ECPG INSTALLATIONECPG INSTALLATIONECPG INSTALLATION

ECPG INSTALLATION ECPG INSTALLATION ECPG INSTALLATION ECPG INSTALLATION

Page PagePage Page 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 7-1 7-17-1 7-1 7-1

Operation & Maintenance Manual for ECPG Operation & Maintenance Manual for ECPGOperation & Maintenance Manual for ECPG Operation & Maintenance Manual for ECPG Operation & Maintenance Manual for ECPG

Note : Note : Note : Note :

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.a.

a. Magnetic pick upMagnetic pick upMagnetic pick upMagnetic pick upMagnetic 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 : Note : Note : Note :

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.

INSTALLATION INSTALLATION INSTALLATION INSTALLATION INSTALLATION 7-2

7-27-2 7-2 7-2

Operation & Maintenance Manual for ECPG Operation & Maintenance Manual for ECPG Operation & Maintenance Manual for ECPG Operation & Maintenance Manual for ECPG Operation & Maintenance Manual for ECPG

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 b. Actuator b. Actuator b. Actuator 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 ¹ ²

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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 Caution Caution Caution Caution

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

Installation Installation Installation Installation 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 N•m).

Connect the connector to the actuator. The connector is

“keyed”, so that it connects in one direction only.

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c.c.

c. ActuatorActuatorActuatorActuatorActuator removalremovalremovalremovalremoval fromfromfromfrom thefromthethethethe housinghousinghousinghousinghousing

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 : Note : Note : Note :

Note : Always shut off the supply to the ECPG by turning the key switch to “Off”, before servicing the actuator.

Cleaning Cleaning Cleaning Cleaning

Cleaning thethethethethe fuelfuelfuelfuel ScreenfuelScreenScreenScreenScreen

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 d. Actuator d. Actuator d. Actuator

d. Actuator HousingHousingHousingHousingHousing

The actuator housing is mounted on the fuel pump as per following procedure:

Retrofitting Retrofitting Retrofitting Retrofitting

Retrofitting preparation:preparation:preparation:preparation: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:

Note: In case of retrofitting, the fuel pump needs recalibration along with the actuator housing, using proper code for calibration.

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Fuel Pump

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 N•m (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 e. ECPG Controller e. ECPG Controller e. ECPG Controller 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 Warning Warning Warning Warning

To avoid personal injury, or death, it is important To avoid personal injury, or death, it is important To avoid personal injury, or death, it is important To avoid personal injury, or death, it is important To avoid personal injury, or death, it is important that all electrical equipment be properly bonded or that all electrical equipment be properly bonded or that all electrical equipment be properly bonded or that all electrical equipment be properly bonded or that all electrical equipment be properly bonded or grounded. All metallic parts that could become grounded. All metallic parts that could become grounded. All metallic parts that could become grounded. All metallic parts that could become grounded. All metallic parts that could become energized under abnormal conditions must also be energized under abnormal conditions must also be energized under abnormal conditions must also be energized under abnormal conditions must also be energized under abnormal conditions must also be properly bonded or grounded.

properly bonded or grounded.

& & & &

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f.f.

f. PPPPPooooower Sourwer Sourwer Sourwer Sourwer Sourcecececece

The ECP-G is designed to operate between 20 and 30 volts D.C. Due to the circuitry and method of operation of Due to the circuitry and method of operation of Due to the circuitry and method of operation of Due to the circuitry and method of operation of Due to the circuitry and method of operation of the chargers, the controller will not function the chargers, the controller will not function the chargers, the controller will not function the chargers, the controller will not function the chargers, the controller will not function pr

prpr pr

properloperloperloperloperlyyyyy... Connect the batter Connect the batter Connect the batter Connect the batter Connect the battery cy cy cy cy charharharharharggggger to theer to theer to theer to theer to the batter

b) To disconnect the +24VDC supply to ECPG, doTo disconnect the +24VDC supply to ECPG, doTo disconnect the +24VDC supply to ECPG, doTo disconnect the +24VDC supply to ECPG, doTo disconnect the +24VDC supply to ECPG, do not remove the 19 pin connector (Connector A) of not remove the 19 pin connector (Connector A) of not remove the 19 pin connector (Connector A) of not remove the 19 pin connector (Connector A) of not remove the 19 pin connector (Connector A) of the harness. Disconnect the battery cables from the harness. Disconnect the battery cables from the harness. Disconnect the battery cables from the harness. Disconnect the battery cables from the harness. Disconnect the battery cables from the battery terminals.

the battery terminals.

