ECP 4083935 - O&m - Ecpg

Operation & Maintenance Manual for ECPG
TABLE OF CONTENTS
i.
Introduction ................................................................................................................................................... i-1
1.
Electronic Control Panel with Speed Governor .............................................................................................. 1-1
2.
ECPG Dimensions ....................................................................................................................................... 2-1
3.
Engine Start-up & Adjustments .................................................................................................................... 3-1
4.
Engine Protection ......................................................................................................................................... 4-1
5.
Fault Code Information ................................................................................................................................. 5-1
6.
Troubleshooting ............................................................................................................................................ 6-1
7.
Installation .................................................................................................................................................... 7-1
8.
Appendix ...................................................................................................................................................... 8-1
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
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.
i-3
i-4
General Safety Instructions

Important Safety Notice
WARNING
Read and understand all of the safety precautions and warnings before performing any repair. This list contains the
general safety precautions that must be followed to provide personal safety. Special safety precautions are included
in the procedures when they apply.
Make sure the work area surrounding the product is safe. Be aware of hazardous conditions that can exist.
Always wear protective glasses and protective shoes when working.
Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
Disconnect the battery and discharge any capacitors before beginning any repair work. Disconnect the air
starting motor if equipped to prevent accidental engine starting. Put a Do Not Operate tag in the operators
compartment or on the controls.
Use ONLY the proper engine barring techniques for manually rotating the crankshaft. Do not attempt to rotate
the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property
damage, or damage to the fan blade(s) causing premature fan failure.
If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling system.
Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands
to support the product before performing any service work.
Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related items are
removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that
utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal
injury.
To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or
more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct
capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting
hooks must not be side-loaded.
Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact
with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case
of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY
CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturers instructions to provide complete safety when using these materials. KEEP OUT OF REACH
OF CHILDREN.
To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines, tubes,
and compartments.
Always use tools that are in good condition. Make sure you understand how to use them before performing
any service work. Use ONLY genuine Cummins or Cummins Recon replacement parts.
Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of
less quality if replacements are necessary.
i-5
General Repair Instructions

