant Temperature


sensor signal wire (pin N) shorted
to ground in the engine harness. If
short is observed, repair the wires
that have short circuits, or replace
the engine harness.

Replace the ECPG.

6-8

Operation & Maintenance Manual for ECPG

Fault Code

Reason
Engine Coolant Temperature has exceeded the warning
threshold for high coolant temperature

146

Cause

Coolant Level low

Effect (Only when fault code is


active)
Warning
High Coolant Temperature warning
relay driver is energized. No effect
on engine performance.
Correction
Check level. Add Coolant if
necessary.

OK

Intake Air temperature too


high

Disconnect underhood air. Check


for air recirculation from radiator
entering air cleaner

OK

Radiator/Heat Exchanger
fins obstructed or damaged

Check fins for damage and debris.

OK

Pipe coupling or hose


collapsed

Check the pipe coupling or hose if


damaged.

OK

Fan shroud damaged

Inspect shroud for damage.

OK

Fan belt slipping or


viscous fan malfunction

Check fan RPM.

OK

Radiator Cap Malfunction

Check / replace radiator cap.

Operation & Maintenance Manual for ECPG

Fault Code

Reason
Engine Coolant Temperature has exceeded the warning
threshold for high coolant temperature

146
Contd.

Cause
Loss of Raw water supply
to HE

6-9

Effect (Only when fault code is


active)
Warning
High Coolant Temperature warning
relay driver is energized. No effect
on engine performance.
Correction
Check the raw water flow pressure
and see whether it is in the
specified limit.

OK

Radiator core obstructed


or damaged (internal)

Inspect radiator and clean if


necessary.

OK

Water pump malfunctioning

Check the water pump and replace


it if incase found defective.

OK

Coolant Temperature
sensor defective

Check the Coolant Temperature


sensor as per sensor specification.
If it is not as per specification,
replace the sensor.

OK

Engine harness defective

OK

ECPG Malfunctioning

Check the sensor supply voltage


(+ 12 V) between pin N and pin A
of engine harness. If not, repair the
wires that have short circuits / open
circuits or replace the engine
harness.

Replace the ECPG.

6-10

Operation & Maintenance Manual for ECPG

Fault Code

Reason

151

Engine coolant temperature has exceeded the shutdown


threshold for high coolant temperature

Cause

Coolant Level low

Effect (Only when fault code is


active)
Shutdown
Engine will shutdown

Correction
Check level. Add coolant, if
necessary.

OK

Intake Air temperature too


high

Disconnect underhood air. Check


for air recirculation from radiator
entering air cleaner

OK

Radiator/HE fins
obstructed or damaged

Check fins for damage and debris.

OK

Pipe coupling or hose


collapsed

Check the pipe coupling or hose if


damaged.

OK

Fan shroud damaged

Inspect shroud for damage.

OK

Fan belt slipping or


viscous fan malfunction

Check fan RPM.

OK

Radiator Cap Malfunction

Check /replace radiator cap.

Operation & Maintenance Manual for ECPG

Fault Code
151 Contd.

Reason
Engine coolant temperature has exceeded the shutdown
threshold for high coolant temperature

Cause
Loss of Raw water supply
to HE

6-11

Effect (Only when fault code is


active)
Shutdown
Engine will shutdown

Correction
Check the raw water flow pressure
and see whether it is in the
specified limit.

OK

Radiator core obstructed


or damaged (internal)

Inspect radiator and clean if


necessary.

OK

Water pump malfunctioning

Check the water pump and replace


it if incase found defective.

OK

Coolant Temperature
sensor defective

Check the Coolant Temperature


sensor as per sensor specification.
If it is not as per specification,
replace the sensor.

OK

Engine harness defective

OK

ECPG Malfunctioning

Check the sensor supply voltage


(+ 12 V) between pin N and pin A
of engine harness. If not, repair the
wires that have short circuits / open
circuits or replace the engine
harness.

Replace the ECPG.

6-12

Operation & Maintenance Manual for ECPG

Fault Code

Reason

153

Engine Intake air temperature sensor signal is shorted high.

Cause
Intake Air Temperature
sensor short

OK

Engine harness defective

OK

ECPG Malfunctioning

Effect (Only when fault code is


active)
Warning
No engine protection for Intake Air
Temperature. No effect on engine
performance.

Correction
Check the Intake Air Temperature
sensor resistance as per sensor
specification. If it is not as per
sensor specification, replace the
sensor.

Check if the Intake Air Temperature


sensor signal wire (pin S) is
shorted to + 24 V battery supply in
the engine harness. If short is
observed, repair the wires that have
short circuits or replace the engine
harness.

Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code

Reason

154

Engine Intake Air Temperature sensor signal is shorted low.

Cause
Intake Air Temperature
sensor open

OK

Engine harness defective

OK

ECPG Malfunctioning

6-13

Effect (Only when fault code is


active)
Warning
No engine protection for Intake Air
Temperature. No effect on engine
performance.

Correction
Check the Intake Air Temperature
sensor resistance as per sensor
specification. If it is not as per
sensor specification, replace the
sensor.

Check the Intake Air Temperature


sensor signal wire (pin S) shorted
to ground in the engine harness. If
short is observed, repair the wires
that have short circuits or replace
the engine harness.

Replace the ECPG.

6-14

Operation & Maintenance Manual for ECPG

Fault Code

Reason
Engine Intake Air Temperature has exceeded the warning
threshold for high intake air temperature.

155

Cause

Intake Air Temperature


Sensor defective.

OK

LTA Pump failure

Effect (Only when fault code is


active)
Warning
High intake air temperature
warning relay driver is energized.
No effect on engine performance.

Correction
Check the nominal resistance with
DMM (Digital multimeter) of Intake
Air temperature sensor by referring
sensor specification.
If it is not as per specification,
replace the sensor.

Check for LTA pump working. If not,


replace the pump. Also check LTA
raw water pump operation.

OK

Incorrect engine installation


or mechanical problem

OK

ECPG Malfunctioning

Check :
- CAC plumbing.
- Engine compartment
temperature
- Lack of insulation on exhaust
manifold or turbocharger.

Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code

Reason
Engine speed signal indicates that engine speed greater
than overspeed threshold.

234

Cause
Incorrect calibration

OK

Fuel Actuator stuck in open


position

6-15

Effect (Only when fault code is


active)
Shutdown
Engine will shutdown.
Overspeed shutdown relay driver is
energized.
Correction
Use proper calibration and check
engine overspeed limit is set
sufficiently higher than the rated
engine speed.

Clean or replace the fuel actuator.

OK

Fuel actuator getting +24V


battery supply continuously

OK

Check other engine related


factors referring to engine
T & R Manual

If +24 V supply is present on


actuator,
1) check the engine harness for
actuator connection shorting to
supply voltage.
If short, repair the wires that have
short circuits or replace the
engine harness.
2) If supply voltage is still present
on actuator, replace the ECPG.

