ECP 4083935_o&m_ecpg

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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

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

SECTION

SECTION i -

i -

i - INTRODUCTION

i -

INTRODUCTION

Section Contents

Page Page Page Page 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 i-1 i-1 i-1 i-1 i-1

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About

About the

the

the Manual

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)

Electronic Control Panel with Governor (ECPG)Electronic Control Panel with Governor (ECPG)

Electronic Control Panel with Governor (ECPG)Electronic Control Panel with Governor (ECPG) as recommended by Cummins India Limited. This manual does notnotnotnotnot 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 notnotnotnotnot 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).

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To

To The

The

The Owner

The

Owner

Owner and

Owner

and

and Operator

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: NOTE: NOTE: NOTE:

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 i-3 i-3 i-3 i-3

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General Safety Instructions

Important Safety Notice

Important Safety Notice Important Safety Notice Important Safety Notice 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 mustmustmustmust be followed to provide personal safety. Special safety precautions are includedmust in the procedures when they apply.

• Make sure the work area surrounding the product is safe. Be aware of hazardous conditions that can exist. ••••• AlwaysAlwaysAlwaysAlwaysAlways wearwearwearwearwear protective glasses and protective shoes when working.

••••• DoDoDoDoDo notnotnotnotnot 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 NotNotNotNotNot Operate” tag in the operator’s compartment or on the controls.

• Use ONLY the proper engine barring techniques for manually rotating the crankshaft. Do notnotnotnotnot 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 notnotnotnot check for pressure leaks with your hand. High pressure oil or fuel can cause personalnot 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. AlwaysAlwaysAlwaysAlwaysAlways use a spreader bar when necessary. The lifting hooks mustmustmustmustmust notnotnotnotnot be side-loaded.

• Corrosion inhibitor contains alkali. Do notnotnotnotnot get the substance in your eyes. Avoid prolonged or repeated contact with skin. Do notnotnotnotnot 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 mustmustmustmust be used with caution. Follow themust 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,OFF,OFF,OFF,OFF, and hot fluids in lines, tubes, and compartments.

••••• AlwaysAlwaysAlwaysAlwaysAlways 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.

••••• AlwaysAlwaysAlwaysAlwaysAlways use the same fastener part number (or equivalent) when replacing fasteners. Do notnotnotnotnot use a fastener of less quality if replacements are necessary.

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General

General Repair

Repair

Repair Instructions

Instructions

This engine incorporates the latest diesel technology; yet, it is designed to be repaired using normal repair practices performed to quality standards.

••••• CumminsCummins India Ltd.,CumminsCumminsCumminsIndia Ltd.,India Ltd.,India Ltd.,India Ltd., doesdoesdoesdoes notdoesnot recommendnotnotnotrecommendrecommendrecommendrecommend ororororor authorizeauthorizeauthorize anyauthorizeauthorizeanyanyany modificationsanymodifications ormodificationsmodificationsmodificationsororor repairsorrepairs torepairsrepairsrepairstotototo enginesenginesenginesenginesengines ororororor components

components components components

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repair repair repair

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classified classified classified

classified asasasasas safety-related:safety-related:safety-related:safety-related:safety-related: Air

Air Air Air

Air CompressorCompressorCompressorCompressorCompressor Cooling

Cooling Cooling Cooling Cooling FanFanFanFanFan Fan

Fan Fan Fan

Fan HubHubHubHub AssemblyHubAssemblyAssemblyAssemblyAssembly Fan

Fan Fan Fan

Fan MountingMountingMountingMountingMounting Bracket(s)Bracket(s)Bracket(s)Bracket(s)Bracket(s) Fan

Fan Fan Fan

Fan MountingMountingMountingMountingMounting CapscrewsCapscrewsCapscrewsCapscrewsCapscrews Fan

Fan Fan Fan

Fan HubHubHubHubHub SpindleSpindleSpindleSpindleSpindle Flywheel Flywheel Flywheel Flywheel Flywheel Flywheel Flywheel Flywheel Flywheel

Flywheel CrankshaftCrankshaftCrankshaftCrankshaft AdapterCrankshaftAdapterAdapterAdapterAdapter Flywheel