This engine incorporates the latest diesel technology; yet, it is designed to be repaired using normal repair practices
performed to quality standards.
Cummins India Ltd., does not recommend or authorize any modifications or repairs to engines or
components except for those detailed in Cummins Ser
vice Inf
ormation. In par
ticular
ed
Service
Information.
particular
ticular,, un-authoriz
un-authorized
sonal injur
y. Belo
w is a par
tial listing of components
repair to saf
ety-related components can cause per
Below
partial
safety-related
personal
injury
classified as safety-related:
Air Compressor
Fuel Shutoff Assemblies
Cooling Fan
Fuel Suppl
y Tubes
Supply
Fan Hub Assembly
Lifting Brackets
Fan Mounting Bracket(s)
Throttle Controls
Fan Mounting Capscrews
Turboc
har
ger Compressor Casing
urbochar
harg
Fan Hub Spindle
Turboc
har
ger Oil Drain Line(s)
urbochar
harg
Flywheel
Turboc
har
ger Oil Suppl
y Line(s)
urbochar
harg
Supply
Flywheel Crankshaft Adapter
Turboc
har
g
er
T
urbine
Casing
urbochar
harg
Flywheel Mounting Capscrews
Vibration Damper Mounting Capscrews
Follow All Safety Instructions Noted in the Procedures.
Follow the manufacturers recommendations for cleaning solvents and other substances used during the
repair of the engine. Always use good safety practices with tools and equipment.
Provide A Clean Environment and Follow the Cleaning Instructions Specified in the Procedures
The engine and its components must be kept clean during any repair. Contamination of the engine and
components will cause premature wear.
Perform the Inspections Specified in the Procedures.
Replace all Components or Assemb
lies Whic
h are Dama
ged or Worn Be
yond the Specifications
Assemblies
Which
Damag
Bey
Use Genuine Cummins New or ReCondD Service Parts and Assemblies
The assembly instructions have been written to use again as many components and assemblies as
possible. When it is necessary to replace a component or assembly, the procedure is based on the use
of new Cummins India Ltd. or Cummins ReCon components. All of the repair services described in this
manual are available from all Cummins Distributors and most Dealer locations.
Follow
Disassemblly and Assemb
Assemblly Pr
Procedures
Damag
Follo
w The Specified Disassemb
ocedures to Avoid Dama
ge to the Components.
Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a
Cummins Authorized Repair Location.
ECPG DOS AND DONTS
DONTs
1. DO NOT remove the ECPG connectors A, B and C when +24V supply is conected to ECPG.
2. DO NOT attempt to open the ECPG enclosure.
3. DO NOT attempt to remove or repair any of the ECPG electronic parts (components, cables etc.). There are no
user serviceable parts inside ECPG.
4. Precaution during welding:
i) DO NOT connect ground cable of welding machine to ECPG
ii) DO NOT perform welding near Engine when ECPG harness is conected to ECPG.
5. DO NOT expose ECPG to sunlight, humidity, heat, water while in operation.
6. Servicing of ECPG is to be done by Authorized Cummins Personnel Only.
DOs
1. Precautions during welding :
i) First, disconnect battery cables from battery terminals.
ii) Then, disconnect the connectors A, B, C from the ECPG
2. Contact authorized service personnel in case of ECPG failure.
i-6
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.
i-7
ELECTRICAL SYMBOLS
Name
Symbol
Battery
Name
Transfer
Alternator
(Frequency
Source)
Capacitor
Resistor
Fuse
Variable
Resistor
(Potentiometer)
3 Terminal
Device
2 Terminal
Device
Circuit Breaker
Jumper Wire
Terminal Strip
Switches :
(N.O.)
Normally Open
Coil
Magnetic Core
(N.C.)
Normally Closed
Transfer
Transfer
3 position
Transformer
Variable Reluctance
Magnetic Pickup
Relay Contact :
(N.O.)
Normally Open
(N.C.)
Normally Closed
Female Contact
Male Contact
Symbol
i-8
Name
Symbol
Name
Shields:
Earth Safety Ground
Shielded Wire
**
Shielded Pair
**
Crossing of Conductors
(wires) not Connected
Junction of Connected
Conductors (wires)
Grounded
Chassis or Frame
Connection
Conducting connection to a chassis
or frame, or equivalent chassis connection of a printed wiring board.
The chassis or frame (or equivalent
chassis connection of a printed wiring
board) may be at a different potential
than the earth or structure in which
this chassis or frame (or printed
wiring board) is mounted.
Direct Conducting Connection to Circuit
Return.
Conducting connection to a structure
that services a function similar to that
of an earth ground (that is, a structure
such as a frame of an air, space or
land vehicle that is not conductively
connected to earth.)
This symbol may be used in

place of symbol for direct conducting connection to circuit
return to indicate a ground
connection having a specified
protective function (e.g., for
protection against electrical
shock in case of a fault).
Ref. Electrical and Electronics
Graphic Symbols and abbreviated names.
Symbol
i-9
ACR
ONYMS AND ABBREVIA
TIONS
ACRONYMS
ABBREVIATIONS
A
Ampere
Hz
Hertz
AC
Alternating Current
IP53
Ingress Protection - Dust-Protected &
AMF
Auto Mains Failure
AMPS
Amperes
Spraying Water
IP54
Ingress Protection - Dust-Protected &
AWG
American Wire Gage
B+
Battery Positive
In
Inch
Degree Celsius
I/O
Input / Output
CTS
Coolant Temperature Sensor
kg
Kilogram
CW
Clockwise
kPa
Kilopascal
CCW
Counterclockwise
kW
Kilowatt
DC
Direct Current
lb
Pound
ECP
Electronic Control Panel
LED
Light-Emitting Diode
ECP+G / ECPG
Electronic Control Panel with Governor
LLOP
Low Lube Oil Pressure
EMC
Electro-Magnetic Compatibility
mA
Milli-Ampere
EMF
Electro-Motive Force
mW
Milli-Watts
EMI
Electro-Magnetic Interference
mm
Millimeter
EPROM
Erasable Programmable Read Only
MPU
Magnetic Pickup
Memory
N-m
Newton-meter
E-STOP
Emergency Stop
O/M
Owner-Operator Manual
Splashing Water
ESS
Engine Speed Sensor
OEM
Original Equipment Manufacturer
Degree Fahrenheit
OPS
Oil Pressure Sensor
FSOV
Fuel Shutoff Valve
OS
Over Speed
ft (FT)
Foot
PC
Personal Computer
GND
Ground
P-P
Peak to Peak
GOEM
G-Drive Original Equipment
P/N
Part Number
Manufacturer
psi
Pounds Per Square Inch
H2O
Water
rpm (RPM)
Revolutions Per Minute
HCT
High Coolant Temperature
PWM
Pulse Width Modulator
HE
Heat Exchanger
Volts
Hg
Mercury
PT
Pressure Time
hp
Horsepower
MS
Military Standard
i-10
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:
i-11
Important Reference Numbers