Refer T & R Manual.

6-16

Operation & Maintenance Manual for ECPG

Fault Code

Reason
Engine coolant level has dropped below the shutdown
threshold for low coolant level.

235

Cause
Coolant is low

Effect (Only when fault code is


active)
Shutdown
Engine will shutdown.
Correction
Check the coolant level.
Add coolant, if necessary.

OK

Coolant level sensor faulty

OK

Engine harness defective

Inspect the coolant level sensor for


damaged, corroded, bent, broken,
expanded or pushed back pins. If
sensor pins are found damaged,
replace the sensor.
Also inspect the sensor for dirt,
debris, moisture in or on the sensor
pins.
If observed, flush the dirt, debris,
moisture from the sensor pins.

Check Pin R of engine harness


shorted to + 24 V battery supply.
If short is observed, repair the wires
or replace the engine harness.

OK

ECPG malfunctioning

Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code
359

Reason
Engine cranked but failed to start

6-17

Effect (Only when fault code is


active)
Warning
No effect on engine performance.

Cause
Fuel in the tank is low

Correction
Add fuel.

OK

Fuel filter choked

Clean or replace the fuel filters.

OK

Fuel inlet restriction


excessive

Inspect the fuel line and remove the


obstructions and clean the line.

OK
Check air in the fuel. Tighten the
fuel line connections. Tighten filter.
Check tank stand pipe

Air in fuel

OK

Fuel shut off valve not getting


the + 24 V battery supply

OK

Fuel Shut Off Valve not


operating

Check the engine harness for FSO


valve connection open or short, if
faulty, repair the wires that have
short circuits / open circuits or
replace the engine harness.
If voltage is still not preset, replace
the ECPG.
Check the resistance of FSO Valve.
If resistance as per specification,
check for mechanical operation. If
not, replace the FSO Valve.

OK

Actuator not getting supply

OK

Actuator coil open / short or


sticky

Check the engine harness for


actuator connection, short or open,
if faulty, repair the wires that have
short circuits / open circuits or
replace the engine harness.
If voltage is still not preset, replace
the ECPG.
Check the fuel actuator coil
resistance. If as per specification,
check actuator for stickiness. If
sticky, clean / replace the actuator.
If coil resistance not as per
specification, replace the actuator.

6-18

Operation & Maintenance Manual for ECPG

Fault Code

Reason

415

Engine Lube Oil Pressure has dropped below the shutdown


threshold for low oil pressure

Cause

Incorrect Oil level

Effect (Only when fault code is


active)
Shutdown
Engine will shutdown.

Correction
Check the dipstick calibration.
Check the oil level. Add oil if
necessary.

OK

Lube Oil pressure sensor


not at correct location

Check location. Refer to engine


specification. Relocate sensor, and
check operation.

OK

Lube Oil diluted in the


engine with fuel or coolant

Check for fuel or coolant


contamination in the engine oil. If
contaminated remove the cause.
Drain the oil. Fill the fresh oil.

OK

Full flow Lube Oil filter


plugged

Replace oil filter.

OK

Oil suction tube broken or


tube seals leaking.

Remove oil sump. Inspect/replace


suction tube.

OK

Malfunction Oil pressure


regulator in Oil Filter head.

Remove oil sump. Inspect/replace


suction tube.

OK

Lubricating Oil pump


malfunction

Inspect lubricating oil pump.


Replace or repair the pump if
possible.

Operation & Maintenance Manual for ECPG

Fault Code

Reason

415
Contd.

Engine Lube Oil Pressure has dropped below the shutdown


threshold for low oil pressure
Cause

Lube oil pressure sensor


defective

6-19

Effect (Only when fault code is


active)
Shutdown
Engine will shutdown.
Correction
Check the lube oil pressure sensor
as per sensor specification. If it is
not as per specification, replace the
sensor.

OK

Sensor getting + 5 V supply

Check the sensor supply voltage


between pin G and pin J of engine
harness. If not, check the engine
harness.

OK

Engine harness defective

OK

ECPG Malfunctioning

Check the continuity between


connector A and engine harness
(pin G, pin H or pin J). If no
continuity is observed, repair the
wires that have short circuits or
replace the engine harness.

Replace the ECPG.

6-20

Operation & Maintenance Manual for ECPG

Fault Code
441

Reason
Low voltage has been detected during engine crank

Cause
Battery charge low

Effect (Only when fault code is


active)
Warning
1) Engine may not crank.
2) Possible loss of ECPG
functionality.
Correction
Check electrolyte level and specific
gravity of battery cells. If low,
charge or replace the battery.

OK

Battery rating too low

Replace battery with correct rating.

OK

ECPG Malfunctioning

Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code
1411

Reason
Speed Bias Analog Input signal is shorted high.

Cause

The Speed Bias Analog Input


Signal shorted to high

OK

Source of signal delivering


Speed Bias voltage from
O.E.M. equipment stuck to
high.

6-21

Effect (Only when fault code is


active)
Warning
The Speed Bias Analog Input Signal
feature will be disabled.
Possible loss of engine performance.
Correction
Check the O.E.M. harness for short
circuit the signal wire to + 5 V or
+ 24 V battery supply.
If short is observed, repair the wires
that have short circuits or replace
the O.E.M. harness.

Isolate the ECPG. Check and


rectify the source of signal from
O.E.M. equipment.
If problem still persists, replace the
O.E.M. source of signal equipment.

OK

ECPG malfunctioning

Replace the ECPG.

6-22

Operation & Maintenance Manual for ECPG

Fault Code
1416

Reason
Engine fail to shutdown

Cause
Fuel Shut Off valve
permanently ON after
turning the key switch from
Run position to Off
position.

OK

Fuel Shut Off valve is in


manual override mode

Effect (Only when fault code is


active)
Warning
Engine failed to stop even after a
stop command was issued by the
system.
No engine protection feature.
Correction
Check engine harness for FSO
valve wire short to + 24 V battery
supply. If short is observed, repair
the wires or replace the engine
harness. If problem still persists,
replace the ECPG.

Check and be sure that the manual


override screw on fuel shutoff valve
is out to maximum travel.

OK

Fuel Shut Off valve


malfunctioning

OK

Engine fuel drain line


restricted

Check that the Fuel Shut Off valve


is turned off when 24 Volts from
ECPG is removed by turning the
key switch from Run position to
Off position.

Check restriction. Replace or


reroute engine fuel drain line.

OK

Engine injector(s)
malfunctioning or injector(s)
O-ring(s) damaged.

Please refer T & R manual of the


engine for mechanical and fuel
systems repair problems.

Operation & Maintenance Manual for ECPG

Fault Code
1438

Reason
Engine fail to crank

Cause
MPU not operative (fault
occurs even if engine cranks)

6-23

Effect (Only when fault code is


active)
Warning
No effect on engine performance.

