Ecp-4083935oampmecpg PDF

Operation & Maintenance Manual for ECPG 1
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
Operation & Maintenance Manual for ECPG i-1
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

i-2 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).
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.
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 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 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.
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
Service ormation. In par
Information. ticular
ticular,, un-authoriz
particular ed
un-authorized
repair to safety-related components can cause per
safety-related sonal injur
personal injuryy. Below is a par
Below tial listing of components
partial
classified as safety-related:
Air Compressor Fuel Shutoff Assemblies
Cooling Fan Fuel Suppl
Supplyy Tubes
Fan Hub Assembly Lifting Brackets
Fan Mounting Bracket(s) Throttle Controls
Fan Mounting Capscrews Turboc
urbocharharger Compressor Casing
harg
Fan Hub Spindle Turboc
urbocharhar
hargger Oil Drain Line(s)
Flywheel Turboc
urbocharhar
hargger Oil Suppl
Supply y Line(s)
Flywheel Crankshaft Adapter Turboc
urbocharharg
harg er Turbine Casing
Flywheel Mounting Capscrews Vibration Damper Mounting Capscrews
• Follow All Safety Instructions Noted in the 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 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
Assemblies Whichh are Dama
Damag ged or Worn Be Bey yond the Specifications
• 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
• Follo Disassemblly and Assemb
w The Specified Disassemb Assemblly Pr Procedures
ocedures to Avoid Dama Damag 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 DO’S AND 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.
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.
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.
ELECTRICAL SYMBOLS
Name Symbol Name Symbol
Battery Transfer
Alternator
(Frequency
Source)
Capacitor
Resistor
Fuse
Variable 3 Terminal
Resistor Device
(Potentiometer)
Circuit Breaker
2 Terminal
Device
Jumper Wire
Terminal Strip
Switches :
Coil
(N.O.)
Normally Open Magnetic Core
(N.C.)
Normally Closed
Transformer
Transfer
Transfer Variable Reluctance

3 position Magnetic Pickup
Relay Contact :
Female Contact
(N.O.)
Normally Open
(N.C.) Male Contact

Normally Closed
Name Symbol Name Symbol
Shields: Earth Safety Ground
Shielded Wire ** 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
Shielded Pair protective function (e.g., for
protection against electrical
shock in case of a fault).
** Ref. Electrical and Electronics
Graphic Symbols and abbrevi-
ated names.
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 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.)
ACRONYMS AND ABBREVIA

ACRONYMS TIONS
ABBREVIATIONS
A Ampere Hz Hertz
AC Alternating Current IP53 Ingress Protection - Dust-Protected &
AMF Auto Mains Failure Spraying Water
AMPS Amperes IP54 Ingress Protection - Dust-Protected &
AWG American Wire Gage Splashing Water
B+ Battery Positive In Inch
o
C 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
ESS Engine Speed Sensor OEM Original Equipment Manufacturer
o
F 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 V Volts
Hg Mercury PT Pressure Time
hp Horsepower MS Military Standard
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:
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) ____________________

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

Operation & Maintenance Manual for ECPG 1-1
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 ........................................................................................................................................ 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

1-2 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 ECPG
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.
The primary function of the ECPG is to govern the engine ECPG

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 ECPG
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.
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
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 ECPG’s to a host computer acting as a supervisor
DATA LINK
for facilitating data acquisition and logging using a PC
CONNECTOR
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 CONNECTOR-C
via the engine harness to the ECP-G. The data link uses
two wire RS-485 serial communication standard. A RS- 4105287
4073853
485 to RS-232 convertor (Part No. 4071717) is required ECPG
ECPG to data-link adapter
Service Tool
for connecting the data link to a PC’s RS-232 serial cable, adapter side stub
communication port.
The configurable features will be discussed in this manual, ○ ○ ○ ○
however, all functions of Service Tool are not covered.

4071935
Refer to the Service Tool manual (Part No. 3243816) for ECPG
4071717
more detailed information about using Service Tool. Note 4071851 Data-link Adapter
that the PC that has the Service Tool software installed PC to data-link 4071852
adapter cable ECPG to data-link
requires a separate service cable to communicate with adapter cable ECPG
side stub
the ECPG through the RS-485 service datalink connector
on the Engine Harness. SERVICE TOOL
ECPG front panel
The front operator interface panel comprises of the

following:
8 GREEN &&&& 8 RED
(i) Four digit “7 Segment Display”, to indicate the LEDs LEDs
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.
Three Position Idle/Rated Scan Push
(iv) Scan Push button: The display is toggled between Key Switch Toggle Switch Button
“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)

ENGINE OEM
The Extension Harness provides the means for mounting HARNESS HARNESS
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.
CAUTION
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

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 MAGNETIC
PICK-UP
ECP-G
2. Starter magnetic switch 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 ECPG
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.
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

Intake Air The intake air temperature sensor is used to monitor the
Temperature Sensor 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 Lube oil pressure sensor is mounted on the engine block

OIL oil gallery. A three-pin connector is provided to connect
PRESSURE
SENSOR 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. Coolant level sensor

COOLANT LEVEL
COOLANT LEVELINDICATOR
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.
f. 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 Housing
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.
CONNECTOR DETAILS
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
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)

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)

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
1-10
ECPG Hardwired Interconnections
Data Link
Connector
Service Tool
Interface
Connector ‘A’
Ø Engine Sensors
• Speed Connector ‘C’
• Coolant Temperature Ø Future Scope
• Intake Air Temperature
• Lube Oil Pressure
• Coolant Level ECPG Rear View
View
Ø FSO valve
Ø ECPG Power & Ground
Ø Fuel Actuator
Ø Starter magnetic S/W ECPG Front Vie
Front w
View
Connector ‘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/ Single
Over Speed Alarm OFF / RUN / Parameter /
• Customer O/P START Idle / Rated All parameters
Mode mode Scan mode
SECTION 2
ECPG DETAILS
DETAILS
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
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.
QTY.
1
1
1
SWITCH,PUSH BUTTON
SEAL,FRONT COVER
ITEM DESCRIPTION
SWITCH,TOGGLE
PLATE,COOLER
PANEL DISPLAY
SWITCH, IGNITION
7
PANEL BACK
21
97.3
4084285
4084218
4083975
ITEM NO.
4084219
504975
3875362
4071721
REF. NO.
2
7
4
2
3
6
1
263.9
1
3
65
313.9
4
ECPG ELECTRONIC INTERFACES
(OEM Scope of
Supply)
ECPG FEATURES
FEATURES
a. Power down 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 OFF
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.
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 START

be in ‘R UN’ position to star
‘RUN’ startt the engine
through remove start input.
c. Over cranking prevention

Starter disengage speed > 300 RPM
300
When the key switch is held in Start position, the starter
magnetic switch will turn on, causing the starter to engage
Engine Speed
to the flywheel ring gear teeth and rotate the engine. As

the engine picks up speed, the starter magnetic switch
Fail
to is de-activated by the ECPG automatically.
start Crank
/ Speed
crank This disengages the starter from the flywheel ring gear,
solenoid condition
preventing the starter from Over cranking.