Flywheel Flywheel Flywheel

Flywheel MountingMountingMountingMountingMounting CapscrewsCapscrewsCapscrewsCapscrewsCapscrews

i-5 i-5 i-5 i-5 i-5 Fuel Fuel Fuel Fuel

Fuel ShutoffShutoffShutoffShutoff AssembliesShutoffAssembliesAssembliesAssembliesAssemblies Fuel

Fuel Fuel Fuel

Fuel SupplSupplSupplSupplySupplyy TyyTTTTubesubesubesubesubes Lifting

Lifting Lifting Lifting

Lifting BracketsBracketsBracketsBracketsBrackets Throttle

Throttle Throttle Throttle

Throttle ControlsControlsControlsControlsControls T

T T T

Turbocurbocurbocurbocharurbocharharharharggggergerererer CompressorCompressorCompressorCompressorCompressor CasingCasingCasingCasingCasing T

T T T

Turbocurbocurbocurbocharurbocharharharharggggerger OilerererOilOilOilOil DrainDrainDrainDrainDrain Line(s)Line(s)Line(s)Line(s)Line(s) T

T T T

Turbocurbocurbocharurbocurbocharharharhargggggererer OilererOilOilOil SupplOilSupplSupplSupplySupplyyyy Line(s)Line(s)Line(s)Line(s)Line(s) T

T T T

Turbocurbocurbocurbocharurbocharharharhargggggerer TerererTTTTurbineurbineurbineurbineurbine CasingCasingCasingCasingCasing Vibration

Vibration Vibration Vibration

Vibration DamperDamperDamperDamperDamper MountingMountingMountingMountingMounting CapscrewsCapscrewsCapscrewsCapscrewsCapscrews ••••• FollowFollowFollowFollow AllFollowAllAllAll SafetyAllSafetySafetySafetySafety InstructionsInstructionsInstructions NotedInstructionsInstructionsNotedNotedNoted inNotedinin theininthethethe Procedures.theProcedures.Procedures.Procedures.Procedures.

- Follow the manufacturer’s recommendations for cleaning solvents and other substances used during the repair of the engine. AlwaysAlwaysAlwaysAlwaysAlways use good safety practices with tools and equipment.

••••• ProvideProvideProvideProvide AProvideAAAA CleanCleanCleanCleanClean EnvironmentEnvironment andEnvironmentEnvironmentEnvironmentandandandand FollowFollowFollowFollow theFollowthe CleaningthethetheCleaningCleaningCleaningCleaning InstructionsInstructionsInstructionsInstructions SpecifiedInstructionsSpecifiedSpecified inSpecifiedSpecifiedininin theinthethethethe ProceduresProceduresProceduresProceduresProcedures - The engine and its components mmmmmustustustustust be kept clean during any repair. Contamination of the engine and

components will cause premature wear.

••••• PerformPerformPerformPerformPerform thethethethethe InspectionsInspectionsInspectionsInspectionsInspections SpecifiedSpecified inSpecifiedSpecifiedSpecifiedinininin thethethethethe Procedures.Procedures.Procedures.Procedures.Procedures.

••••• ReplaceReplace allReplaceReplaceReplaceallallallall ComponentsComponentsComponentsComponentsComponents ororororor AssembAssembliesAssembAssembAssemblieslieslieslies WhicWhicWhicWhichWhichhh arehareareareare DamaDamaDamagDamaDamagggedgeded orededororor WorWWWWornornorn BeornornBeBeBeBeyyyyyondondondondond thethethethethe SpecificationsSpecificationsSpecificationsSpecificationsSpecifications ••••• UseUse GenuineUseUseUseGenuineGenuineGenuineGenuine CumminsCumminsCumminsCummins NewCumminsNewNewNewNew ororor ReCondDororReCondDReCondDReCondDReCondD ServiceServiceServiceServiceService PartsParts andPartsPartsPartsandandand AssembliesandAssembliesAssembliesAssembliesAssemblies

- 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.