Correction
Refer to Speed Signal Lost fault
diagnosis. See fault code 3115.

OK

Battery connections are


broken, loose or corroded

Clean and tighten the Battery


connections.

OK

Battery charge low

Check electrolyte level and specific


gravity of battery cells. If low,
charge or replace the battery.

OK

Battery rating too low

Replace battery with correct rating.

OK

Engine starting circuit


component Malfunctioning.
OK

Check whether engine drive


unit engages
OK

Engine starting Motor pinion


or ring gear on pinion
damage

Check if +24 V battery supply appears at starter magnetic switch during


start. If +24V battery supply does not appear, check for engine harness
continuity.
Check for continuity : Check the continuity between Pin E of
Connector A and starter magnetic switch connections. If no continuity
is observed, repairs the wires or replace the engine harness.
If continuity is observed, and problem still persists, replace the ECPG.
Check if the starter solenoid gets
supply voltage.
If not, change the starter magnetic
switch.
If problem still persists, check if the
starter solenoid is working properly.
Remove engine starting motor and
check for damage

OK

Hydraulic Lock in engine


cylinder

Check intake or exhaust valve


operation.

6-24

Operation & Maintenance Manual for ECPG

Fault Code

Reason
Speed Bias Analog Input signal is shorted low.

3111

Cause

The Speed Bias Analog Input


Signal shorted to ground

Effect (Only when fault code is


active)
Warning
The Speed Bias Analog Input
signal feature will be disabled.
Possible loss of engine
performance.
Correction
Check the O.E.M. harness for short
circuit the signal wire to ground.
If short is observed, repair the wires
that have short circuits or replace
the O.E.M. harness.

OK

Source of signal delivering


Speed Bias voltage from
O.E.M. equipment stuck to
low.

Isolate the ECPG. Check and


rectify the source of signal from
O.E.M. equipment.
If problem still persists, replace the
O.E.M. source of signal equipment.

OK

ECPG malfunctioning

Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code
3112

Reason
Speed Raise switch is shorted High

6-25

Effect (Only when fault code is


active)
Warning
The Speed Raise Switch feature will
be disabled.
Possible loss of engine performance.

Cause

Correction

The Speed Raise Switch on


the A.M.F. or Customer
panel shorted to high.

Check the speed raise switch on the


A.M.F. or customer panel for short.
If short is observed, repair or replace
the switch.

OK

OEM harness defective

OK

ECPG malfunctioning

Check the O.E.M. harness for


speed raise input short to +24 V
battery supply. If short circuit is
observed, repair the wires that have
short circuits or replace the O.E.M.
harness.

Replace the ECPG.

6-26

Operation & Maintenance Manual for ECPG

Fault Code
3113

Reason
Speed Lower switch is shorted high

Effect (Only when fault code is


active)
Warning
The Speed Lower Switch feature will
be disabled.
Possible loss of engine performance.

Cause

Correction

The Speed Lower Switch


on the A.M.F. or customer
panel shorted to high.

Check the speed lower switch on the


A.M.F. or customer panel for short.
If short is observed, repair or replace
the speed lower switch.

OK

O.E.M. harness defective

Check the O.E.M. harness for


speed lower input short to + 24 V
battery supply. If short circuit is
observed in the O.E.M. harness,
repair the wires that have short
circuits or replace the harness.

OK

ECPG malfunctioning

Replace the ECPG.

Operation & Maintenance Manual for ECPG

Fault Code

Reason
Speed signal was lost while engine running.

3115

Cause
Loose MPU connection

6-27

Effect (Only when fault code is


active)
Shutdown
Engine will shutdown.
Correction
Check whether MPU connector is
properly secured to the engine
harness.

OK

MPU coil resistance as per


sensor specification

OK

MPU tip damaged

Check the resistance of the MPU


coil. Refer sensors specifications, if
not within specification, replace the
MPU.

Check the tip of the MPU for


damage.
If the tip is damaged, replace the
MPU.

OK

Gap between MPU tip and


engine flywheel ring gear
teeth more than the engine
specification

Check the gap between MPU tip


and engine flywheel ring gear teeth.
If gap is more, adjust the gap as per
engine specification.

OK

Engine harness defective

Check the continuity between


Connector A (Pin B and Pin T)
and MPU connector.
If no continuity is observed repair
the wires or replace the engine
harness.
If continuity is observed and the
problem still persists, replace the
ECPG.

6-28

Operation & Maintenance Manual for ECPG

Fault Code
3116

Reason
Fuel actuator PWM signal is close to maximum for long
enough time due to possibly stuck actuator or insufficient
fuel supply.

Cause

Fuel is not available

Effect (Only when fault code is


active)
Warning
Possible loss of engine performance
at higher loads.
Correction
Check the engine fuel supply and
ensure that air lock has not
occured.

OK

Fuel filter(s) choked

Check the fuel filter(s) and clean or


replace it, if necessary.

OK

Fuel Actuator sticky

Remove the fuel actuator located on


engine fuel pump and clean it with
clean diesel (not compressed air) or
replace it, if necessary.

OK

Fuel actuator not getting


supply

Check the engine harness for short


circuits or open circuits.
For short circuits : If short or open
circuits observed between
Connector A and actuator
connector, repair the wires that have
short or open circuits or replace the
engine harness.
For open circuits : Check the
continuity between Connector A
(pin F and pin M) and the fuel
actuator connector. If no continuity
is observed, repair the wires or
replace the engine harness.
If continuity is observed, and the
problem still persists, replace the
ECPG.

Operation & Maintenance Manual for ECPG

Fault Code
3118

Reason
Powerdown hardware within ECPG malfunctioning

Cause
Powerdown hardware within
ECPG failed

6-29

Effect (Only when fault code is


active)
Warning
1) No effect on engine performance.
2) Potential battery drain.
Correction
Replace ECPG

6-30

Operation & Maintenance Manual for ECPG

NO
TES
NOTES
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Operation & Maintenance Manual for ECPG

7-1

SECTION 7
ECPG INSTALLATION
Page
Installation ............................................................................................................................................................ 7-2
Magnetic Pick up .......................................................................................................................................... 7-2
Actuator ....................................................................................................................................................... 7-3
Actuator Removal from the Housing ............................................................................................................. 7-5
Actuator Housing .......................................................................................................................................... 7-5
ECPG Controller ........................................................................................................................................... 7-6
Power Source ............................................................................................................................................... 7-7
Isolating Grounding ....................................................................................................................................... 7-7
Replacement of Parts ................................................................................................................................... 7-8
Removal of I/O Board ................................................................................................................................. 7-10
Removal of CPU Board .............................................................................................................................. 7-10