6 sec. 6 sec.
ON ON ON
As long as the engine is running, taking the key switch
Starter
6 sec. 6 sec.
OFF OFF OFF to Start position will not activate the starter key switch.
This prevents starter damage that can be caused by an
TIME (seconds)
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.
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 In ‘all parameters scan’ mode, all the parameters are

SELECTION
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.
All
parameters
scanned
sequentially
{
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
The value of the selected parameter is displayed
between
Single scan /
continuously on the 7-segment digital display.
all parameters
scan mode.
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
alwa
alwa ys be in ‘RA
ways TED’ position so that on
‘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 RUN

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.
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 HCT ALARM H

diagram OR use suitable interface circuits to make use LLOP ALARM G I A
B
of the alarm relay driver outputs.. OS/HIGH IMT ALARM A1;
F J C
CUSTOMER
SELECTION D
Refer Section 8-2 for specification of relays to be used. OUTPUT
E
OEM INTERFACE PANEL OEM CONNECTOR "B

ON CONTROLLER
i. Remote start
OEM "B" CONNECTOR
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
H A
I
G B
E
J
D
C
command. +24 volts DC should be applied continuously
at this input till engine starts.
N/O PIN ‘D’ Note that the Starter magnetic switches (2 Nos. in case
CONTACT 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
+ 24 V D C (+24)
starter protection and over cranking preventation.
Note : Use ‘potential free contact’ for this input.
j. Remote stop
On applying 24 volts DC is externally applied to pin J of
OEM "B" CONNECTOR
the Connector B, the supply to the fuel shut off valve is
removed and fuel actuator is closed the engine is shut
H A
down remotely.
I
G B
+ 24 V DC F
J
C
Note : Applying +24 volts DC to Remote Start and
E D
Remote Stop inputs at the same time shall not start

PIN ‘J’ the engine.
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
battery voltage is measured and displayed on the digital
Voltage display.
l. Battery Charging Indication
With no charging current flowing to the battery from the

Battery
charging alternator, the charging failure LED glows . Hence
Charging
failure
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.
NOTES
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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
ENGINE STARTUP AND ADJUSTMENTS

Service Tool
Configurable
a. Governor gain adjust Feature
The governor gain can be set by changing the value using
the PC based service tool.
Caution
Data Link
Convertor
Improper configuration or adjustment of governor
gain feature can cause unstable engine operation.
The customer is responsible for performing the
Feature = Governor To ECPG
necessary system tests to ensure that the feature is
Trim = Governor Gain Adjust
properly configured.
b. Droop adjust
Service Tool
The droop can be set by changing the value electronically Configurable
using the PC based service tool. Feature
Caution
Improper configuration or adjustment of Droop Data Link

Convertor
feature can cause unstab
unstablele engine operation. The
customer is responsible for performing the necessary
system tests to ensure that the feature is properly To ECPG
Feature = Reference Speed
configured. Trim = Droop
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: (No. Load Speed - Full Load Speed)
% Droop = ————————————————– x 100
Full Load Speed
51.5 Hz (1545 RPM) for 3 % Speed droop
52.5 Hz (1575 RPM) for 5 % Speed droop
If the rated kW is not available, use the available kW to

get the engine speed, as computed by the formula :
3 % DROOP
Available kW load 51.50
{
S = NLS – ———————— x (NLS - FLS)
{ 51
FREQUENCY (Hz)
(Rated kW load) 50
Where,
S = Speed at available load 49
NLS = No load speed (Same as high idle speed)
FLS = Full load speed
(Rated speed normally 1500 RPM) 0% 50 % 100%
LOAD
Note : The default Droop is factory set to 3%.
c. Isochronous mode
ISOCHRONOUS SPEED MODE
For Isochronous speed operation, the droop setting needs
to be set at 0 %.
51
FREQUENCY (Hz)
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
SPEED RAISED
Raise’ to ‘Speed Lower’ Inputs, or through ‘Speed bias
Input’ one of these sources can be selected through PC
Based tool settable trim.
i) Raise / Lower Switches
SPEED LOWER Two switch input contacts called as “Speed Raise”
(+) 24 VDC
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
OEM / CUSTOMER PANEL frequency.
The customer can implement the frequency adjust
feature by connecting the speed Raise / speed Lower
Service Tool push buttons on the Connector B to (+) 24 Volts.
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
Note : Use ‘potential free contacts’ for these inputs.
Feature = Reference Speed ii) Speed Bias input

Parameter = Speed Adjust Source To ECPG
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.
Service Tool
Configurable Note : The speed bias signal and the signal return
Feature 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.
Data Link
Convertor Caution
Feature = Reference Speed The Voltage input must not exceed 5 Volts DC for the
To ECPG
Parameter = Speed Adjust Ramp Rate speed bias input. Improper configuration or
adjustment of speed bias input feature can cause
unstable engine operation. The customer is

responsible for performing the necessary system OEM "B" CONNECTOR
tests to ensure that the feature is properly configured.
The Speed bias Trim feature can be enabled using the H A

I
(0 - 5 V D C )
service tool as described in the enclosed figure. G
I
J
B
ANALOG OUTPUTS F C
E D
e. Alternate Frequency Input (50/60 Hz)

An alternate frequency input is provided for selection
between one of the two generator set frequency settings OEM / CUSTOMER PANEL
(50 Hz or 60 Hz).
This feature can be set through the service tool as shown
in the enclosed figure.
Note : The alternate frequency selection feature is only Service Tool
Configurable
enabled for engines rated for dual speed operation. For
Feature
engines rated for single speed operation, the alternate
frequency input is non operational and no service tool
related settings need to be made.
Data Link
If the frequency selection using the alternate frequency Convertor
input changes for dual speed engine operation while the

engine is running, the selected frequency setting will not
Feature = Reference Speed To ECPG
take effect until the engine is shut down and restarted.
Parameter = Genset Operating Mode
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
genset y.
only
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
ENGINE PROTECTION
The engine protection parameters shown on the right can

be configured within preset limits using the service tool. Engine Speed
The service tool does not allow to set the values of the Coolant Temperature
parameter beyond the minimum and maximum limits. The Lube Oil Pressure
service tool does not allow the setting of parameter Air Inlet Temperature
values beyond the minimum and maximum limits. Coolant Level
a. Fault Diagnosis
There are eight red colour LED’s on the front display of

the ECPG. These LED’s light up individually when a
Individual
fault is reported active by the ECPG.
Fault diagnosis is displayed next to the LED which is

illuminated.
#
} 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 # If fault
condition is
code list and trouble shooting tree in the manual for further detected,
details. 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.
Fault Code Viewing :

Procedure for viewing fault code varies slightly depending
on whether user is in Single parameter or continuous
scan mode.
parameters
scanned
{
All
sequentially
#
Single Parameter Mode :
Example : Consider that user is monitoring Coolant
Temperature and Green LED for Coolant temperature is
glowing with value of coolant temperature displayed on
Toggle
between Digital display.
Single scan /
all parameters
scan mode. 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.
7. Wait until scan reaches ECP fault code. Push and
scanned
{
All
parameters
sequentially
#
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 When ECP fault code is selected for display, any new
between
Single scan / fault code will be displayed, when it is registered in the
all parameters
scan mode. 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.
Service Tool
Configurable c. Ser vice Tool
Service
Feature
The engine protection parameters and the fault codes

are available to the user using the service tool.
Data Link
Convertor
Feature = Reference Speed To ECPG

