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Operation & Maintenance Manual for Cummins ECPG Electronic Control Panel P#4083953 Full description
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TABLE OF CONTENTS
Samsung
Page
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 Ser vice Tool Software. Refer to the
Installation & Operation manual for the ECP-G Service Tool (Bulletin No. 3243816).
Preventative maintenance is the easiest and least expensive type of maintenance. Follow the
maintenance schedule recommendations outlined in Maintenance Guidelines.
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.
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
wear protective glasses and protective shoes when working.
• Do not
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 operator’s
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
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
manufacturer’s 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.
This engine incorporates the latest diesel technology; yet, it is designed to be repaired using normal repair practices
performed to quality standards.
• Cummins IndiaIndia Ltd., does not recommend or authorize any modifications or repairs to engines or
components e e xcept ffor those
those detailed
detailed in
in Cummins
Cummins Ser Ser vice Inf
Inf ormation. In In par
par ticular , un-authoriz
un-authoriz ed
repair to
to saf
saf ety-related components
components can can cause
cause per
per sonal injur
injur y. Belo
Belo w is
is a
a par
par tial listing
listing of
of components
components
classified as
as safety-related:
safety-related:
Air Compressor
Compressor Fuel Shutoff
Shutoff Assemblies
Assemblies
Cooling Fan
Fan Fuel Suppl
Suppl y T
Tubes
Fan Hub
Hub Assembly
Assembly Lifting Brackets
Brackets
Fan Mounting
Mounting Bracket(s)
Bracket(s) Throttle
Throttle Controls
Controls
Fan Mounting
Mounting Capscrews
Capscrews Turboc har g er Compressor
Compressor Casing
Casing
Fan Hub
Hub Spindle
Spindle Turboc har g er Oil
Oil Drain
Drain Line(s)
Line(s)
Flywheel Turboc har g er Oil
Oil Suppl
Suppl y Line(s)
Line(s)
Flywheel Crankshaft
Crankshaft Adapter
Adapter Turboc har g er TTurbine Casing
Casing
Flywheel Mounting
Flywheel Mounting Capscrews
Mounting Capscrews Vibration Damper
Damper Mounting
Mounting Capscrews
Capscrews
• Follow All
All Safety
Safety Instructions
Instructions Noted
Noted in
in the
the Procedures.
Procedures.
- Follow the manufacturer’s 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
A Clean
Clean Environment
Environment andand Follow
Follow the
the Cleaning
Cleaning Instructions
Instructions Specified
Specified in
in the
the Procedures
Procedures
- The engine and its components m ust be kept clean during any repair. Contamination of the engine and
components will cause premature wear.
• Perform the
the Inspections
Inspections Specified
Specified in
in the
the Procedures.
Procedures.
• Replace all
all Components
Components or Assemb lies Whic
or Assemb Whic h are
are Dama
Dama g ed or
or W
W orn Be
Be y ond the
the Specifications
Specifications
• Use Genuine
Genuine Cummins
Cummins New New or
or ReCondD
ReCondD Service
Service Parts
Parts and
and Assemblies
Assemblies
- The assembly instructions have been written to use again as many components and assemblies as
possible. When it is necessar y 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.
• Follo w The
The Specified
Specified Disassemb
Disassemb ly andand Assemb
Assemb l y Pr
Pr ocedures to
to A
A v oid Dama
Dama g e to
to the
the Components.
Components.
Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a
Cummins Authorized Repair Location.
DO’s
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.
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.
INSPECTION is required.
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.
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