7-2

Operation & Maintenance Manual for ECPG

INSTALLATION

Note : Normally magnetic pickup, actuator housing,


actuator, engine harness, ECP-G controller are mounted
on the engine at the time of the shipment. However, the
installation procedure for these parts is given below to
aid retro fitting / replacement in field.
a. Magnetic pick up
A magnetic pickup is an electromagnetic device. It
is mounted on the flywheel housing so that the ring
gear teeth are sensed by the pickup. Two pin MS
connector is provided to connect the magnetic pick
up to the engine harness.
The magnetic pickup is connected between pin B
and T of engine connector through harness.
Installation:
1. Remove the magnetic pickup from the engine
harness if connected. Then screw the magnetic
pickup downwards till it contacts a flywheel gear tooth.
2. Unscrew the pickup by 1/2 - 3/4 of a turn to maintain
a proper gap between pickup and flywheel teeth.
Sensing distance should be between 0.71 to 1.07mm
(0.042 inch) from the flywheel gear tooth.
Screw the pickup all the way down until it contacts the
flywheel gear tooth.
The pickup will screw in very easy, do not use excessive
pressure to install the pickup.
Note : If the pickup does not screw in with finger
pressure, check the hole and the pickup threads.
Tap the hole again, if required. Refer to the
previous page for the chip removal procedure.

Back the pickup out 1/2 to 3/4 of a turn.


If you can get a feeler gauge between the magnetic pickup
and the flywheel gear tooth, back the pickup out 0.028 to
0.71 to 1.07mm (0.042 inch) from the flywheel gear tooth.

Operation & Maintenance Manual for ECPG

7-3

Tighten the locknut down on the flywheel housing.


Plug the electrical connection into the pickup, when
required.
Install the main generator, if it was removed.

When the flywheel gear teeth pass the pickup, an A.C.


voltage is induced. One cycle is induced for each gear
tooth.

If the pickup signal is less than 2.5 volts A.C. when


cranking the engine, screw the pickup in 1/8 to 1/4 turn.

b. Actuator
Two O rings are used for mounting the actuator in the
housing.
1) Part number : 3865398 Seal O Ring
2) Part number : 3042542 Seal O Ring

7-4

Operation & Maintenance Manual for ECPG

Two O rings and four Allen screws and washers are


used to clamp the housing on the fuel pump. The actuator
cable is used to connect actuator terminals to a connector
in the engine harness at connector A at pin F & pin M.

Caution
Actuator is a delicate part and should be handled with
care, while removing, cleaning or putting back in the
housing.

Installation
Lubricate the two-barrel O rings with clean engine oil.
Insert the actuator in the housing and rotate it clockwise
till it is inserted completely. Using a 1,1/4-inch spanner,
tighten the actuator, (torque of 5.6 Nm).

Connect the connector to the actuator. The connector is


keyed, so that it connects in one direction only.

Operation & Maintenance Manual for ECPG

7-5

c. Actuator removal from the housing


Actuator may be needed to be removed from the housing
for cleaning the fuel filter, replacing or for diagnostic
purpose.
Remove the actuator connector. Using the 1,1/4" spanner,
remove the actuator from the housing.
Note : Always shut off the supply to the ECPG by turning
the key switch to Off, before servicing the actuator.

Cleaning the fuel Screen


There is a 10-micron fuel screen in the inlet side of the
actuator; the filter screen should be periodically cleaned.
Pull the two smallest fuel filter windows outwards. Hold
the actuator in both the hands, with the connector pointed
outwards. Pull the two fuel filter windows which are
smallest outwards, the fuel filter screen opens. Clean
the filter screen with shop air at pressure ~1Kg/cm2
(0.980 bar). Snap the filter back into place by pushing
the filter windows together.

d. Actuator Housing
The actuator housing is mounted on the fuel pump as
per following procedure:

Retrofitting preparation:
a) Remove the copper tube/rubber hose connecting the
fuel shutoff valve to the injectors from the fuel
shutdown valve side.
b) Remove the shutdown valve with the O ring.
c) Remove the fuel pump return line along with the
elbow, if used.
d) Remove the tacho drive, if it is on the top of the
pump.
e) Plug it with an aluminum plug.
f)

Clean the top of the fuel pump. The fuel pump is


ready for mounting the actuator housing.

Note: In case of retrofitting, the fuel pump needs


recalibration along with the actuator housing, using proper
code for calibration.

Fuel Pump

7-6

Operation & Maintenance Manual for ECPG

1.

Place the actuator housing with two O rings, these


O rings act as a face seal in fuel outlet and fuel
return path respectively.

2.

Clamp the housing on the fuel pump using four Allen


screws. Torque of 5.6 Nm (50.4 in-lb) should be
given.

3. Mount fuel shutoff valve on the actuator housing as


per standard procedure.
4.

Connect the fuel pump return line on the actuator


housing.

5.

Connect the copper tubing going to injectors from


the fuel shut off valve.

e. ECPG Controller

&&&&

Normally all ECP-G controllers are engine mounted on a


bracket with the help of four vibration isolators. If it is
not so, then a suitable provision for mounting the controller
needs to the provided by the user. It can be fixed on a
bracket or on a separate stand near the alternator. The
controller should be mounted such that the front and rear
sides are accessible and convenient for any kind of
adjustment and connections. The mounting place should
be such that, the cable routing length is not more than
the length of the extension cable provided.
The mounting location should be such that the controller
is not directly exposed to Sun, heat, humidity, water,
while in operation.
Four mounting holes are provided on the ECPG to connect
it on vibration isolators.
Warning
To avoid personal injury, or death, it is important
that all electrical equipment be properly bonded or
grounded. All metallic parts that could become
energized under abnormal conditions must also be
properly bonded or grounded.

Operation & Maintenance Manual for ECPG

f.

Power Sour
ce
Source

The ECP-G is designed to operate between 20 and 30


volts D.C.

Caution
a) Do not connect the ECPG to a batter
yc
har
ger
battery
char
harg
er..
Due to the circuitry and method of operation of
the chargers, the controller will not function
pr
operl
y. Connect the batter
y c
har
ger to the
properl
operly
battery
char
harg
batter
y
.
battery
b) To disconnect the +24VDC supply to ECPG, do
not remove the 19 pin connector (Connector A) of
the harness. Disconnect the battery cables from
the battery terminals.
Caution
To a
void dama
ge to the ECPG, connect all electrical
av
damag
connections to the ECPG and remove the ECPG from
the generator set prior to using any type of welding
equipment that requires electrical power to operate.
Caution
To pre
vent loss of v
aluab
le inf
ormations suc
h as fault
prevent
valuab
aluable
informations
such
codes, power must be available to the ECPG at all
times during normal engine operation.
g.

Isolated Grounding

When using a grounding method other than negative


ground system, where electrical system ground is not
connected to battery (-ve), take into consideration the
following :
1) The load sharing / paralleling equipment interfacing
to the ECPG should have the same grounding
method and is isolated electrically.
2) Starter wiring harness, battery charging alternator
and other components like free wheeling diode must
be designed to operate properly when connected
using the grounding method being implemented.