Trim = Droop
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 HCT ALARM H
to drive either a lamp or a relay. Following relay / lamp LLOP ALARM G I A
drivers are provided : B
OS/HIGH IMT ALARM A1; C
CUSTOMER F J
Engine Warning conditions : SELECTION E D
OUTPUT
(1) High Coolant Temperature
(2) Low Lube Oil Pressure OEM INTERFACE PANEL OEM CONNECTOR "B
ON CONTROLLER
(3) Engine Overspeed / High Intake Air Temp.
shutdown
(4) Customer output.
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 provided ffor

pro or
specific engine models only for these engine High
Intake Air Temp. Alarm and Engine over
over speed alarm
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 Turn key switch to
‘OFF’ position.
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 non-
valatile memory of 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
Fault Engine Default Fault Description Effect (Only when fault is active)
Code Protection/ Fault Response
System Fault
135 System Warning Engine Lube Oil Pressure sensor signal is No engine protection for Lube Oil Pressure.
shorted high No effect on engine performance.
141 System Warning Engine Lube Oil Pressure sensor signal is No engine protection for Lube Oil Pressure.
shorted low No effect on engine performance.
143 Engine Warning Engine Lube Oil Pressure has dropped below the Low Lube Oil Pressure warning relay driver is
Protection warning threshold for Low Lube Oil Pressure energized. No effect on engine performance.
144 System Warning Engine Coolant Temperature sensor signal is No engine protection for Coolant Temperature.
shorted high No effect on engine performance.
145 System Warning Engine Coolant Temperature sensor signal is No engine protection for Coolant Temperature.

146 Engine Warning Engine Coolant Temperature has exceed the High Coolant Temperature warning relay driver is
Protection warning threshold for High Coolant Temperature energized. No effect on engine performance.
151 Engine Shutdown Engine Coolant temperature has exceed the Engine will shutdown.
Protection shutdown threshold for high Coolant Temperature
153 System Warning Engine Intake Air Temperature sensor signal is No engine protection for Intake Air Temperature.
Shorted high No effect on engine performance.
154 System Warning Engine Intake Air Temperature Sensor signal is No engine protection for Intake Air Temperature.
System Fault
155 Engine Warning Engine Intake Air Temperature has exceed the High Intake Air Temperature warning relay driver
Protection warning threshold for High Intake Air Temperature is energized. No effect on engine performance.
234 Engine Shutdown Engine Speed Signal indicates that engine speed Engine will shutdown. Fuel Shut-Off Valve
Protection is greater than Overspeed threshold (S.D. Coil) is de-energized (valve closed).
Overspeed shutdown relay driver is energized.
235 Engine Shutdown Engine Coolant Level has dropped below the Engine will shutdown.
Protection shutdown threshold for Low Coolant Level.
359 System Warning Engine cranked but failed to start No effect on engine performance
415 Engine Shutdown Engine Lube Oil Pressure has dropped below the Engine will shutdown.
Protection shutdown threshold for Low Oil Pressure
441 System Warning Low voltage has been detected for battery Engine may not crank. Possible loss of ECPG
during engine crank. 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.
5-3
5-4
System Fault
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.
3115 System Shutdown Speed signal was lost while engine running. Engine will shutdown.

3116 System Warning Fuel Actuator PWM signal is close to maximum Possible loss of engine performance at
for long enough time due to possibly stuck higher loads.
actuator or insufficient fuel supply.
3118 System Warning Powerdown hardware within ECPG malfunctioning. 1) No effect on engine performance.
2) ECPG will not powerdown. Potential
battery drain.
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
High Coolant Temperature Warning Warning 90oC (194 oF)

93oC (199 oF)
High Coolant Temperature Shutdown Shutdown 96oC (205 oF)
High Intake Manifold Temperature Warning 75oC (167 oF)

Warning
Low Lube Oil Pressure Warning Warning RPM Threshold (bar)

0 0
500 0.5
1100 1.0
1500 2.7
Low Lube Oil Pressure Shutdown Shutdown RPM Threshold (bar)

0 0
500 0.3
1100 0.6
1500 2.4
Low Coolant Level Shutdown Low Coolant Level

NOTES
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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
TROUBLESHOO
TROUBLESHOOTING
OUBLESHOOTING
Effect (Only when fault code is

Fault Code Reason
active
135 Engine Lube Oil Pressure sensor signal is shorted high. Warning
No engine protection for Lube Oil
Pressure. No effect on engine
performance.
Cause Correction
Inspect the sensor for damaged,

corroded, bent, broken, expanded or
Lube Oil Pressure sensor pushed back pins. If sensor pins are
short 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,
OK 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
Engine harness defective
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
OK 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.
ECPG Malfunctioning Replace the ECPG.


Fault Code Reason
active)
Warning
141 Engine Oil pressure sensor signal is shorted low.
No engine protection for Lube Oil
Pressure. No effect on engine
performance.
Cause Correction
Inspect the sensor for damaged,

corroded, bent, broken, expanded or
Lube Oil Pressure sensor pushed back pins. If sensor pins are
open found damaged, replace the sensor.
pins.
OK moisture from the sensor pins.
not as per sensor specification,
replace the sensor.
Check the sensor supply voltage

Engine harness defective 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
OK
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.


Fault Code Reason
active)
Engine Oil Pressure has dropped below the warning Warning
143
threshold for low lube oil pressure. Low lube oil pressure warning relay
driver is energized.
No effect on engine performance.
Cause Correction
Check the dipstick calibration.

Insufficient lube oil in engine
Check the oil level in the engine.
Add oil if level below dipstick mark.
OK
Check the mounting location of lube

Lube Oil Pressure sensor oil pressure sensor on engine. Refer
not at correct location on to engine specification. If location is
engine incorrect, relocate sensor and
check operation.
OK
Check for fuel or coolant

Lube oil diluted with fuel or contamination in the lube oil.
coolant If contaminated, remove the cause.
Drain all the oil in engine and fill the
fresh lube oil in the engine.
OK
Full flow lube oil filter(s)

Replace lube oil filter(s).
plugged
OK
Lube oil suction tube broken Remove oil sump. Inspect/replace

or tube seals leaking the suction tube.
OK
Malfunction lube oil pressure

Remove oil sump. Inspect/replace
regulator in lube oil filter
suction tube.
head.
OK
Lubricating oil pump Inspect lubricating oil pump. repair

malfunction or replace the pump if necessary.