Fill in the part name and number in the blank spaces provided below. This will give you a reference whenever
service or maintenance is required.
ECPG Sr. No.
____________________
Engine Model
____________________
Engine Serial Number
____________________
Engine Control Parts List (CPL) Number
____________________
Engine Oil Type and Viscosity

Fuel Pump Part Number
SAE grade 15 W 40
____________________
Filter Part Numbers:

Air Cleaner Element
____________________
Coolant (C-Series)
____________________
Lubricating Oil
____________________
Fuel
____________________
Belt Part Number (Alternator)
____________________
i-12
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
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 ........................................................................................................................................
Harness ........................................................................................................................................................
Extension Harness (Option) ..........................................................................................................................
Inputs ...........................................................................................................................................................
Outputs ........................................................................................................................................................
1-5
1-5
1-5
1-6
1-6
Sensors ................................................................................................................................................................
Magnetic Pick-up ..........................................................................................................................................
Coolant Temperature Sensor ........................................................................................................................
Intake Air Temperature Sensor .....................................................................................................................
Lube Oil Pressure Sensor .............................................................................................................................
Coolant Level Sensor ...................................................................................................................................
Actuator and Actuator Housing .....................................................................................................................
1-6
1-6
1-7
1-7
1-7
1-7
1-8
Connector Details ..................................................................................................................................................

Connector-A .................................................................................................................................................
Connector-B .................................................................................................................................................
Connector-C .................................................................................................................................................
Data Link Connector (9 Pin) ..........................................................................................................................
1-9
1-9
1-9
1-9
1-9
ECPG Hardwired Interconnections ...................................................................................................................... 1-10
1-2
Electronic control panel with speed

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

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

Operator Control Interface
Engine Monitoring
Engine Protection
System Fault Diagnostics.
Electronic Service Tool
Theory of operation
The magnetic pickup senses the engine speed at the
flywheel ring gear and generates an AC voltage with its
frequency proportional to the engine speed. The signal is
sensed by the ECPG and is used as a speed feedback.
ECPG
The actuator mounted in the actuator housing is used to

control the fuel flow from the fuel pump to the injectors.
Actuator valve (with no current flowing in the actuator
coil) is normally closed. Actuator opens depending upon
the current through the actuator coil.
The ECPG compares the electrical signal from the
magnetic pickup with a preset speed reference point (for
e.g. 1500 RPM). If there is a difference in the two signals,
the controller will change the amount of current flowing
through to the actuator coil.
A change in the amount of current to the actuator coil
makes the actuator shaft to linearly open/ close the fuel
outlet port, and controls the amount of fuel flow to the
engine. This in turn controls the engine speed.
The ECPG controls the engine speed at the set reference
speed (for e.g. 1500 RPM) from No load to Full load (For
Isochronous operation). It also provides programmable
speed droop function. It requires no special settings as
the software in the ECPG controls the engine speed.
ECPG
1-3
INTRODUCTION TO PARTS
The ECPG enclosure is made of glass reinforced plastic
and is divided into two halves, the front enclosure and
the rear enclosure.
&&&&
These two enclosures are sealed by a rubber seal.

Six M5 x 0.5, 50mm length Phillips head screws are used
for mounting it.
The ECPG comprises of two sub assemblies (printed

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

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

OEM connections, through three connectors called as
Connector A (19-pin), Connector B (10-pin), and Connector
C (7-pin). The CPU board interfaces with the service
tool through D-type connector called as datalink
connector.
I/O Board
1-4
The Connector A interfaces with the engine sensors and