7-7

7-8

Operation & Maintenance Manual for ECPG

h. Replacement of Parts
ed Cummins
(T
o be perf
ormed b
y authoriz
(To
performed
by
authorized
personnel only)
This section describe the procedure for removal and
installation of circuit boards and parts that are contained
in the ECPG.
Turn off or remove AC power from the battery charger
and then remove the negative (-) battery cable from the
set starting battery. This is to make sure that the set will
not start while working on it and to avoid circuit board
damage caused by voltage spikes when removing and
replacing circuit board connectors.
CAUTION
Always disconnect the battery charger from its AC
source before disconnecting the battery cables.
Otherwise, disconnecting the cables can result in
voltage spikes high enough to damage the DC control
circuits of the set.
1) Turn the key switch to off position.

OFF

2) Remove the two mating connectors in the harness


from Connector A and Connector B.

CA
UTION
CAUTION

ENGINE
HARNESS

OEM
HARNESS

No user serviceable parts inside ECPG. Do not


attempt to ope the ECPG enclosure while battery and
ECPG harness is connected to ECPG. P
otential risk
Potential
of electrical shock.
3) Remove the six Phillips head screws (M5 x 50 mm)
on the back of the plastic enclosure.

Operation & Maintenance Manual for ECPG

7-9

4) Gently pull out the rear plastic enclosure half. This


gives access to the two boards and the flat ribbon
cable.

5) The plastic enclosure houses the two printed circuit


boards,
(1) CPU Board,
(2) Input/Output (I/O) Board.

I/O board

26 pin FRC cable

CPU board

6) Remove the 26 pin FRC cable from the I/O and CPU
board by pulling out the locking wedges and gently
pulling out the flat ribbon cable. Take care not to
bend the pins.

7) Remove the 14 pin FRC cable from the I/O and CPU
board by pulling out the locking wedges and gently
pulling out the flat ribbon cable. Take care not to
bend the pins.

26 pin FRC cable

7-10

Operation & Maintenance Manual for ECPG

i.

Removal of the I/O board


a) Remove the two M8 x 1.5 hex screws connecting
the I/O board heat sink.

b) Remove the four M4 x 0.5 screws on the three


MS connectors.

c) Remove the three nuts on the three position key


switch.

j.

Removal of CPU Board


The CPU Board is attached to the front plastic
enclosure with the help of four M3 x 0.5 screws.
a) Remove the four M3 x 0.5 screws using a screw
driver.
b) Pull out the CPU Board from the plastic
enclosure.

Operation & Maintenance Manual for ECPG

8-1

SECTION 8
APPENDIX
Page
Appendix-A - Operating, Electrical & Environmental Specifications ....................................................................... 8-2
Appendix-B - Glossary of Power Terms ................................................................................................................. 8-3
Appendix-C - Electrical Wiring Diagram ................................................................................................................. 8-9
Wiring diagram for Engines with Single Starter ............................................................................................. 8-9
Wiring diagram for Engines with Two Starter ............................................................................................... 8-10
Appendix-D - ECPG Sensor Specifications ......................................................................................................... 8-11
Appendix-E - List of Replacement Parts .............................................................................................................. 8-12
Customer Literature Comments ........................................................................................................................... 8-13

8-2

Operation & Maintenance Manual for ECPG

Appendix - A
OPERATING, ELECTRICAL & ENVIRONMENTAL SPECIFICATIONS
Operation
Governor Mode .................................................................................. Isochronous to 6% Droop
Governor Gain Adjust ........................................................................ 0.9 to 1.1
Frequency Adjust Range .................................................................... 4Hz
Power
Nominal Operating Voltage ................................................................ +24VDC
Operating Voltage Range ................................................................... +20 to +32VDC
Maximum Continuous Voltage ........................................................... +32VDC
Ground Polarity ................................................................................. Negative Ground
Nominal Operating Current ................................................................. 1.5A @ +24VDC
Maximum Operating Current .............................................................. 4.5A @ +18VDC
Sleep Mode Operating Current ........................................................... 100mA (nominal)
Ready Mode Operating Current .......................................................... 850mA (nominal)
[ECPG On & Engine Not Running]
Environmental
Ambient ECPG Housing Operating Temp. ......................................... 0 to 70C (0 to158F)
Storage Temperature ......................................................................... 0 to 70C (0 to158F)
Vibration Limits ................................................................................. 20-100Hz, 93.6mm/sec:
Physical
Dimensions (Including Heat Sink; ...................................................... 314 mm (L) x 264 mm (H) x 118.3 mm (D)
excluding mounting brackets) ............................................................ (12.34 x 10.37 x 4/64)
Weight ............................................................................................... 2.53 kg (5.596 lbs.)
Housing Enclosure ............................................................................ Glass Filled Plastic
Heat Sink Metal ................................................................................. Aluminum
Protection
Reverse Polarity Protection ............................................................... +28VDC Maximum
Electrical Interface Characteristics
Lamp/Relay Driver Supply
Supply Voltage .................................................................................. +12VDC Nominal @ 80 mA
Lamp/Relay Drivers
Driver Type. ....................................................................................... Low-Side (switched GND/Open)
Driver Voltage Rating ......................................................................... +24VDC Nominal
Maximum Sink Current (Driver On) .................................................... 80mA
Analog (Adjustable) Inputs
Nominal Input Voltage Adjustment Range .......................................... 0-5VDC
Maximum Input Voltage ..................................................................... 5VDC
Speed (Frequency) Bias Reference & Voltage Supply
0-5 VDC Reference Voltage ............................................................... +5VDC

Operation & Maintenance Manual for ECPG

8-3

Appendix - B
GLOSSARY OF POWER TERMS
A.C. - See Alternating Current.
Alternating Current - Electrical current which repeatedly
varies from zero to a positive maximum value to zero to
a negative maximum value and back to zero at a periodic
rate. Since the applied voltage continually reverses
polarity, the resultant current flow alternates in direction
within the circuit.

Capacitance - The property of a device which resists


changes in voltage. In an A.C. circuit, a capacitive load
will cause the voltage to lag behind the current flow. Stated
more conventionally, the current leads the applied voltage.
A capacitive load is, therefore, a leading power factor
load (see Power Factor).

Alternating Current Leading Applied


Voltage Caused by Capacitive Load
Alternating Current = I
Applied Voltage = V
AMP An abbreviation for the term Ampere.
Ampere - The unit of measure of electrical current flow.
One ampere of current will flow when one volt of electrical
potential is applied across one ohm of resistance.
Auto-Transformer A transformer of single coil
construction in which both the primary and secondary
connections are made on the same coil but use different
taps.
Bi-State - Refers to the type of electrical device, or the
signal supplied by such a device, that has two discrete
and mutually exclusive states. For example, a twoposition toggle switch is a bi-state switching device that
is either open or closed.
B- Symbol used to designate the negative polarity of
a D.C. voltage supply.
B+ Symbol used to designate the positive polarity of
a D C voltage supply.