••••• FolloFollowFolloFolloFollowwww TheThe SpecifiedTheTheTheSpecifiedSpecifiedSpecifiedSpecified DisassembDisassembDisassembDisassemblllllyDisassemby andyyyandandand AssembandAssembAssemblllllyAssembAssembyyyy PrPrPrProceduresProcedures tooceduresoceduresocedurestototo AtoAAAvAvvvoidvoidoidoidoid DamaDamaDamagDamaDamaggggeeeee toto thetototothethethethe Components.Components.Components.Components.Components. Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a Cummins Authorized Repair Location.

ECPG DO’S AND DON’TS ECPG DO’S AND DON’TSECPG DO’S AND DON’TS ECPG DO’S AND DON’TSECPG DO’S AND DON’TS DON’Ts

DON’Ts DON’Ts DON’Ts DON’Ts

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.Authorized Cummins Personnel Only.Authorized Cummins Personnel Only.Authorized Cummins Personnel Only.Authorized Cummins Personnel Only. DO’s

DO’s DO’s DO’s 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.

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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 - WARNING - WARNING - WARNING -

WARNING - Serious personal injury or extensive property damage can result if the warning instructions are not followed.

CAUTION - CAUTION - CAUTION - CAUTION -

CAUTION - Minor personal injury can result or a part, an assembly, or the engine can be damaged if the caution instructions are not not not not not followed.

Indicates a REMOVAL or DISASSEMBLY REMOVAL or DISASSEMBLY REMOVAL or DISASSEMBLY REMOVAL or DISASSEMBLY REMOVAL or DISASSEMBLY step. Indicates an INSTALLATION or ASSEMBLY INSTALLATION or ASSEMBLY INSTALLATION or ASSEMBLY INSTALLATION or ASSEMBLY INSTALLATION or ASSEMBLY step. INSPECTION INSPECTION INSPECTION INSPECTION INSPECTION is required. CLEAN CLEAN CLEAN CLEAN

CLEAN the part or assembly. PERFORM

PERFORM PERFORM PERFORM

PERFORM a mechanical or time MEASUREMENT.MEASUREMENT.MEASUREMENT.MEASUREMENT.MEASUREMENT. LUBRICATE

LUBRICATE LUBRICATE LUBRICATE

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE WRENCH or TOOL SIZE WRENCH or TOOL SIZE WRENCH or TOOL SIZE WRENCH or TOOL SIZE will be given.

TIGHTEN TIGHTEN TIGHTEN TIGHTEN

TIGHTEN to a specific torque.

PERFORM PERFORM PERFORM PERFORM

PERFORM an electrical MEASUREMENT.MEASUREMENT.MEASUREMENT.MEASUREMENT.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.

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Name Name Name Name

Name SymbolSymbolSymbolSymbolSymbol

Transfer Capacitor Fuse Circuit Breaker Jumper Wire Coil Magnetic Core Transformer Variable Reluctance Magnetic Pickup Female Contact Male Contact Name Name Name Name

Name SymbolSymbolSymbolSymbolSymbol Battery Alternator (Frequency Source) Resistor Variable 3 Terminal Resistor Device (Potentiometer) 2 Terminal Device Terminal Strip Switches : Switches : Switches : Switches : Switches : (N.O.) Normally Open (N.C.) Normally Closed Transfer Transfer 3 position Relay Contact : Relay Contact : Relay Contact : Relay Contact : Relay Contact : (N.O.) Normally Open (N.C.) Normally Closed

ELECTRICAL SYMBOLS

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Shields: Shields: Shields: Shields: Shields: Shielded Wire Shielded Pair Crossing of Conductors (wires) not Connected

Junction of Connected Conductors (wires) Grounded Grounded Grounded Grounded Grounded Chassis or Frame Connection

Conducting connection to a chassis or frame, or equivalent chassis con-nection 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.)