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

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

The datalink connector is 9 pin D type connector
interfacing with PC based service tool.
The data link is intended to be used to connect single or
multiple ECPGs to a host computer acting as a supervisor
for facilitating data acquisition and logging using a PC
based service tool.
There are many features of the ECPG that are configured
using the service tool. Electronic service tool is a
packaged software application that installs on a IBM
compatible PC. The Service Tool is available as a Kit
(Part No. 4105287) on a CD. The Service PC, running
the ECP-G Tool is connected to the ECP-G via a RS-232
serial communication cable. The enclosed figure
illustrates the method used to connect the Service PC
via the engine harness to the ECP-G. The data link uses
two wire RS-485 serial communication standard. A RS485 to RS-232 convertor (Part No. 4071717) is required
for connecting the data link to a PCs RS-232 serial
communication port.
The configurable features will be discussed in this manual,
however, all functions of Service Tool are not covered.
Refer to the Service Tool manual (Part No. 3243816) for
more detailed information about using Service Tool. Note
that the PC that has the Service Tool software installed
requires a separate service cable to communicate with
the ECPG through the RS-485 service datalink connector
on the Engine Harness.
DATA LINK
CONNECTOR
CONNECTOR-C
4105287
ECPG
Service Tool
4073853
ECPG to data-link adapter
cable, adapter side stub
4071851
PC to data-link
adapter cable
4071935
ECPG
4071717
Data-link Adapter
4071852
ECPG to data-link
adapter cable ECPG
side stub
SERVICE TOOL
1-5
ECPG front panel

The front operator interface panel comprises of the
following:
(i) Four digit 7 Segment Display, to indicate the
scanned engine parameters.
8 GREEN
LEDs
&&&&
Three Position
Key Switch
Idle/Rated
Toggle Switch
8 RED
LEDs
(ii) A column of green LEDs on the left hand side with

legends to indicate the parameter being selected for
display.
(iii) A column of red LEDs on the right hand side with
legends to indicate the fault condition.
(iv) Scan Push button: The display is toggled between
All Parameters and Single Parameter scan mode
by the momentary pressing of the scan button. It is
mounted on the front plate of the ECPG.
(v) Three position key switch : The key switch on the
front panel is used to Wake up ECPG and start/
stop the engine. It is used to turn the 24 V DC battery
ON/OFF and thus start the engine. Refer Section ECPG Features, Power down mode.
(vi) Idle / Rated Toggle switch : The engine mode is
toggled between idle and rated using this switch.
Harness
The outputs from all the sensors are connected to the
ECPG through the engine harness. This harness is
connected to the ECPG through Connector A.
The other harness, which is the OEM harness connects
the OEM outputs like remote start, remote stop and alarm
relay drivers through Connector B.
Extension Harness (Option)
The Extension Harness provides the means for mounting
the ECPG off the engine, such as generator set or some
other remote location. This is accomplished by extending
the circuits from the engine harness connector to the
ECPG mounting location. The maximum length of
extension harness is 10 meters.
CA
UTION
CAUTION
No attempt should be made to bypass/tap
existing engine sensors, actuators or to operate
the engine using 3rd party governor control
systems.
Following inputs / outputs are connected to the ECPG
ENGINE
HARNESS
OEM
HARNESS
Scan Push
Button
1-6
by two harnesses at the rear of the ECPG.

Inputs
1. Battery Supply Voltage
2. Coolant Temperature sensor
3. Intake Air temperature sensor (only on KTA50G8 and
KTA38G5 engine models)
4. Lube Oil Pressure sensor
5. Engine speed sensor i.e. magnetic pickup
6. Low coolant level sensor
7. Scan push button
8. Key switch
9. Remote start
10. Remote stop
11. Idle / Rated switch
12. Alternate Frequency switch
13. Speed bias input
14. Battery charging failure indication
SENSOR FEEDBACK
15. Raise
AIR INTAKE TEMPERATURE
16. Lower
Outputs
1. Fuel shut-off valve
2. Starter magnetic switch
MAGNETIC
PICK-UP
ECP-G
FUEL PUMP
LOP
3. High coolant temperature alarm relay driver

ENGINE
4. Low lube oil pressure alarm relay driver
FUEL SHUTOFF VALVE,

FUEL ACTUATOR
5. High Intake air temperature alarm relay driver
OEM
INTERFACE
6. Engine overspeed relay driver

7. Fuel actuator
The figure shows how various parts are functionally
connected. Following major parts are included in the
ECPG.
SENSORS
a. Magnetic pickup
The magnetic pickup is an electromagnetic device. It is
mounted on the flywheel housing. It senses the engine
speed at the flywheel ring gear and generates AC voltage
with its frequency proportional to the engine speed. A
Two pin MS connector is provided to connect the magnetic
pick up to the engine harness.
The magnetic pickup is connected between pin B
(RPM ) and T (RPM +) of Connector A through engine
harness.
ECPG
1-7
b. Coolant temperature sensor
COOLANT TEMPERATURE SENSOR
A coolant temperature sensor is mounted on the

thermostat housing.
The sensor is fitted in an adapter. A two-pin connector
is provided to connect the coolant temperature sensor to
the engine harness.
The sensor is connected between pin P and N of
Connector A through the engine harness.
c. Intake Air temperature sensor
Intake Air
Temperature Sensor
The intake air temperature sensor is used to monitor the