Fault Code Reason
active)
Engine Oil Pressure has dropped below the warning Warning
143
threshold for low lube oil pressure. Low lube oil pressure warning relay
Contd.
driver is energized.
Cause Correction

Lube oil pressure sensor not as per specification, replace the
defective sensor.
OK
Sensor getting + 5 V supply Check the sensor supply voltage

harness. If not, check the engine
harness.
OK
Check the continuity between

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


Fault Code Reason
active
144 Engine coolant temperature sensor signal is shorted high. Warning

No engine protection for coolant
temperature. No effect on engine
performance.
Cause Correction
Coolant Temperature Check the Coolant Temperature

sensor short sensor resistance as per sensor
specification. If it is not as per
OK 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
OK circuits, or replace the engine
harness.


Fault Code Reason
active
145 Engine Coolant Temperature sensor signal is shorted low. Warning

No engine protection for coolant
temperature. No effect on engine
performance.
Cause Correction
Coolant Temperature Check the Coolant Temperature

sensor open sensor resistance as per sensor
sensor.

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


Fault Code Reason
active)
Engine Coolant Temperature has exceeded the warning Warning
146
threshold for high coolant temperature High Coolant Temperature warning
relay driver is energized. No effect
on engine performance.
Cause Correction
Check level. Add Coolant if

Coolant Level low
necessary.
OK
Disconnect underhood air. Check

Intake Air temperature too
for air recirculation from radiator
high
entering air cleaner
OK
Radiator/Heat Exchanger
Check fins for damage and debris.
fins obstructed or damaged
OK
Pipe coupling or hose Check the pipe coupling or hose if

collapsed damaged.
OK
Fan shroud damaged Inspect shroud for damage.
OK
Fan belt slipping or

Check fan RPM.
viscous fan malfunction
OK
Radiator Cap Malfunction Check / replace radiator cap.


Fault Code Reason
active)
Engine Coolant Temperature has exceeded the warning Warning
146
threshold for high coolant temperature High Coolant Temperature warning
Contd.
relay driver is energized. No effect
on engine performance.
Cause Correction
Loss of Raw water supply Check the raw water flow pressure
to HE and see whether it is in the
specified limit.
OK
Radiator core obstructed Inspect radiator and clean if

or damaged (internal) necessary.
OK
Water pump malfunctioning Check the water pump and replace

it if incase found defective.
OK

sensor as per sensor specification.
Coolant Temperature If it is not as per specification,
sensor defective replace the sensor.
OK
Engine harness defective 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
OK circuits or replace the engine
harness.


Fault Code Reason
active)
Engine coolant temperature has exceeded the shutdown Shutdown
151
threshold for high coolant temperature Engine will shutdown
Cause Correction
Check level. Add coolant, if

Coolant Level low
necessary.
OK
Disconnect underhood air. Check

Intake Air temperature too
for air recirculation from radiator
high
entering air cleaner
OK
Radiator/HE fins Check fins for damage and debris.

obstructed or damaged
OK
Pipe coupling or hose Check the pipe coupling or hose if

collapsed damaged.
OK
Fan shroud damaged Inspect shroud for damage.
OK
Fan belt slipping or

Check fan RPM.
viscous fan malfunction
OK
Radiator Cap Malfunction Check /replace radiator cap.


Fault Code Reason
active)
Engine coolant temperature has exceeded the shutdown Shutdown
151 Contd.
threshold for high coolant temperature Engine will shutdown
Cause Correction
Loss of Raw water supply Check the raw water flow pressure
to HE and see whether it is in the
specified limit.
OK
Radiator core obstructed Inspect radiator and clean if

or damaged (internal) necessary.
OK
Check the water pump and replace

Water pump malfunctioning
it if incase found defective.
OK

sensor as per sensor specification.
Coolant Temperature If it is not as per specification,
sensor defective replace the sensor.
OK
Engine harness defective 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
OK circuits or replace the engine
harness.


Fault Code Reason
active)
Warning
153 Engine Intake air temperature sensor signal is shorted high.
No engine protection for Intake Air
Temperature. No effect on engine
performance.
Cause Correction
Intake Air Temperature Check the Intake Air Temperature

sensor short sensor resistance as per sensor
sensor.
Check if the Intake Air Temperature

Engine harness defective 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
OK short circuits or replace the engine
harness.


Fault Code Reason
active)
154 Engine Intake Air Temperature sensor signal is shorted low. Warning
No engine protection for Intake Air
Temperature. No effect on engine
performance.
Cause Correction
Intake Air Temperature Check the Intake Air Temperature

sensor open sensor resistance as per sensor
sensor.
Check the Intake Air Temperature

Engine harness defective 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
OK
the engine harness.


Fault Code Reason
active)
Engine Intake Air Temperature has exceeded the warning Warning

155
threshold for high intake air temperature. High intake air temperature
warning relay driver is energized.
Cause Correction
Check the nominal resistance with

DMM (Digital multimeter) of Intake
Intake Air Temperature Air temperature sensor by referring
Sensor defective. sensor specification.
If it is not as per specification,
OK replace the sensor.
Check for LTA pump working. If not,

LTA Pump failure
replace the pump. Also check LTA
raw water pump operation.
OK
Check :
Incorrect engine installation - CAC plumbing.
or mechanical problem - Engine compartment
temperature
- Lack of insulation on exhaust
OK manifold or turbocharger.


Fault Code Reason
active)
Engine speed signal indicates that engine speed greater Shutdown
234
than overspeed threshold. Engine will shutdown.
Overspeed shutdown relay driver is
energized.
Cause Correction
Use proper calibration and check

Incorrect calibration engine overspeed limit is set
sufficiently higher than the rated
OK engine speed.
Fuel Actuator stuck in open

Clean or replace the fuel actuator.
position
OK
If +24 V supply is present on
actuator,
1) check the engine harness for
Fuel actuator getting +24V actuator connection shorting to
battery supply continuously supply voltage.
If short, repair the wires that have
short circuits or replace the
OK
engine harness.
2) If supply voltage is still present
on actuator, replace the ECPG.
Check other engine related

factors referring to engine Refer T & R Manual.
T & R Manual

Fault Code Reason
active)
Engine coolant level has dropped below the shutdown Shutdown
235
threshold for low coolant level. Engine will shutdown.
Cause Correction
Check the coolant level.

Coolant is low
Add coolant, if necessary.
OK
Inspect the coolant level sensor for
damaged, corroded, bent, broken,
expanded or pushed back pins. If
Coolant level sensor faulty sensor pins are found damaged,
replace the sensor.
OK pins.
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.


Fault Code Reason
active)
359 Engine cranked but failed to start Warning

Cause Correction
Fuel in the tank is low Add fuel.
OK
Fuel filter choked Clean or replace the fuel filters.
OK
Fuel inlet restriction Inspect the fuel line and remove the
excessive obstructions and clean the line.
OK
Check air in the fuel. Tighten the

Air in fuel fuel line connections. Tighten filter.
Check tank stand pipe
OK
Check the engine harness for FSO
valve connection open or short, if
Fuel shut off valve not getting faulty, repair the wires that have
the + 24 V battery supply short circuits / open circuits or
OK If voltage is still not preset, replace
the ECPG.
Check the resistance of FSO Valve.