Earth Safety Ground

** This symbol may be used in place of symbol for direct con-ducting 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 abbrevi-ated names. i-8 i-8 i-8 i-8 i-8

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A Ampere

AC Alternating Current AMF Auto Mains Failure AMPS Amperes

AWG American Wire Gage B+ Battery Positive

o_C _{Degree Celsius}

CTS Coolant Temperature Sensor CW Clockwise

CCW Counterclockwise DC Direct Current

ECP Electronic Control Panel

ECP+G / ECPG Electronic Control Panel with Governor EMC Electro-Magnetic Compatibility EMF Electro-Motive Force

EMI Electro-Magnetic Interference EPROM Erasable Programmable Read Only

Memory

E-STOP Emergency Stop ESS Engine Speed Sensor

o_F _{Degree Fahrenheit}

FSOV Fuel Shutoff Valve ft (FT) Foot

GND Ground

GOEM G-Drive Original Equipment Manufacturer

H₂O Water

HCT High Coolant Temperature HE Heat Exchanger Hg Mercury hp Horsepower

ACR

ACRONYMS

ONYMS

ONYMS AND

ONYMS

AND

AND ABBREVIA

AND

ABBREVIA

ABBREVIATIONS

TIONS

Hz Hertz

IP53 Ingress Protection - Dust-Protected & Spraying Water

IP54 Ingress Protection - Dust-Protected & Splashing Water

In Inch

I/O Input / Output kg Kilogram kPa Kilopascal kW Kilowatt

lb Pound

LED Light-Emitting Diode LLOP Low Lube Oil Pressure mA Milli-Ampere

mW Milli-Watts mm Millimeter MPU Magnetic Pickup N-m Newton-meter

O/M Owner-Operator Manual

OEM Original Equipment Manufacturer OPS Oil Pressure Sensor

OS Over Speed PC Personal Computer P-P Peak to Peak P/N Part Number

psi Pounds Per Square Inch rpm (RPM) Revolutions Per Minute PWM Pulse Width Modulator

V Volts PT Pressure Time MS Military Standard i-9 i-9 i-9 i-9 i-9

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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:

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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 SAE grade 15 W 40

Fuel Pump Part Number ____________________

Filter Part Numbers:

• Air Cleaner Element ____________________

• Coolant (C-Series) ____________________

• Lubricating Oil ____________________

••••• Fuel ____________________

Belt Part Number (Alternator) ____________________

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Illustrations

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

The illustrations included in this manual are intended to illustrate procedures performed or location of particular items.

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.

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.

ECPG Connector ECPG Connector ECPG Connector ECPG Connector ECPG Connector ‘A’‘A’‘A’‘A’‘A’

Connector Fuel Actuator Connector Fuel Actuator Connector Fuel Actuator Connector Fuel Actuator Connector Fuel Actuator

ECPG ECPG ECPG ECPG ECPG i-12 i-12 i-12 i-12 i-12

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SECTION 1

SECTION 1 ECPG GENERAL INFORMATION

ECPG GENERAL INFORMATION

Page Page Page Page 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 ... 1-5 Harness ... 1-5 Extension Harness (Option) ... 1-5 Inputs ... 1-6 Outputs ... 1-6 Sensors ... 1-6 Magnetic Pick-up ... 1-6 Coolant Temperature Sensor ... 1-7 Intake Air Temperature Sensor ... 1-7 Lube Oil Pressure Sensor ... 1-7 Coolant Level Sensor ... 1-7 Actuator and Actuator Housing ... 1-8 Connector Details ... 1-9 Connector-A ... 1-9 Connector-B ... 1-9 Connector-C ... 1-9 Data Link Connector (9 Pin) ... 1-9 ECPG Hardwired Interconnections ... 1-10 1-1 1-11-1 1-1 1-1

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Electronic control panel with speed

governor

Description Description Description Description 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 har ness 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.

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

Theory Theory Theory

Theory ofofofof operationofoperationoperationoperationoperation

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. 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 ECPG ECPG ECPG ECPG ECPG ECPG ECPG ECPG ECPG ECPG ECPGECPG ECPG ECPG ECPG ECPG ECPG ECPG ECPG 1-2 1-2 1-2 1-2 1-2

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INTRODUCTION TO PARTS INTRODUCTION TO PARTS INTRODUCTION TO PARTS INTRODUCTION TO PARTS 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.

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.

CPU Board

I/O Board

& & & &

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Operation & Maintenance Manual for ECPG Operation & Maintenance Manual for ECPGOperation & Maintenance Manual for ECPG Operation & Maintenance Manual for ECPG Operation & Maintenance Manual for ECPG 1-4

1-4 1-4 1-4 1-4

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 :

• 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 ‘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 ECPG’s 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 485 serial communication standard. A RS-485 to RS-232 convertor (Part No. 4071717) is required for connecting the data link to a PC’s 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.