Capacitor ~ A device possessing the property of


capacitance. A typical capacitor consists of two
conducting surfaces separated by an insulating material.
A capacitor stores electrical energy, blocks the flow of
D.C. and permits the flow of A.C. to a degree largely
dependent on the capacitance and the frequency of the
applied A.C.
Circuit - An electrical path through which an electric
current may flow from a voltage supply to a load and
return. A closed or complete circuit is one where current
is flowing. An open circuit is where the path has been
disrupted, such as an open switch or circuit breaker, thus
stopping current flow.
Circuit Breaker - A protective device for opening a circuit
where current flow exceeds a predetermined value.
Circulating Current - Also called Cross Current. Current
which flows between paralleled generators, most apparent
with no external load on the paralleled generators.
Circulating current is caused (1) by unequal excitation of
the generators (reactive current, which may be reduced
by changing the voltage regulator adjustment or
connections); and (2) by unequal power from the engines
that are driving the generators real current (and power)
which can be eliminated by governor adjustments.
Conductor - A wire cable, bus, or other device intended
to distribute current from the supply to the load.
Technically, a conductor is any device which will permit
the flow of current.

8-4

Operation & Maintenance Manual for ECPG

Contactor - A device for opening and closing an electric


circuit. Contactors are normally used in motor circuits
where large amounts of current are controlled.
Cross Current - See Circulating Current.
Cross Current Compensation - A term, no longer
approved, for a circuit arrangement that made paralleled
generators share the reactive component of load current
in proportion to the generator ratings. The circuit
arrangement could also essentially eliminate the reactive
component of circulating current flowing between
paralleled generators See Reactive Differential (Cross
Current) Compensation and Reactive Droop
Compensation).
Current (Electrical, Symbol I) - The rate of transfer of
electricity from one point to another. Current is usually a
movement of electrons, but may also be a movement of
positive ions, negative ions, or holes. Current is usually
measured in amperes.
Cycle 00 - A complete set of events before repetition
occurs. In alternating current or voltage, a cycle starts at
zero, continues to a maximum positive value returns to
zero, continues to a maximum negative value, and is
completed at zero.

Diode - A two terminal solid-state device which permits


current to flow in one direction, but not in the other. In
alternating current circuits, a diode will permit one half
cycle to flow but will resist the flow of the opposite half
cycle of current. Thus, alternating current is converted
to direct current by a diode.

Direct Current (D.C.) - An electric current that flows in


one direction only. Conventional direct current is defined
as flowing from positive to negative in the circuit outside
the source (example: a battery or combination of diodes).
Conventional current flows in the direction of the arrow
through a diode.

Direct Current I
Applied Voltage V
Distribution Panel A control panel containing circuit
breakers, transfer switches, and other control devices
which distribute the electrical power, such as from a
generator set to the loads.
Double Pole Switch - A switch which has two sets of
contacts which operate on two independent circuits at
the same time.

Typical Alternating Current


or Voltage Cycle
D.C. - See Direct Current.
Typical Double Pole Switch Shown as a
Single Throw Type in the Off Position

Operation & Maintenance Manual for ECPG

E - Symbol used to represent electrical potential (voltage).


Earth Ground - An intentional connection made between
the earth and the metallic frame of electrical equipment
as a means to eliminate possible voltage hazards to
personnel. Earth Ground also serves, in some cases, to
reduce electrical interference in sensitive circuits such
as television and radio equipment.
EMI - An abbreviation for the term electromagnetic
interference which is sometimes caused by SCR type
devices and evident in radio and television operation.
Energy - The capability of performing work.
Frequency - The number of complete cycles of alternation
current per unit of time. Typically, frequency is expressed
in cycles per second or Hertz (Hz).
Frequency Droop - A decrease in steady state frequency
output of a generator caused by an increase in load. This
decrease in frequency from the no load frequency is
expressed as a percentage of the full load frequency or:

(FNL - FFL) X 100


%F Droop =
FFL
Where: % F Droop = Percent Frequency Droop
FNL = No Load Frequency
FFL = Full Load Frequency
Frequency droop may be used to provide governor
stability and for load sharing between paralleled generator
sets.
Frequency Meter - An instrument designed to measure
the frequency of an alternating current system.
Gain - The increase in signal power that is produced by
an amplifier, usually given as the ratio of output to input
voltage, current, or power. In generator set systems, a
low gain setting on the electric governor or voltage
regulator provides a relatively small signal to correct
variations of frequency or voltage. The frequency and/or
voltage may wander or be slow in recovering to stable
conditions after a load change. A high gain setting provides
a relatively large signal to correct variations of frequency
and/or voltage. If the gain is set too high, the electric
governor or voltage regulator may over-correct.

8-5

This may produce unacceptable hunting of the frequency


and/or voltage.
Gate - The third terminal of an SCR to which a voltage
must be applied before the SCR will conduct.
Governor - A device which controls engine speed and
thus the generator output frequency.
Ground - A connection, either accidental or intentional,
between an electrical potential and the earth or some
conducting body serving in place of the earth.
Heat Sink - A device which absorbs heat from electrical
devices such as diodes and SCRs and dissipates the
heat to the surrounding air.
Hertz - A term equivalent to cycles per second (See
Frequency).
Hunting - Oscillation in frequency or in voltage where
steady state conditions are not reached, particularly after
a load transient change.
I - Symbol used to represent current.
Impedance - The opposition to the flow of alternating
current.
Induced Voltage - The voltage which is produced by
relative motion between a wire and a magnetic field.
Inductance - The property of a device which resists
changes in current. In an A.C. circuit, an inductive load
will cause the current to lag behind the applied voltage.
Stated more conventionally, the current lags the applied
voltage. An inductive load is therefore a lagging power
factor load (see Power Factor).