Fuel Shut Off Valve not If resistance as per specification,
operating check for mechanical operation. If
not, replace the FSO Valve.
OK
Check the engine harness for
actuator connection, short or open,
if faulty, repair the wires that have
short circuits / open circuits or
Actuator not getting supply
If voltage is still not preset, replace
OK
the ECPG.
Check the fuel actuator coil

Actuator coil open / short or resistance. If as per specification,
sticky check actuator for stickiness. If
sticky, clean / replace the actuator.
If coil resistance not as per
specification, replace the actuator.

Fault Code Reason
active)
Engine Lube Oil Pressure has dropped below the shutdown Shutdown
415
threshold for low oil pressure Engine will shutdown.
Cause Correction
Check the dipstick calibration.

Incorrect Oil level
Check the oil level. Add oil if
necessary.
OK
Check location. Refer to engine

Lube Oil pressure sensor
specification. Relocate sensor, and
not at correct location
check operation.
OK
Check for fuel or coolant

Lube Oil diluted in the contamination in the engine oil. If
engine with fuel or coolant contaminated remove the cause.
Drain the oil. Fill the fresh oil.
OK
Full flow Lube Oil filter

Replace oil filter.
plugged
OK
Oil suction tube broken or Remove oil sump. Inspect/replace

tube seals leaking. suction tube.
OK
Malfunction Oil pressure Remove oil sump. Inspect/replace

regulator in Oil Filter head. suction tube.
OK
Inspect lubricating oil pump.

Lubricating Oil pump
Replace or repair the pump if
malfunction
possible.

Fault Code Reason
active)
415 Engine Lube Oil Pressure has dropped below the shutdown Shutdown
Contd. threshold for low oil pressure Engine will shutdown.
Cause Correction

Lube oil pressure sensor not as per specification, replace the
defective sensor.
OK
Sensor getting + 5 V supply Check the sensor supply voltage

harness. If not, check the engine
harness.
OK

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


Fault Code Reason
active)
441 Low voltage has been detected during engine crank Warning
1) Engine may not crank.
2) Possible loss of ECPG
functionality.
Cause Correction
Check electrolyte level and specific

Battery charge low
gravity of battery cells. If low,
charge or replace the battery.
OK
Battery rating too low Replace battery with correct rating.
OK


Fault Code Reason
active)
Warning
1411 Speed Bias Analog Input signal is shorted high.
The Speed Bias Analog Input Signal
feature will be disabled.
Cause Correction
Check the O.E.M. harness for short

The Speed Bias Analog Input circuit the signal wire to + 5 V or
Signal shorted to high + 24 V battery supply.
If short is observed, repair the wires
the O.E.M. harness.
OK
Source of signal delivering Isolate the ECPG. Check and

Speed Bias voltage from rectify the source of signal from
O.E.M. equipment stuck to O.E.M. equipment.
high. If problem still persists, replace the
O.E.M. source of signal equipment.
OK


Fault Code Reason
active)
1416 Engine fail to shutdown Warning

Engine failed to stop even after a
stop command was issued by the
system.
No engine protection feature.
Cause Correction
Fuel Shut Off valve Check engine harness for FSO

permanently ‘ON’ after valve wire short to + 24 V battery
turning the key switch from supply. If short is observed, repair
‘Run’ position to ‘Off’ the wires or replace the engine
position. harness. If problem still persists,
replace the ECPG.
OK
Check and be sure that the manual

Fuel Shut Off valve is in
override screw on fuel shutoff valve
manual override mode
is out to maximum travel.
OK
Check that the Fuel Shut Off valve

Fuel Shut Off valve is turned ‘off’ when 24 Volts from
malfunctioning ECPG is removed by turning the
key switch from ‘Run’ position to
‘Off’ position.
OK
Engine fuel drain line Check restriction. Replace or

restricted reroute engine fuel drain line.
OK
Engine injector(s) Please refer T & R manual of the

malfunctioning or injector(s) engine for mechanical and fuel
O-ring(s) damaged. systems repair problems.

Fault Code Reason
active)
1438 Engine fail to crank Warning

Cause Correction
MPU not operative (fault Refer to ‘Speed Signal Lost’ fault

occurs even if engine cranks) diagnosis. See fault code 3115.
OK
Battery connections are Clean and tighten the Battery

broken, loose or corroded connections.
OK
Check electrolyte level and specific

Battery charge low gravity of battery cells. If low,
charge or replace the battery.
OK
Battery rating too low Replace battery with correct rating.
OK
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.
Engine starting circuit Check for continuity : Check the continuity between Pin ‘E’ of
component Malfunctioning. 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.
OK
Check if the starter solenoid gets

supply voltage.
Check whether engine drive If not, change the starter magnetic
unit engages switch.
If problem still persists, check if the
OK
starter solenoid is working properly.
Engine starting Motor pinion Remove engine starting motor and

or ring gear on pinion check for damage
damage
OK
Hydraulic Lock in engine Check intake or exhaust valve

cylinder operation.

Fault Code Reason
active)
3111 Speed Bias Analog Input signal is shorted low. Warning

The Speed Bias Analog Input
signal feature will be disabled.
Possible loss of engine
performance.
Cause Correction
Check the O.E.M. harness for short

The Speed Bias Analog Input circuit the signal wire to ground.
Signal shorted to ground If short is observed, repair the wires
the O.E.M. harness.
OK
Source of signal delivering Isolate the ECPG. Check and

Speed Bias voltage from rectify the source of signal from
O.E.M. equipment stuck to O.E.M. equipment.
low. If problem still persists, replace the
O.E.M. source of signal equipment.
OK


Fault Code Reason
active)
3112 Speed Raise switch is shorted High Warning

The Speed Raise Switch feature will
be disabled.
Cause Correction
The Speed Raise Switch on Check the speed raise switch on the
the A.M.F. or Customer A.M.F. or customer panel for short.
panel shorted to high. If short is observed, repair or replace
the switch.
OK
Check the O.E.M. harness for

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


Fault Code Reason
active)
3113 Speed Lower switch is shorted high Warning

The Speed Lower Switch feature will
be disabled.
Cause Correction
The Speed Lower Switch Check the speed lower switch on the
on the A.M.F. or customer A.M.F. or customer panel for short.
panel shorted to high. If short is observed, repair or replace
the speed lower switch.
OK
Check the O.E.M. harness for

speed lower input short to + 24 V
O.E.M. harness defective 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


Fault Code Reason
active)
3115 Speed signal was lost while engine running. Shutdown

Engine will shutdown.
Cause Correction
Check whether MPU connector is

Loose MPU connection properly secured to the engine
harness.
OK
Check the resistance of the MPU

MPU coil resistance as per coil. Refer sensors specifications, if
sensor specification not within specification, replace the
MPU.
OK
Check the tip of the MPU for

MPU tip damaged damage.
If the tip is damaged, replace the
MPU.
OK
Gap between MPU tip and Check the gap between MPU tip
engine flywheel ring gear and engine flywheel ring gear teeth.
teeth more than the engine If gap is more, adjust the gap as per
specification engine specification.
OK
Connector A (Pin ‘B’ and Pin ‘T‘)
and MPU connector.
Engine harness defective 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.