CONNECTOR-A CONNECTOR-B DATA LINK CONNECTOR CONNECTOR-C SERVICE TOOL 4073853

ECPG to data-link adapter cable, adapter side stub

4071851 PC to data-link adapter cable 4071717 Data-link Adapter 4071852 ECPG to data-link adapter cable ECPG side stub 4071935 ECPG ○ ○ ○ ○ 4105287 ECPG Service Tool

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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 1-51-51-51-51-5

ECPG front panel ECPG front panel ECPG front panel ECPG front panel ECPG front panel

The front operator interface panel comprises of the following:

(i) Four digit “7 Segment Display”, to indicate the scanned engine parameters.

(ii) A column of green LED’s on the left hand side with legends to indicate the parameter being selected for display.

(iii) A column of red LED’s 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.

ECPG Features, Power down mode. ECPG Features, Power down mode. ECPG Features, Power down mode. ECPG Features, Power down mode.

(vi) Idle / Rated Toggle switch : The engine mode is toggled between idle and rated using this switch.

Harness Harness Harness Harness 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) Extension Harness (Option) Extension Harness (Option) Extension Harness (Option) 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.

CACACACACAUTION UTION UTION UTION UTION

No attempt should be made to bypass/tap No attempt should be made to bypass/tap No attempt should be made to bypass/tap No attempt should be made to bypass/tap No attempt should be made to bypass/tap existing engine sensors, actuators or to operate existing engine sensors, actuators or to operate existing engine sensors, actuators or to operate existing engine sensors, actuators or to operate existing engine sensors, actuators or to operate the engine using 3rd party governor control the engine using 3rd party governor control the engine using 3rd party governor control the engine using 3rd party governor control the engine using 3rd party governor control systems.

systems. systems. systems. systems.

Following inputs / outputs are connected to the ECPG

8 RED LEDs 8 GREEN

LEDs

Three Position Idle/Rated Scan Push Key Switch Toggle Switch Button

& & & &

OEM HARNESS ENGINE

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by two harnesses at the rear of the ECPG. Inputs

Inputs Inputs Inputs 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 15. Raise 16. Lower Outputs Outputs Outputs Outputs Outputs

1. Fuel shut-off valve 2. Starter magnetic switch

3. High coolant temperature alarm relay driver 4. Low lube oil pressure alarm relay driver 5. High Intake air temperature alarm relay driver 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 SENSORS SENSORS SENSORS SENSORS a. Magnetic pickup a. Magnetic pickup a. Magnetic pickup a. Magnetic pickup 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.

ENGINE

ECP-G

FUEL PUMP

FUEL SHUTOFF VALVE

OEM INTERFACE SENSOR FEEDBACK

FUEL ACTUATOR

AIR INTAKE TEMPERATURE

LOP MAGNETIC PICK-UP ECPG ECPG ECPG ECPG ECPG 1-6 1-6 1-6 1-6 1-6 ,

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b. Coolant temperature sensor b. Coolant temperature sensor b. Coolant temperature sensor b. Coolant temperature sensor b. 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 c. Intake Air temperature sensor c. Intake Air temperature sensor c. Intake Air temperature sensor c. 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. d. d. d.

d. Lube oil pressure sensorLube oil pressure sensorLube oil pressure sensorLube oil pressure sensorLube 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.

e. e. e. e.

e. Coolant level sensorCoolant level sensorCoolant level sensorCoolant level sensorCoolant 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 : Note : Note : Note :

Note : The sensor locations shown in the figures areThe sensor locations shown in the figures areThe sensor locations shown in the figures areThe sensor locations shown in the figures areThe sensor locations shown in the figures are of VTA-28 engine as an example.

of VTA-28 engine as an example. of VTA-28 engine as an example. of VTA-28 engine as an example. of VTA-28 engine as an example.