Alternating Current Lagging Applied


Voltage Caused by Inductive Load

8-6

Inductor - A device possessing the property of


inductance. An inductor stores electrical energy, passes
D.C., and opposes the flow of A.C. to a degree largely
dependent on the inductance and the frequency of the
applied A.C. A typical inductor consists of a coil of wire.
In Phase - Alternating currents or voltages are in phase
with respect to each other if they cross through zero and
reach their positive and negative maximum values
together.
Insulation - A non-conductive material such as rubber
or plastic intended to prevent current from flowing.
Technically, insulation is any material which stops the
flow of current.
Isochronous - As it applies to engine governors,
maintaining constant steady state speed regardless of
the load within the rating of the engine. Thus, a generator
set is said to be isochronous if the frequency remains
the same regardless of load.
Normally Closed (Symbol N.C.) - As applied to a
magnetically operated device such as a valve or the
contacts of a relay, Normally Closed indicates that the
valve or the relay contacts are closed when no power is
supplied to the operating magnet.
Normally Open (Symbol N.O.) - As applied to a magnetically operated device such as a valve or the contacts of
a relay, Normally Open indicates that the valve or the
relay contacts are open when no power is supplied to the
operating magnet.
Ohm - The unit of measure of electrical resistance. One
ohm of resistance will allow a current of one ampere to
flow with an applied potential of one volt.
Ohmmeter - An instrument for measuring electrical
resistance.
Ohms Law - A fundamental law expressing the
relationship between voltage, current, and resistance in
electrical circuits. The law states that E = IR or voltage
is equal to current times resistance.
Open Circuit - 1) A circuit that does not provide a
complete path for the flow of current. 2.) A condition of
an electrical circuit caused by the breaking of continuity
of one or more conductors of the circuit; often an

Operation & Maintenance Manual for ECPG

undesired condition. 3) An arrangement of conductors


and equipment that depends upon lack of continuity for
operation, as open-circuit telegraphy; a circuit in which
continuity is incomplete or interrupted.
Oscillogram - The permanent record produced by an
oscillograph, or a photograph of the trace produced by
an oscilloscope.
Oscillograph - A measurement device for determining
waveform by recording the instantaneous values of a
quantity such as voltage as a function of time.
Oscilloscope - An instrument primarily for making visible
the instantaneous value of one or more rapidly varying
electrical quantities as a function of time or of another
electrical or mechanical quantity.
Oscilloscope, Dual Beam - An oscilloscope in which
the cathode-ray tube produces two separate electron
beams that may be individually or jointly controlled.
Parallel Connection - An electrical connection in which
the input of one element is connected to the input of
another element. The output connections are similarly
connected together thus providing two or more paths for
current to flow.

Parallel Connection
Parallel Operation - The method by which two or more
generators having the same voltage and frequency
characteristics are connected to a common load.
Permanent Magnet Generator - A generator which uses
permanent magnets to create a magnetic field. As applied
to Cummins Generators: a permanent magnet generator,
within the main generator, supplies the power to the
voltage regulator which in turn supplies the power to the
exciter field. The permanent magnet generator still
supplies power during a short circuit of the main generator.
This permits the main generator to sustain high short
circuit currents. The output of the permanent magnet
generator is electrically isolated from the main generator
output and is not adversely affected by main generator
output waveform distortion such as from SCR type loads.

Operation & Maintenance Manual for ECPG

PMG - See Permanent Magnet Generator.


Polarity - An electrical term which indicates the direction
in which current flows in a conductor. In a direct current
system, current flows in the same direction. In an
alternating current system, current changes direction as
the polarity of the A.C. voltage source changes.
Potential - Another term to indicate voltage.
Potential Difference - The difference in voltage between
two points in a circuit.
Power - Defined as the rate of performing work.
Mechanical power is measured in horsepower or kilowatts.
Electrical power is measured in Kilowatts.
Power Factor - The ratio of the true power (KW)
requirements of a load to the apparent power (KVA)
requirements of a load. The combined loads applied to a
power source may have a resistive, capacitive, or
inductive effect.
Resistive loads such as incandescent lighting or resistive
heating elements cause no shift in the voltage/current
wave forms and are, therefore, unity (1.0) power factor
loads.
Inductive and capacitive loads, however, cause the
voltage and current waveforms to shift with respect to
one another. These types of loads are commonly called
power factor loads (i.e., the power factor is less than
1.0).
See INDUCTANCE and CAPACITANCE for more
information.
Power factor is frequently multiplied by 100 and expressed
as a percentage.

8-7

Resistor (Symbol R) - A device or component designed


to have a definite amount of resistance. Resistors are
used in circuits to limit current flow or to provide a voltage
drop.
Resistor, Fixed - A component which is used to control
voltage and current by introducing a constant resistance
of known value into the circuit.
Resistor, Variable - Similar to a fixed resistor except
the resistance value can be adjusted. The voltage adjust
rheostat is a variable resistor.
Rheostat - A variable resistor.
Series Connection - An electrical connection in which
the input of one element is connected to the output of
another element providing only one path for current to
flow.

Series Connection
Short Circuit - An abnormal connection (including an
arc of relatively low resistance, whether made
accidentally, or intentionally, between two points of
different potential in a circuit. Equipment, not protected
by fuse or circuit breakers, may be damaged by a short
circuit.
Single Pole Switch - A switch which has only one set
of contacts.

The formula for power factor is:


True Power (KW)
Power Factor =
Apparent power (KVA)
R - Symbol used to represent resistance.
Relay - An electromechanical device having a magnetic
coil which, when energized, opens or closes several sets
of contacts.
Resistance - Opposition to the flow of current.

Typical Single Pole Switch Shown as a


Single Throw Type in the Off Position
Single Throw Switch - A switch which opens a set of
contacts in one switch position and closes the contacts
in the other position.

Typical Single Throw Switch Shown as


a Single Pole Type in the Off Position

8-8

Operation & Maintenance Manual for ECPG

Speed Droop - A decrease in steady state speed of an


engine due to an increase in applied load. This decrease
in speed from the no load speed is expressed as a
percentage of full load speed or:

(SNL - SFL) X 100


%S Droop =
SFL
Where : %SDroop = Percent Speed Droop
SFL = Full Load Speed
SNL = No Load Speed
Solenoid - An electromechanical device which when
energized, acts on a movable core or plunger in the center
of the energizing coil to perform mechanical work.
Solid-State - A term which applies to electronic devices
which are constructed using semiconductor material.
Such devices include transistors, SCRs, and diodes.
Stability - Freedom from undesired variations or
oscillation. In generator set systems, the generator set
is stable if it can maintain or quickly re-establish
steady state conditions of voltage and frequency after
a sudden load change.
Tachometer - An instrument for measuring the rate of
rotation expressed in revolutions per minute.
Temperature Drift - A change in the value of a
component caused by changes in operating temperature.
Terminal - A mechanical device for making electrical
connections.
Thyristor (SCR) - A Silicon-Controlled Rectifier is a
structure with an external connection (gate) to one of the
inter layer. With no gate current, the SCR characteristic
is that of a four-level diode.
Transformer - A device using a laminated iron core with
a primary and secondary winding. A transformer changes
some level of input (primary) voltage or current to a
proportional output (secondary) voltage or current (see
Current Transformer and Potential Transformer).
Transient - A temporary change from the steady state
conditions.
V - Symbol used to represent voltage.
Volt - The unit of measure of electrical potential (voltage).