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

LUBE
OIL
PRESSURE
SENSOR
Lube oil pressure sensor is mounted on the engine block

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

The coolant level sensor is a switch type sensor. It
is used to detect the coolant level of the engine. The
sensor is connected at Pin-R of Connector A to the
engine harness.
Note : The sensor locations shown in the figures are

of VTA-28 engine as an example.
1-8
f.
Actuator and actuator housing
The actuator is a linear proportional valve. The actuator

is housed in the aluminum housing. This assembly is
used as a valve for controlling the speed and horsepower
of the engine by controlling the fuel flow. The actuator is
connected between Pin-F and Pin-M of Connector A to
the engine harness.
Actuator
Actuator is closed when no current is flowing through the

actuator coil. When current is passed through the actuator
coil, the actuator port opens proportional to the actuator
current.
Housing
CONNECTOR DETAILS
Connector-A
Sr. No.
PIN
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
Battery (24 VDC) Negative

Engine speed sensor return
Not Connected
Fuel shut off valve output
Starter magnetic switch output
Fuel actuator output
Lube oil pressure sensor supply
Lube oil pressure sensor signal (output)
Lube oil pressure sensor return
Datalink start output relay driver (future expansion)
Battery (24 VDC) Positive
Fuel actuator return
Coolant temperature sensor signal
Coolant temperature sensor signal
Coolant level sensor signal
Intake Air temperature sensor signal
Engine speed sensor signal
Intake Air temperature sensor signal
Battery charging failure signal
Connector-B
Sr. No.
Letter
1
2
3
4
5
6
7
8
9
10
A
B
C
D
E
F
G
H
I
J
Description
Battery (24 VDC) Negative
Speed raise / Alternate Frequency
Speed lower
Remote Start
High intake air / Engine overspeed alarm relay driver
Low lube oil pressure alarm relay driver
High coolant temperature alarm relay driver
Customer selectable output
Speed bias signal
Remote stop
Data Link Connector (9 pin)

Sr. No.
Letter
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
Description
Data link positive
Data link negative
Not connected
Not connected
Not connected
Not connected
Not connected
Not connected
Not connected
Connector - C (Future use)

Sr. No.
Letter
1
2
3
4
5
6
7
A
B
C
D
E
F
G
Description
Electrical STC valve return
Not connected
Not connected
Fuel rail pressure sensor signal (output)
Fuel rail pressure sensor supply
Fuel rail pressure sensor return
Electrical STC valve output
1-9
1-10
ECPG Hardwired Interconnections

Data Link
Connector
Service Tool
Interface
Connector A
Engine Sensors
Speed
Coolant Temperature
Intake Air Temperature
Lube Oil Pressure
Coolant Level
FSO valve
ECPG Power & Ground
Fuel Actuator
Starter magnetic S/W
Connector C
Future Scope
ECPG Rear Vie