COOLANT TEMPERATURE SENSOR

COOLANT LEVEL INDICATOR

LUBE OIL PRESSURE SENSOR 1-7 1-71-7 1-7 1-7 Intake Air Temperature Sensor

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f. f.f.

f.f. Actuator and actuator housingActuator and actuator housingActuator and actuator housingActuator and actuator housingActuator 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 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. Actuator Housing 1-8 1-8 1-8 1-8 1-8

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CONNECTOR DETAILS CONNECTOR DETAILS CONNECTOR DETAILS CONNECTOR DETAILS CONNECTOR DETAILS Connector-A Connector-A Connector-A Connector-A Connector-A

Sr. No. PIN Description

1 A Battery (24 VDC) Negative

2 B Engine speed sensor return

3 C Not Connected

4 D Fuel shut off valve output

5 E Starter magnetic switch output

6 F Fuel actuator output

7 G Lube oil pressure sensor supply

8 H Lube oil pressure sensor signal (output)

9 J Lube oil pressure sensor return

10 K Datalink start output relay driver (future expansion)

11 L Battery (24 VDC) Positive

12 M Fuel actuator return

13 N Coolant temperature sensor signal 14 P Coolant temperature sensor signal

15 R Coolant level sensor signal

16 S Intake Air temperature sensor signal

17 T Engine speed sensor signal

18 U Intake Air temperature sensor signal 19 V Battery charging failure signal

Connector-B Connector-B Connector-B Connector-B Connector-B

Sr. No. Letter Description

1 A Battery (24 VDC) Negative

2 B Speed raise / Alternate Frequency

3 C Speed lower

4 D Remote Start

5 E High intake air / Engine overspeed alarm relay driver 6 F Low lube oil pressure alarm relay driver

7 G High coolant temperature alarm relay driver

8 H Customer selectable output

9 I Speed bias signal

10 J Remote stop

Data Link Connector (9 pin) Data Link Connector (9 pin) Data Link Connector (9 pin) Data Link Connector (9 pin) Data Link Connector (9 pin)

1 1 Data link positive

2 2 Data link negative

3 3 Not connected 4 4 Not connected 5 5 Not connected 6 6 Not connected 7 7 Not connected 8 8 Not connected 9 9 Not connected

Connector - C (Future use) Connector - C (Future use) Connector - C (Future use) Connector - C (Future use) Connector - C (Future use)

1 A Electrical STC valve return

2 B Not connected

3 C Not connected

4 D Fuel rail pressure sensor signal (output)

5 E Fuel rail pressure sensor supply

6 F Fuel rail pressure sensor return

7 G Electrical STC valve output

1-9 1-91-9 1-9 1-9

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

1-101-101-101-101-10

ECPG Hardwired Interconnections

Connector Connector Connector Connector Connector ‘A’‘A’‘A’‘A’‘A’

Ø Engine Sensors

• Speed

• Coolant Temperature

• Intake Air Temperature

• Lube Oil Pressure

• Coolant Level

Ø FSO valve

Ø ECPG Power & Ground

Ø Fuel Actuator Ø Starter magnetic S/W Connector Connector Connector Connector Connector ‘B’‘B’‘B’‘B’‘B’ Ø Remote Start Ø Remote Stop Ø Speed bias Ø Switch Input • Raise • Lower • Alternate frequency

Ø Lamp / Relay Driver

• Low lube oil pressure alarm

• Coolant Temperature Alarm

• Air intake temperature/

Over Speed Alarm

• Customer O/P Data Link Data Link Data Link Data Link Data Link Connector Connector Connector Connector Connector Service Tool Interface Connector Connector Connector Connector Connector ‘C’‘C’‘C’‘C’‘C’ Ø Future Scope ECPG Rear ECPG Rear ECPG Rear ECPG Rear ECPG Rear VieVieVieVieViewwwww

OFF / RUN / START Mode Idle / Rated mode Single Parameter / All parameters Scan mode ECPG Fr ECPG Fr ECPG Fr ECPG Fr

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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 2-12-12-12-12-1