Fault Code Reason
active)
3116 Fuel actuator PWM signal is close to maximum for long Warning
enough time due to possibly stuck actuator or insufficient Possible loss of engine performance
fuel supply. at higher loads.
Cause Correction
Check the engine fuel supply and

Fuel is not available ensure that air lock has not
occured.
OK
Check the fuel filter(s) and clean or

Fuel filter(s) choked
replace it, if necessary.
OK
Remove the fuel actuator located on

Fuel Actuator sticky engine fuel pump and clean it with
clean diesel (not compressed air) or
replace it, if necessary.
OK
Check the engine harness for short

Fuel actuator not getting circuits or open circuits.
supply 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
If continuity is observed, and the
problem still persists, replace the
ECPG.

Fault Code Reason
active)
3118 Powerdown hardware within ECPG malfunctioning Warning

1) No effect on engine performance.
2) Potential battery drain.
Cause Correction
Powerdown hardware within

ECPG failed Replace ECPG
NOTES
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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
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.
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 1 2

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 N•m).
Connect the connector to the actuator. The connector is

“keyed”, so that it connects in one direction only.
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 Fuel Pump
code for calibration.
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
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.
f. Power Source
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

batteryyc har
char
hargger
er..
Due to the circuitry and method of operation of
the chargers, the controller will not function
pr operl
properl
operlyy. Connect the batter
batteryy c har
char
hargger to the
battery
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 avoid dama
av damagge to the ECPG, connect all electrical
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 prevent loss of v
prevent aluab
valuable inf
aluable ormations suc
informations h as fault
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.
h. Replacement of Parts
(To be perf
(To ormed b
performed y authoriz
by ed Cummins
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”.
CAUTION
CAUTION
No user serviceable parts inside ECPG. Do not
ENGINE OEM
attempt to ope the ECPG enclosure while battery and
HARNESS HARNESS 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.
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
26 pin FRC cable
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.
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.
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
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 70°C (0° to158°F)
Storage Temperature ......................................................................... 0° to 70°C (0° to158°F)
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
Appendix - B
GLOSSARY OF POWER TERMS
A.C. - See Alternating Current. Capacitance - The property of a device which resists
changes in voltage. In an A.C. circuit, a capacitive load
Alternating Current - Electrical current which repeatedly will cause the voltage to lag behind the current flow. Stated
varies from zero to a positive maximum value to zero to more conventionally, the current leads the applied voltage.
a negative maximum value and back to zero at a periodic A capacitive load is, therefore, a leading power factor
rate. Since the applied voltage continually reverses load (see Power Factor).
polarity, the resultant current flow alternates in direction
within the circuit.
Alternating Current Leading Applied

Voltage Caused by Capacitive Load
Alternating Current = I Capacitor ~ A device possessing the property of

Applied Voltage = V capacitance. A typical capacitor consists of two
conducting surfaces separated by an insulating material.
AMP — An abbreviation for the term Ampere. A capacitor stores electrical energy, blocks the flow of
D.C. and permits the flow of A.C. to a degree largely
Ampere - The unit of measure of electrical current flow. dependent on the capacitance and the frequency of the
One ampere of current will flow when one volt of electrical applied A.C.
potential is applied across one ohm of resistance.
Circuit - An electrical path through which an electric
Auto-Transformer — A transformer of single coil current may flow from a voltage supply to a load and
return. A closed or complete circuit is one where current
construction in which both the primary and secondary
is flowing. An open circuit is where the path has been
connections are made on the same coil but use different
disrupted, such as an open switch or circuit breaker, thus
taps.
stopping current flow.
Bi-State - Refers to the type of electrical device, or the Circuit Breaker - A protective device for opening a circuit
signal supplied by such a device, that has two discrete where current flow exceeds a predetermined value.
and mutually exclusive states. For example, a two- Circulating Current - Also called Cross Current. Current
position toggle switch is a bi-state switching device that which flows between paralleled generators, most apparent
is either ‘open’ or ‘closed’. with no external load on the paralleled generators.
Circulating current is caused (1) by unequal excitation of
B- — Symbol used to designate the negative polarity of the generators (reactive current, which may be reduced
a D.C. voltage supply. by changing the voltage regulator adjustment or
connections); and (2) by unequal power from the engines
B+ — Symbol used to designate the positive polarity of that are driving the generators real current (and power)
a D C voltage supply. 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.
Contactor - A device for opening and closing an electric Diode - A two terminal solid-state device which permits
circuit. Contactors are normally used in motor circuits current to flow in one direction, but not in the other. In
where large amounts of current are controlled. alternating current circuits, a diode will permit one half
cycle to flow but will resist the flow of the opposite half
Cross Current - See Circulating Current. cycle of current. Thus, alternating current is converted
to direct current by a diode.
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
Direct Current (D.C.) - An electric current that flows in
Current) Compensation and Reactive Droop
one direction only. Conventional direct current is defined
Compensation).
as flowing from positive to negative in the circuit outside
the source (example: a battery or combination of diodes).
Current (Electrical, Symbol I) - The rate of transfer of
Conventional current flows in the direction of the arrow
electricity from one point to another. Current is usually a
through a diode.
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
Direct Current I
completed at zero.
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
E - Symbol used to represent electrical potential (voltage). This may produce unacceptable hunting of the frequency
and/or voltage.
Earth Ground - An intentional connection made between
the earth and the metallic frame of electrical equipment Gate - The third terminal of an SCR to which a voltage
as a means to eliminate possible voltage hazards to must be applied before the SCR will conduct.
personnel. Earth Ground also serves, in some cases, to
Governor - A device which controls engine speed and
reduce electrical interference in sensitive circuits such
thus the generator output frequency.
as television and radio equipment.
Ground - A connection, either accidental or intentional,
EMI - An abbreviation for the term electromagnetic
between an electrical potential and the earth or some
interference which is sometimes caused by SCR type
conducting body serving in place of the earth.
devices and evident in radio and television operation.
Heat Sink - A device which absorbs heat from electrical
Energy - The capability of performing work.
devices such as diodes and SCR’s and dissipates the
Frequency - The number of complete cycles of alternation heat to the surrounding air.
current per unit of time. Typically, frequency is expressed
Hertz - A term equivalent to cycles per second (See
in cycles per second or Hertz (Hz).
Frequency).
Frequency Droop - A decrease in steady state frequency
Hunting - Oscillation in frequency or in voltage where
output of a generator caused by an increase in load. This
steady state conditions are not reached, particularly after
decrease in frequency from the no load frequency is
a load transient change.
expressed as a percentage of the full load frequency or:
I - Symbol used to represent current.
(FNL - FFL) X 100
%F Droop = ———————— Impedance - The opposition to the flow of alternating
FFL current.
Where: % F Droop = Percent Frequency Droop Induced Voltage - The voltage which is produced by
FNL = No Load Frequency relative motion between a wire and a magnetic field.
FFL = Full Load Frequency
Inductance - The property of a device which resists
Frequency droop may be used to provide governor changes in current. In an A.C. circuit, an inductive load
stability and for load sharing between paralleled generator will cause the current to lag behind the applied voltage.
sets. Stated more conventionally, the current lags the applied
voltage. An inductive load is therefore a lagging power
Frequency Meter - An instrument designed to measure factor load (see Power Factor).
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 Alternating Current Lagging Applied
governor or voltage regulator may over-correct. Voltage Caused by Inductive Load
Inductor - A device possessing the property of undesired condition. 3) An arrangement of conductors