w
View
ECPG Fr
ont Vie
w
Front
View
Remote Start
Remote Stop
Speed bias
Switch Input
Raise
Lower
Alternate frequency
Lamp / Relay Driver
Low lube oil pressure alarm
Coolant Temperature Alarm
Air intake temperature/
Over Speed Alarm
Customer O/P
OFF / RUN /
START
Mode
Idle / Rated
mode
Single
Parameter /
All parameters
Scan mode
Connector B
2-1
SECTION 2
ECPG DET
AILS
DETAILS
Page
ECPG Dimensions ................................................................................................................................................ 2-2
ECPG Electronic Interfaces .................................................................................................................................. 2-3
ECPG Features .................................................................................................................................................... 2-4
Power Down Mode ........................................................................................................................................
Key Switch and Starter Protection ................................................................................................................
Over Cranking Prevention .............................................................................................................................
Parameter Selection Push Button .................................................................................................................
Idle / Rated Mode Selection .........................................................................................................................
Engine Running Hours ..................................................................................................................................
FSO Supply / Fuel Actuator Command .........................................................................................................
Alarm Relay Drivers .....................................................................................................................................
Remote Start ................................................................................................................................................
Remote Stop ................................................................................................................................................
Battery Voltage ............................................................................................................................................
Battery Charging Indication ...........................................................................................................................
2-4
2-4
2-5
2-5
2-6
2-6
2-6
2-6
2-7
2-7
2-7
2-7
2-2
ECPG DIMENSIONS (PART DESCRIPTION)
7
263.9
6
5
313.9
3875362
4071721
4084285
504975
4
4084219
3
4084218
4083975
REF. NO.
97.3
21
1
PLATE,COOLER
SWITCH,PUSH BUTTON
SWITCH,TOGGLE
SWITCH, IGNITION
PANEL BACK
1
PANEL DISPLAY
SEAL,FRONT COVER
ITEM DESCRIPTION
ITEM NO.
QTY.
The ECPG measures 314 x 264 x 118 mm including the heat-sink. Refer to the section Installation for details and cautions
before selecting a location for mounting the ECPG.
2-3
ECPG ELECTRONIC INTERFACES
(OEM Scope of
Supply)
2-4
ECPG FEA
TURES
FEATURES
a. Power do
wn mode
down
Unswitched 24 VDC volts is connected to the ECPG
through Connector A.
When the key switch is turned to Run position :
-
ECPG wakes up from sleep mode and executes

hardware check where the LEDs and Displays are
checked. ECPG then enters into all parameters scan
mode and is ready to start the engine.
When the key switch is turned to OFF position/key S/W

is in run position and engine is not running.
-
ECPG will not turn off immediately but the power

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

Power down mode can be disabled temporarily using

the service tool as per the attached illustration.
b. Key switch and starter protection

The key switch on the front panel is used to turn on or off
the 24 volts DC battery supply to the ECPG. The key
switch is a three-position switch which controls the three
modes as off, run, start.
i)
OFF
Off mode :
The key switch in off mode disconnects the
supply to the FSOV and fuel actuator, resulting
in engine shut down. It also transits the ECPG
to power down mode.
ii)
Run mode :
When the key switch is turned to Run position,
the controller wakes up. Carries out self check
and is ready to start the engine.
RUN
iii) Start mode :

Turn and hold the key switch to Start position,
for controller to energize the starter magnetic
switch.
A built in software mechanism disengages the
supply to the starter magnetic switch after six
seconds and prevents the starter from damage.
The controller also ramps up the engine speed
from crank to idle/rated mode in a predetermined
time period.
Note : For Amf application, key switch should always
be in R
UN position to star
RUN
startt the engine
through remove start input.
START
2-5
c. Over cranking prevention

Starter disengage speed
> 300 RPM
Engine Speed
300
Starter
solenoid condition
Fail
to
start
/
crank
6 sec.
ON
6 sec.
ON
ON
6 sec.
OFF
6 sec.
OFF
Crank
Speed
When the key switch is held in Start position, the starter

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

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

The starter protection is based on engine speed and not

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

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

The parameter selection switch acts as a toggle to select

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

In all parameters scan mode, all the parameters are

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

continuously on the 7-segment digital display.
2-6
e. Idle / Rated Mode Selection

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

The reading is refreshed after every hour on the display.
g. FSO supply / Fuel actuator command

The percentage duty cycle of the actuator PWM command
is indicated on the front display. This fuel actuator
command is proportional to the current flowing through
the actuator.
RUN
The supply to the fuel shut off valve is turned on the

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

RUN
h. Alarm Relay Drivers

Relays are connected between point E or F or G or H and
point A of the OEM harness for alarm indication.
Use suitable relays as shown in OEM connector wiring
diagram OR use suitable interface circuits to make use
of the alarm relay driver outputs..
Refer Section 8-2 for specification of relays to be used.
HCT ALARM
G
LLOP ALARM
OS/HIGH IMT ALARM
CUSTOMER
SELECTION
OUTPUT
OEM INTERFACE PANEL
H
I
A
B
A1;
J
E
OEM CONNECTOR "B