SECTION 2

SECTION 2 ECPG DET

ECPG DET

ECPG DETAILS

AILS

Page Page Page Page Page ECPG Dimensions ... 2-2 ECPG Electronic Interfaces ... 2-3 ECPG Features ... 2-4 Power Down Mode ... 2-4 Key Switch and Starter Protection ... 2-4 Over Cranking Prevention ... 2-5 Parameter Selection Push Button ... 2-5 Idle / Rated Mode Selection ... 2-6 Engine Running Hours ... 2-6 FSO Supply / Fuel Actuator Command ... 2-6 Alarm Relay Drivers ... 2-6 Remote Start ... 2-7 Remote Stop ... 2-7 Battery Voltage ... 2-7 Battery Charging Indication ... 2-7

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ECPG DIMENSIONS (PART DESCRIPTION) ECPG DIMENSIONS (PART DESCRIPTION)ECPG DIMENSIONS (PART DESCRIPTION) ECPG DIMENSIONS (PART DESCRIPTION)ECPG DIMENSIONS (PART DESCRIPTION)

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.

2-2 2-2 2-2 2-2 2-2 REF. NO. ITEM NO. ITEM DESCRIPTION QTY. 1 4084218 PANEL DISPLAY 1 2 4 083975 SEAL,FRONT COVER 1 3 4084219 PANEL BACK 1 4 504975 SWITCH, IGNITION 1 5 3875362 SWITCH,TOGGLE 1 6 4071721 SWITCH,PUSH BUTTON 1 7 4084285 PLATE,COOLER 1 313.9 263.9 97.3 21 7 4 5 6 2 3 1

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ECPG ELECTRONIC INTERFACES ECPG ELECTRONIC INTERFACESECPG ELECTRONIC INTERFACES ECPG ELECTRONIC INTERFACES ECPG ELECTRONIC INTERFACES

2-3 2-3 2-3 2-3 2-3

(OEM Scope of

Supply)

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ECPG FEA ECPG FEA ECPG FEA ECPG FEA ECPG FEATURESTURESTURESTURESTURES a.

a. a. a.

a. PPPPoPoower dooower dower dower dower down modewn modewn modewn modewn mode

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.

b.b.

b.b. Key switch and starter protectionKey switch and starter protectionKey switch and starter protectionKey switch and starter protectionKey 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 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.

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 : Note :Note :

Note :Note : For Amf application, key switch should alwaysFor Amf application, key switch should alwaysFor Amf application, key switch should alwaysFor Amf application, key switch should alwaysFor Amf application, key switch should always be in

be in be in

be in be in ‘R‘R‘R‘R‘RUN’UN’UN’ position to starUN’UN’ position to star position to star position to star position to start the enginet the enginet the enginet the enginet the engine through remove start input.

through remove start input.through remove start input. through remove start input.through remove start input.

RUN OFF START 2-4 2-4 2-4 2-4 2-4

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c. c. c. c.

c. Over cranking preventionOver cranking preventionOver cranking preventionOver cranking preventionOver cranking prevention

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.

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.

d. d. d. d.

d. Scan push buttonScan push buttonScan push buttonScan push buttonScan 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.

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.

The value of the selected parameter is displayed continuously on the 7-segment digital display.

TIME (seconds) 6 sec. ON 6 sec. ON ON OFF 6 sec. OFF 6 sec. solenoid condition Engine Speed Starter 300 Crank Speed OFF Starter disengage speed

Fail to start / crank > 300 RPM OFF PARAMETER SELECTION All parameters scanned sequentially

{

Toggle between Single scan / all parameters scan mode. 2-5 2-5 2-5 2-5 2-5

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e. e.e.

e.e. Idle / Rated Mode SelectionIdle / Rated Mode SelectionIdle / Rated Mode SelectionIdle / Rated Mode SelectionIdle / 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

NoteNote

NoteNote ::::: For AMF application, Idle/Rated switch shouldFor AMF application, Idle/Rated switch shouldFor AMF application, Idle/Rated switch shouldFor AMF application, Idle/Rated switch shouldFor AMF application, Idle/Rated switch should al

alal

alalwawawawaways be in ys be in ys be in ys be in ys be in ‘RA‘RA‘RA‘RA‘RATED’TED’TED’TED’TED’ position so that on position so that on position so that on position so that on position so that on Remote Start, engine goes to rated speed. Remote Start, engine goes to rated speed.Remote Start, engine goes to rated speed. Remote Start, engine goes to rated speed.Remote Start, engine goes to rated speed.

f. f.f.

f.f. Engine Running HoursEngine Running HoursEngine Running HoursEngine Running HoursEngine 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. g.g.

g.g. FSO supply / Fuel actuator commandFSO supply / Fuel actuator commandFSO supply / Fuel actuator commandFSO supply / Fuel actuator commandFSO 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.