One Volt of electrical potential will force a current of one


Ampere to flow through a resistance of one Ohm.
Voltage - Electrical potential or pressure which forces
current to flow through a circuit.
Voltage Dip - A temporary reduction in voltage generally
resulting from an increase in load.
Voltage Droop - A decrease in steady state voltage of a
generator due to an increase in load applied. This decrease
in voltage from the no load voltage is expressed as a
percentage of the full load voltage or

(VNL- VFL) X 100


%VDroop =
VFL
Where: % VDroop = Percent Voltage Droop
VNL = No Load Voltage
VFL = Full Load Voltage
Voltmeter - An instrument designed to measure electrical
potential or voltage.

LCL

+ Ve

26

33E

+ Ve

25

STARTER 45

26

EARTH WIRE

BATTERY 24 V.D.C.

- Ve + Ve

36

39E

25

LOW COOLANT
LEVEL SENSOR

35 +Ve

ALTERNATOR

- Ve

36
-Ve

GND

OUTPUT

+5V

ECPG ACTUATOR

SHUT DOWN COIL

- Ve

45

17

38
35

39E
38

17
E

MAGNETIC
SWITCH

39E

DATALINK
START

INTAKE
AIR TEMP.
SENSOR

MAG.
PICK-UP

COOLANT TEMP.
SENSOR

A1;

-Ve

CIRCUIT NO.

B,T

SHIELDED
1 SQ. MM
CABLE

P.V.C. 95 SQ. MM

1 SQ. MM
200

11
26,45

G,H,J,N,P,S,U,R

1.5 SQ. MM
4.5 SQ. MM
30

14

AMP.
CAPACITY WIRE GAUGE

25,33E,38,17

G,E,V,A,L,F,M
39E,D

19 PIN CONNECTOR

WIRING DIAGRAM FOR ENGINES WITH SINGLE STARTER

S0.C7A5L0E

WIRING DIAGRAM FOR ENGINES WITH SINGLE STARTER

1. 24 VOLT NEGATIVE GROUND SYSTEM

2. TURN THE STARTING KEY SWITCH


TO START POSITION TO CRANK
THE ENGINE.

Operation & Maintenance Manual for ECPG


8-9

APPENDIX - C

ELECTRICAL WIRING DIAGRAMS

8-10

WIRING DIAGRAM FOR ENGINES WITH TWO STARTERS


WIRING DIAGRAM FOR ENGINES WITH TWO STARTERS
D

SHUT DOWN COIL


19 PIN CONNECTOR

-Ve

A
B

ECPG ACTUATOR

G
H
J
K
L
M

35 +Ve
R

36
-Ve

P
LOW COOLANT
LEVEL SENSOR

33E

OUTPUT

DATALINK
START

+ Ve

R
A1;

AIR INTAKE
TEMP.
SENSOR

T
U

25

V
V

+5V

GND

- Ve

B
C

G
H
J
K
L
M
N
P

S0C.A7L5E0

R
S
T
U
V

COOLANT TEMP.
SENSOR

CIRCUIT NO.
26

A
36

25

38
35

45
17

STARTER

17

39E

EARTH WIRE
45
- Ve
- Ve + Ve

26

17

17
STARTER 45 39E

26
+ Ve

38

E
38

38

MAGNETIC
SWITCH

BATTERY 24 V.D.C.

AMP.
CAPACITY WIRE GAUGE

G,E,V,A,L,F,M
39E,D

14

1.5 SQ. MM

25,33E,38,17

30

4.5 SQ. MM

1. 24 VOLT NEGATIVE GROUND SYSTEM

G,H,J,N,P,S,U,R

11

26,45

200

EARTH WIRE
B,T

2. TURN THE STARTING KEY SWITCH


TO START POSITION TO CRANK
THE ENGINE.

1 SQ. MM
P.V.C. 95 SQ. MM

SHIELDED
1 SQ. MM
CABLE

Operation & Maintenance Manual for ECPG

ALTERNATOR

Operation & Maintenance Manual for ECPG

8-11

APPENDIX - D
DATALINK

ECPG CONNECT
OR
CONNECTOR

RS-485 Serial Communication Standard

Retaining capscrew torque=1 Nm [9 in-lb]

SHORT CIRCUIT TO EXTERNAL VOLTAGE


ALL CONTINUITY CHECKS

OK if < 1.5 VDC

OK (no open circuit) if < 10


ALL SHORTS TO GROUND
ESS circuits

ECPG POWER SUPPLY

20 to 32 VDC

OK (no short circuit) if > 10M

All other circuits


OK (no short circuit) if > 100k

ECPG SENSOR SPECIFICA


TIONS
SPECIFICATIONS
OIL PRESSURE SENSOR
Torque = 14 Nm [124 in-lb]

ALL TEMPERA
TURE SENSORS
TEMPERATURE
Torque = 15 Nm [133 in-lb]

Pressure
(kPa)

Pressure
[psia]

Voltage
(VDC)

Temperature
(oC)

Temperature
(oF)

Resistance
()

0
207
414
621
827

0
30
60
90
120

0.5
1.5
2.5
3.5
4.5

0
25
50
75
100

32
77
122
167
212

30k to 36k
9k to 11k
3k to 4k
1350 to 1500
600 to 675

ENGINE SPEED SENSOR


Torque = 34 to 47 Nm [25 to 35 ft-lb]
Coil Resistance = 750 to 1600

8-12

Operation & Maintenance Manual for ECPG

APPENDIX - E
LIST OF REPLACEMENT PARTS
Sr. No.

Part name

Part Number

ECP-G Assembly
1
2
3
4
5
6

ECP-G Assembly
Key switch
Parameter selection push button
Toggle switch (for Idle/Rated mode selection)
Vibration Isolator
Mounting bracket

4083935
504975
4071721
3875362
3229922
4084240

Sensors
1
2
3
4
5
6
7
8
9

Coolant temperature sensor


Air Intake temperature sensor
Lube oil pressure sensor
Coolant level sensor
Adapter for Coolant temperature sensor
Adapter for Air intake temperature sensor
Magnetic pick up
Lube Oil Pressure sensor adaptor (V 28 engine)
Lube Oil Pressure sensor adaptor
(495, 743, 855 series engines)

3865346
3408345
3408560
4072714
4084218
4084219
3879986
4104562
3814448

Actuator and Actuator housing


1
2
3
4
5

Fuel Actuator with O ring


Fuel actuator housing
Fuel actuator filter screen
Fuel actuator O rings (1)
Fuel actuator O rings (2)

3330601
4071944
3867393
3865398
3642542

Harness

1
2
3
4
5
6
7
8
9

Engine harness
KT/KTA 1150/KTA 19 G4/G3 engines
NT 495
NTA 495
NT/NTA 743
NT/NTA 855
VT/VTA 28
Extension harness 10 meters
Extension harness 5 meters
OEM harness

4084232
4085697
4085698
4085700
4085692
4085693
4072993
4072992
4054744

Operation & Maintenance Manual for ECPG

8-13

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8-14

Operation & Maintenance Manual for ECPG

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