ON CONTROLLER
OEM "B" CONNECTOR
J
C
F
D
Remote start
Note that the Starter magnetic switches (2 Nos. in case

of KV engines) draw current from this 24 V source. The
cables and the contact must therefore be appropriately
rated. Recommend 10 amps capability. It also includes
starter protection and over cranking preventation.
PIN D
N/O
CONTACT
i.
Applying +24 volts DC (with respect to engine battery

negative) through an external contact at Pin D of the
Connector B, would start the engine with this remote start
command. +24 volts DC should be applied continuously
at this input till engine starts.
2-7
+ 24 V D C (+24)
Note : Use potential free contact for this input.

j.
OEM "B" CONNECTOR
H
I
Note : Applying +24 volts DC to Remote Start and

Remote Stop inputs at the same time shall not start
the engine.
J
C
F
E
On applying 24 volts DC is externally applied to pin J of

the Connector B, the supply to the fuel shut off valve is
removed and fuel actuator is closed the engine is shut
down remotely.
+ 24 V DC
Remote stop
PIN J
N/O
CONTACT
Note : Use potential free contact for this input.

CAUTION
Do not connect +24V from battery to pin A (ground)
of OEM connector
connector..
k. Battery voltage
"
A 24V battery is connected to power up the ECPG. This

battery voltage is measured and displayed on the digital
display.
Battery
Voltage
l.

Battery
Charging
failure
Battery Charging Indication
With no charging current flowing to the battery from the

charging alternator, the charging failure LED glows . Hence
this LED glows when the engine is not running.
As the engine starts running and the charging alternator
starts supplying charging current to the batteries, the
LED turns OFF.
If this LED glows when the engine is running, it indicates
that the charging alternator is not generating voltage.
2-8
NOTES
_________________________________________________________________________________________
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_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
3-1
SECTION 3
ENGINE STARTUP AND ADJUSTMENTS
Page
Engine Startup and Adjustments ........................................................................................................................... 3-2
Governor Gain Adjust ................................................................................................................................... 3-2
Droop Adjust ................................................................................................................................................ 3-2
Isochronous Mode ........................................................................................................................................ 3-3
Frequency Adjust ......................................................................................................................................... 3-3
Raise/Lower Switches .......................................................................................................................... 3-3
Speed Bias Input ................................................................................................................................. 3-3
Alternate Frequency ............................................................................................................................. 3-4
3-2
ENGINE STARTUP AND ADJUSTMENTS
Service Tool
Configurable
Feature
a. Governor gain adjust

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

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

% Droop = x 100
Full Load Speed
If the rated kW is not available, use the available kW to

get the engine speed, as computed by the formula :
3 % DROOP
Note : The default Droop is factory set to 3%.
51.50
51
FREQUENCY (Hz)
Available kW load
S = NLS x (NLS - FLS)
(Rated kW load)
Where,
S
= Speed at available load
NLS = No load speed (Same as high idle speed)
FLS = Full load speed
(Rated speed normally 1500 RPM)
50
49
0%
50 %
LOAD
100%
3-3
c. Isochronous mode
ISOCHRONOUS SPEED MODE
FREQUENCY (Hz)
For Isochronous speed operation, the droop setting needs

to be set at 0 %.
51
The droop setting can be adjusted using the service tool.

50
49
0%
50 %
100%
LOAD
OEM B CONNECTOR
d. Frequency Adjust
The Frequency adjust can be effected through Speed
Raise to Speed Lower Inputs, or through Speed bias
Input one of these sources can be selected through PC
Based tool settable trim.
SPEED RAISED
i)
Two switch input contacts called as Speed Raise

and Speed Lower are provided on the Connector B
to adjust the generator set frequency. The frequency
is adjusted within +/- 4 Hz of rated operating
frequency.
SPEED LOWER
(+) 24 VDC
OEM / CUSTOMER PANEL
The customer can implement the frequency adjust

feature by connecting the speed Raise / speed Lower
push buttons on the Connector B to (+) 24 Volts.
Service Tool
Configurable
Feature
The engine speed will increase or decrease at a pre

programmed rate depending upon the switch
selected. The Raise / Lower ramp rate can be
programmed through the service tool as shown in
the enclosed figure..
Data Link
Convertor
Feature
Parameter
= Reference Speed
= Speed Adjust Source
Note : Use potential free contacts for these inputs.