inductance. An inductor stores electrical energy, passes and equipment that depends upon lack of continuity for
D.C., and opposes the flow of A.C. to a degree largely operation, as open-circuit telegraphy; a circuit in which
dependent on the inductance and the frequency of the continuity is incomplete or interrupted.
applied A.C. A typical inductor consists of a coil of wire.
Oscillogram - The permanent record produced by an
oscillograph, or a photograph of the trace produced by
In Phase - Alternating currents or voltages are in phase
an oscilloscope.
with respect to each other if they cross through zero and
reach their positive and negative maximum values Oscillograph - A measurement device for determining
together. waveform by recording the instantaneous values of a
quantity such as voltage as a function of time.
Insulation - A non-conductive material such as rubber
Oscilloscope - An instrument primarily for making visible
or plastic intended to prevent current from flowing.
the instantaneous value of one or more rapidly varying
Technically, insulation is any material which stops the
electrical quantities as a function of time or of another
flow of current.
electrical or mechanical quantity.
Isochronous - As it applies to engine governors, Oscilloscope, Dual Beam - An oscilloscope in which
maintaining constant steady state speed regardless of the cathode-ray tube produces two separate electron
the load within the rating of the engine. Thus, a generator beams that may be individually or jointly controlled.
set is said to be isochronous if the frequency remains
Parallel Connection - An electrical connection in which
the same regardless of load.
the input of one element is connected to the input of
another element. The output connections are similarly
Normally Closed (Symbol N.C.) - As applied to a
connected together thus providing two or more paths for
magnetically operated device such as a valve or the
current to flow.
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 magneti-

cally 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.
Parallel Connection
Ohm - The unit of measure of electrical resistance. One
Parallel Operation - The method by which two or more
ohm of resistance will allow a current of one ampere to
generators having the same voltage and frequency
flow with an applied potential of one volt.
characteristics are connected to a common load.
Ohmmeter - An instrument for measuring electrical Permanent Magnet Generator - A generator which uses
resistance. permanent magnets to create a magnetic field. As applied
to Cummins Generators: a permanent magnet generator,
Ohm’s Law - A fundamental law expressing the within the main generator, supplies the power to the
relationship between voltage, current, and resistance in voltage regulator which in turn supplies the power to the
electrical circuits. The law states that E = IR or voltage exciter field. The permanent magnet generator still
is equal to current times resistance. supplies power during a short circuit of the main generator.
This permits the main generator to sustain high short
Open Circuit - 1) A circuit that does not provide a circuit currents. The output of the permanent magnet
complete path for the flow of current. 2.) A condition of generator is electrically isolated from the main generator
an electrical circuit caused by the breaking of continuity output and is not adversely affected by main generator
of one or more conductors of the circuit; often an output waveform distortion such as from SCR type loads.
PMG - See Permanent Magnet Generator. Resistor (Symbol R) - A device or component designed
to have a definite amount of resistance. Resistors are
Polarity - An electrical term which indicates the direction
used in circuits to limit current flow or to provide a voltage
in which current flows in a conductor. In a direct current
drop.
system, current flows in the same direction. In an
alternating current system, current changes direction as Resistor, Fixed - A component which is used to control
the polarity of the A.C. voltage source changes. voltage and current by introducing a constant resistance
Potential - Another term to indicate voltage. of known value into the circuit.
Potential Difference - The difference in voltage between Resistor, Variable - Similar to a fixed resistor except
two points in a circuit. the resistance value can be adjusted. The voltage adjust
Power - Defined as the rate of performing work. rheostat is a variable resistor.
Mechanical power is measured in horsepower or kilowatts.
Rheostat - A variable resistor.
Electrical power is measured in Kilowatts.
Power Factor - The ratio of the true power (KW) Series Connection - An electrical connection in which
requirements of a load to the apparent power (KVA) the input of one element is connected to the output of
requirements of a load. The combined loads applied to a another element providing only one path for current to
power source may have a resistive, capacitive, or flow.
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
Series Connection
loads.
Inductive and capacitive loads, however, cause the Short Circuit - An abnormal connection (including an
voltage and current waveforms to shift with respect to arc of relatively low resistance, whether made
one another. These types of loads are commonly called accidentally, or intentionally, between two points of
power factor loads (i.e., the power factor is less than different potential in a circuit. Equipment, not protected
1.0). by fuse or circuit breakers, may be damaged by a short
See INDUCTANCE and CAPACITANCE for more circuit.
information.
Single Pole Switch - A switch which has only one set
Power factor is frequently multiplied by 100 and expressed of contacts.
as a percentage.
The formula for power factor is:
Typical Single Pole Switch Shown as a
True Power (KW) Single Throw Type in the “Off” Position
Power Factor = ——————————
Apparent power (KVA) Single Throw Switch - A switch which opens a set of
R - Symbol used to represent resistance. contacts in one switch position and closes the contacts
in the other position.
Relay - An electromechanical device having a magnetic
coil which, when energized, opens or closes several sets
of contacts.
Typical Single Throw Switch Shown as
Resistance - Opposition to the flow of current. a Single Pole Type in the “Off” Position
Speed Droop - A decrease in steady state speed of an One Volt of electrical potential will force a current of one
engine due to an increase in applied load. This decrease Ampere to flow through a resistance of one Ohm.
in speed from the no load speed is expressed as a
Voltage - Electrical potential or pressure which forces
percentage of full load speed or:
current to flow through a circuit.
(SNL - SFL) X 100
Voltage Dip - A temporary reduction in voltage generally
%S Droop = —————————
resulting from an increase in load.
SFL
Where : %SDroop = Percent Speed Droop Voltage Droop - A decrease in steady state voltage of a
SFL = Full Load Speed generator due to an increase in load applied. This decrease
SNL = No Load Speed in voltage from the no load voltage is expressed as a
percentage of the full load voltage or
Solenoid - An electromechanical device which when
(VNL- VFL) X 100
energized, acts on a movable core or plunger in the center
of the energizing coil to perform mechanical work. %VDroop = ————————
Solid-State - A term which applies to electronic devices VFL
which are constructed using semiconductor material.
Where: % VDroop = Percent Voltage Droop
Such devices include transistors, SCR’s, and diodes.
VNL = No Load Voltage
Stability - Freedom from undesired variations or
oscillation. In generator set systems, the generator set VFL = Full Load Voltage
is stable if it can maintain or quickly re-establish
Voltmeter - An instrument designed to measure electrical
steady state conditions of voltage and frequency after
potential or voltage.
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).
WIRING DIAGRAM FOR ENGINES WITH SINGLE STARTER
APPENDIX - C
WIRING DIAGRAM FOR ENGINES WITH SINGLE STARTER
SHUT DOWN COIL
19 PIN CONNECTOR
F -Ve A A
B
B
M C
ELECTRICAL WIRING DIAGRAMS
ECPG ACTUATOR D D
E E
F F
+5V G
G
OUTPUT H H
GND J J
DATALINK K K
START
L L
LCL
35 +Ve M
* M
R N
N
36 MAG.
-Ve PICK-UP P
A1; P
LOW COOLANT R S0.C7A5L0E
LEVEL SENSOR R
S
S
INTAKE T T
+ Ve
AIR TEMP. U
- Ve 25 SENSOR U
33E W V
V
V
ALTERNATOR
COOLANT TEMP.
SENSOR
AMP. 2. TURN THE STARTING KEY SWITCH
CIRCUIT NO. CAPACITY WIRE GAUGE TO START POSITION TO CRANK
G,E,V,A,L,F,M THE ENGINE.
14 1.5 SQ. MM
39E,D 1. 24 VOLT NEGATIVE GROUND SYSTEM
39E 26 25 38 25,33E,38,17 30 4.5 SQ. MM
35
L G,H,J,N,P,S,U,R 11 1 SQ. MM
A
36 17 26,45 200 P.V.C. 95 SQ. MM
B,T SHIELDED
STARTER 45 17 1 SQ. MM
CABLE
EARTH WIRE 39E
E
26 39E 38
45
+ Ve - Ve + Ve - Ve
MAGNETIC
SWITCH
BATTERY 24 V.D.C.
8-9
8-10
WIRING DIAGRAM FOR ENGINES WITH TWO STARTERS
WIRING DIAGRAM FOR ENGINES WITH TWO STARTERS
SHUT DOWN COIL
19 PIN CONNECTOR
F -Ve A A
B
B
M C
ECPG ACTUATOR D D
E E
F F
+5V G
G
OUTPUT H H
GND J J
DATALINK K K
START
L L
35 +Ve M
* R N
M
N
36
-Ve P
P
LOW COOLANT
LEVEL SENSOR
R
R S0C.A7L5E0
A1; S
AIR INTAKE S
TEMP. T T
SENSOR
- Ve + Ve 25 U
U
W V
33E V
V