Caution

To ao ao ao ao avvvvvoid damaoid damaoid damaoid damaoid damaggggge to the ECPG,e to the ECPG,e to the ECPG,e to the ECPG,e to the ECPG, connect all electrical connect all electrical connect all electrical connect all electrical connect all electrical connections to the ECPG and remove the ECPG from connections to the ECPG and remove the ECPG from connections to the ECPG and remove the ECPG from connections to the ECPG and remove the ECPG from connections to the ECPG and remove the ECPG from the generator set prior to using any type of welding the generator set prior to using any type of welding the generator set prior to using any type of welding the generator set prior to using any type of welding the generator set prior to using any type of welding equipment that requires electrical power to operate.

equipment that requires electrical power to operate.

Caution

To preo preo preo prevent loss of vo prevent loss of vvent loss of vvent loss of valuabvent loss of valuabaluabaluabaluable infle infle infle infle informations sucormations sucormations sucormations sucormations such as faulth as faulth as faulth as faulth as fault codes, power must be available to the ECPG at all codes, power must be available to the ECPG at all codes, power must be available to the ECPG at all codes, power must be available to the ECPG at all codes, power must be available to the ECPG at all times during normal engine operation.

times during normal engine operation.

g.g.

g. Isolated GroundingIsolated GroundingIsolated GroundingIsolated GroundingIsolated 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.

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h.h.

h. Replacement of PartsReplacement of PartsReplacement of PartsReplacement of PartsReplacement of Parts (T

(T(T (T

(To be perfo be perfo be perfo be perfo be performed bormed bormed bormed bormed by authorizy authorizy authorizy authorizy authorized Cumminsed Cumminsed Cumminsed Cumminsed Cummins personnel only)

personnel only) personnel only) personnel only) 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 CAUTION CAUTION CAUTION CAUTION

Always disconnect the battery charger from its AC Always disconnect the battery charger from its AC Always disconnect the battery charger from its AC Always disconnect the battery charger from its AC Always disconnect the battery charger from its AC source before disconnecting the battery cables.

source before disconnecting the battery cables.

Otherwise, disconnecting the cables can result in Otherwise, disconnecting the cables can result in Otherwise, disconnecting the cables can result in Otherwise, disconnecting the cables can result in Otherwise, disconnecting the cables can result in voltage spikes high enough to damage the DC control voltage spikes high enough to damage the DC control voltage spikes high enough to damage the DC control voltage spikes high enough to damage the DC control voltage spikes high enough to damage the DC control circuits of the set.

circuits of the set.

1) Turn the key switch to off position.

2) Remove the two mating connectors in the harness from Connector “A” and Connector “B”.

CA CACA CACAUTIONUTIONUTIONUTIONUTION

No user serviceable parts inside ECPG. Do not No user serviceable parts inside ECPG. Do notNo user serviceable parts inside ECPG. Do not No user serviceable parts inside ECPG. Do notNo user serviceable parts inside ECPG. Do not attempt to ope the ECPG enclosure while battery and attempt to ope the ECPG enclosure while battery andattempt to ope the ECPG enclosure while battery and attempt to ope the ECPG enclosure while battery andattempt to ope the ECPG enclosure while battery and ECPG harness is connected to ECPG.

ECPG harness is connected to ECPG.ECPG harness is connected to ECPG.

ECPG harness is connected to ECPG.ECPG harness is connected to ECPG. P P P P Potential riskotential riskotential riskotential riskotential risk of electrical shock.

of electrical shock.of electrical shock.

3) Remove the six Phillips head screws (M5 x 50 mm) on the back of the plastic enclosure.

OFF

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.

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.

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I/O board

26 pin FRC cable

CPU board

26 pin FRC cable

i.i.

i. Removal of the I/O boardRemoval of the I/O boardRemoval of the I/O boardRemoval of the I/O boardRemoval 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.j.

j. Removal of CPU BoardRemoval of CPU BoardRemoval of CPU BoardRemoval of CPU BoardRemoval 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.

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Operation & Maintenance Manual for ECPG Operation & Maintenance Manual for ECPG Operation & Maintenance Manual for ECPG Operation & Maintenance Manual for ECPG

Operation & Maintenance Manual for ECPG 8-18-18-18-18-1

SECTION 8 SECTION 8 SECTION 8 SECTION 8 SECTION 8

APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX

Page PagePage Page 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

In document ECP 4083935_o&m_ecpg (Page 77-88)