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.

h. h.h.

h.h. Alarm Relay DriversAlarm Relay DriversAlarm Relay DriversAlarm Relay DriversAlarm 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. 2-6 2-6 2-6 2-6 2-6 RUN RUN B C D E F G H I J A HCT ALARM LLOP ALARM

OS/HIGH IMT ALARM CUSTOMER SELECTION OUTPUT A1; OEM CONNECTOR "B ON CONTROLLER OEM INTERFACE PANEL

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A B C D E F G H I J OEM "B" CONNECTOR 24 V D C (+24) " i. i. i. i.

i. Remote startRemote startRemote startRemote startRemote start

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.

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. Note : Use ‘potential free contact’ for this input. Note : Use ‘potential free contact’ for this input. Note : Use ‘potential free contact’ for this input. Note : Use ‘potential free contact’ for this input. Note : Use ‘potential free contact’ for this input. j.

j. j. j.

j. Remote stopRemote stopRemote stopRemote stopRemote stop

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.

Note : Applying +24 volts DC to Remote Start and Note : Applying +24 volts DC to Remote Start and Note : Applying +24 volts DC to Remote Start and Note : Applying +24 volts DC to Remote Start and Note : Applying +24 volts DC to Remote Start and Remote Stop inputs at the same time shall not start Remote Stop inputs at the same time shall not start Remote Stop inputs at the same time shall not start Remote Stop inputs at the same time shall not start Remote Stop inputs at the same time shall not start the engine.

the engine. the engine. the engine. the engine.

Note : Use ‘potential free contact’ for this input. Note : Use ‘potential free contact’ for this input. Note : Use ‘potential free contact’ for this input. Note : Use ‘potential free contact’ for this input. Note : Use ‘potential free contact’ for this input.

CAUTION CAUTION CAUTION CAUTION CAUTION

Do not connect ‘+24V’ from battery to pin A (ground) Do not connect ‘+24V’ from battery to pin A (ground) Do not connect ‘+24V’ from battery to pin A (ground) Do not connect ‘+24V’ from battery to pin A (ground) Do not connect ‘+24V’ from battery to pin A (ground) of OEM connector of OEM connector of OEM connector of OEM connector of OEM connector... k. k. k. k.

k. Battery voltageBattery voltageBattery voltageBattery voltageBattery voltage

A 24V battery is connected to power up the ECPG. This battery voltage is measured and displayed on the digital display.

l. l. l. l.

l. Battery Charging IndicationBattery Charging IndicationBattery Charging IndicationBattery Charging IndicationBattery 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.

A B C D E F G H I J OEM "B" CONNECTOR N/O CONTACT N/O CONTACT + 24 V DC Battery Voltage + Battery Charging failure 2-7 2-7 2-7 2-7 2-7 PIN ‘D’ PIN ‘J’

ECP 4083935_o&m_ecpg

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS

SECTION

SECTION

SECTION

SECTION

SECTION i -

i -

i -

i - INTRODUCTION

i -

INTRODUCTION

INTRODUCTION

INTRODUCTION

INTRODUCTION

Section Contents

Section Contents

Section Contents

Section Contents

Section Contents

About

About

About

About

About the

the

the

the

the Manual

Manual

Manual

Manual

Manual

To

To

To

To

To The

The

The Owner

The

The

Owner

Owner and

Owner

Owner

and

and

and Operator

and

Operator

Operator

Operator

Operator

General Safety Instructions

General Safety Instructions

General Safety Instructions

General Safety Instructions

General Safety Instructions

WARNING

WARNING

WARNING

WARNING

WARNING

General

General

General

General

General Repair

Repair

Repair

Repair

Repair Instructions

Instructions

Instructions

Instructions