ALTERNATOR
COOLANT TEMP.
SENSOR
AMP. 2. TURN THE STARTING KEY SWITCH

CIRCUIT NO. CAPACITY WIRE GAUGE TO START POSITION TO CRANK
26 25 38 38 THE ENGINE.
G,E,V,A,L,F,M
35 26
14 1.5 SQ. MM
39E,D 1. 24 VOLT NEGATIVE GROUND SYSTEM
L
A 25,33E,38,17 30 4.5 SQ. MM
36 17 45
17
G,H,J,N,P,S,U,R 11 1 SQ. MM
STARTER 45 39E 17 17 STARTER
26,45 200 P.V.C. 95 SQ. MM
EARTH WIRE 39E EARTH WIRE
E B,T SHIELDED
26 45 1 SQ. MM
CABLE
+ Ve - Ve 38
38
- Ve + Ve
MAGNETIC
SWITCH
BATTERY 24 V.D.C.
APPENDIX - D
DATALINK ECPG CONNECTOR

CONNECTOR
• RS-485 Serial Communication Standard • Retaining capscrew torque=1 N•m [9 in-lb]
SHORT CIRCUIT TO EXTERNAL VOLTAGE

ALL CONTINUITY CHECKS
• OK if < 1.5 VDC
• OK (no open circuit) if < 10 Ω
ALL SHORTS TO GROUND
ECPG POWER SUPPLY ESS circuits
• 20 to 32 VDC • OK (no short circuit) if > 10MΩ
All other circuits

• OK (no short circuit) if > 100kΩ
ECPG SENSOR SPECIFICATIONS

SPECIFICATIONS
OIL PRESSURE SENSOR ALL TEMPERA TURE SENSORS
TEMPERATURE
Torque = 14 N•m [124 in-lb] Torque = 15 N•m [133 in-lb]
Pressure Pressure Voltage Temperature Temperature Resistance

(kPa) [psia] (VDC) (oC) (oF) (Ω)
0 0 0.5 0 32 30k to 36k

207 30 1.5 25 77 9k to 11k
414 60 2.5 50 122 3k to 4k
621 90 3.5 75 167 1350 to 1500
827 120 4.5 100 212 600 to 675
ENGINE SPEED SENSOR
Torque = 34 to 47 N•m [25 to 35 ft-lb]

Coil Resistance = 750 to 1600 Ω
APPENDIX - E
LIST OF REPLACEMENT PARTS
Sr. No. Part name Part Number
ECP-G Assembly
1 ECP-G Assembly 4083935

2 Key switch 504975
3 Parameter selection push button 4071721
4 Toggle switch (for Idle/Rated mode selection) 3875362
5 Vibration Isolator 3229922
6 Mounting bracket 4084240
Sensors
1 Coolant temperature sensor 3865346

2 Air Intake temperature sensor 3408345
3 Lube oil pressure sensor 3408560
4 Coolant level sensor 4072714
5 Adapter for Coolant temperature sensor 4084218
6 Adapter for Air intake temperature sensor 4084219
7 Magnetic pick up 3879986
8 Lube Oil Pressure sensor adaptor (V 28 engine) 4104562
9 Lube Oil Pressure sensor adaptor 3814448
(495, 743, 855 series engines)
Actuator and Actuator housing
1 Fuel Actuator with O ring 3330601

2 Fuel actuator housing 4071944
3 Fuel actuator filter screen 3867393
4 Fuel actuator ‘O’ rings (1) 3865398
5 Fuel actuator ‘O’ rings (2) 3642542
Harness
Engine harness
1 KT/KTA 1150/KTA 19 G4/G3 engines 4084232
2 NT 495 4085697
3 NTA 495 4085698
4 NT/NTA 743 4085700
5 NT/NTA 855 4085692
6 VT/VTA 28 4085693
7 Extension harness 10 meters 4072993
8 Extension harness 5 meters 4072992
9 OEM harness 4054744
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Operation & Maintenance Manual for ECPG 1

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

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

About the Manual

To The Owner and Operator

Keep records of regularly scheduled maintenance.

General Safety Instructions

• Always wear protective glasses and protective shoes when working.

General Repair Instructions

ECPG DO’S AND DON’TS

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step.

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.

Name Symbol Name Symbol

Transfer Variable Reluctance

(N.C.) Male Contact

Name Symbol Name Symbol

Shields: Earth Safety Ground

Shielded Wire ** This symbol may be used in

Conducting connection to a chassis

Direct Conducting Connection to Circuit

Conducting connection to a structure

ACRONYMS AND ABBREVIA

Important Reference Numbers

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 ____________________

Belt Part Number (Alternator) ____________________

The illustrations included in this manual are intended to

Illustrations showing connector contact positions for

ECPG Connector ‘A’

Illustrations showing connector contact positions for

Connector Fuel Actuator

Electronic Control Panel with Speed Governor ...................................................................................................... 1-2