ii) Speed Bias input
To ECPG
Service Tool
Configurable
Feature
Feature
Parameter
Raise / Lower Switches
The speed bias input can be implemented by

connecting a 0 5 Volts analog input at pin number
I Connector B with reference to engine battery
negative.
Note : The speed bias signal and the signal return
conductors must be protected from EMI by using a
twisted, shielded cable. One end of the shield must be
connected at Pin A of Connector B at the ECP-G end
and the other end to be left open.
= Reference Speed
= Speed Adjust Ramp Rate
Data Link
Convertor
Caution
To ECPG
The Voltage input must not exceed 5 Volts DC for the

speed bias input. Improper configuration or
adjustment of speed bias input feature can cause
3-4
unstable engine operation. The customer is

responsible for performing the necessary system
tests to ensure that the feature is properly configured.
The Speed bias Trim feature can be enabled using the
service tool as described in the enclosed figure.
OEM "B" CONNECTOR
ANALOG OUTPUTS
(0 - 5 V D C )
J
C
F
E
e. Alternate Frequency Input (50/60 Hz)

An alternate frequency input is provided for selection
between one of the two generator set frequency settings
(50 Hz or 60 Hz).
OEM / CUSTOMER PANEL
This feature can be set through the service tool as shown

in the enclosed figure.
Note : The alternate frequency selection feature is only
enabled for engines rated for dual speed operation. For
engines rated for single speed operation, the alternate
frequency input is non operational and no service tool
related settings need to be made.
If the frequency selection using the alternate frequency
input changes for dual speed engine operation while the
engine is running, the selected frequency setting will not
take effect until the engine is shut down and restarted.
The frequency adjust feature using Speed Raise / Speed
Lower inputs is ineffective for dual speed operation.
All software calibrations in the ECP-G shipped out of the
factory have a default setting of 50 Hz ONLY operation.
Separate software calibration(s) needs to be downloaded
into the controller if the genset is to be operated @ 60 Hz
ONLY or 50 Hz / 60Hz (Dual speed operation).
Note : For the Dual speed operation (50 Hz or 60 Hz)
the Raise / lower feature(s) are disabled in the software
calibration.
Note : Alternate frequency feature can be used for
single g
enset application onl
y.
genset
only
Service Tool
Configurable
Feature
Data Link
Convertor
Feature
Parameter
= Reference Speed
= Genset Operating Mode
To ECPG
4-1
SECTION 4
ENGINE PROTECTION
Page
Engine Protection .................................................................................................................................................. 4-2
Fault Diagnosis ............................................................................................................................................ 4-2
Fault Codes .................................................................................................................................................. 4-2
Service Tool ................................................................................................................................................. 4-3
Alarm Relay / Lamp Drivers .......................................................................................................................... 4-4
Fault Acknowledge / Reset ........................................................................................................................... 4-4
4-2
ENGINE PROTECTION
The engine protection parameters shown on the right can
be configured within preset limits using the service tool.
The service tool does not allow to set the values of the
parameter beyond the minimum and maximum limits. The
service tool does not allow the setting of parameter
values beyond the minimum and maximum limits.
Engine Speed
Coolant Temperature
Lube Oil Pressure
Air Inlet Temperature
Coolant Level
a. Fault Diagnosis
There are eight red colour LEDs on the front display of
the ECPG. These LEDs light up individually when a
fault is reported active by the ECPG.
#
Fault diagnosis is displayed next to the LED which is

illuminated.
Individual
LED
glow
when
fault is
detected.
Note : Only active faults are displayed on ECPG digital

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

following way :
1) ECPG Front Panel.
When a fault is detected by the ECPG, the red LED on
the right hand side row ECPG Fault detected lights up.
The user can use the scan push button to view all the
active faults detected by the ECPG displayed in
sequence.
#
LED
glow
when a
fault
occurs.
4-3
Fault Code Viewing :
All
parameters
scanned
sequentially
Procedure for viewing fault code varies slightly depending

on whether user is in Single parameter or continuous
scan mode.
#
Single Parameter Mode :
Toggle
between
Single scan /
all parameters
scan mode.
Example : Consider that user is monitoring Coolant

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

release the scan push button, at this position to
select ECP fault code.
#
8. The display will show all fault codes stored in memory

sequentially.
Toggle
between
Single scan /
all parameters
scan mode.
Service Tool
Configurable
Feature
When ECP fault code is selected for display, any new

fault code will be displayed, when it is registered in the
ECPG. When engine has shut down as a response to
fault, ECPG may power down in the stipulated time before
the user has viewed the fault code. In this case, fault
codes can be viewed even at next power ON the ECPG
following the above procedure.
c. Ser
vice Tool
Service
The engine protection parameters and the fault codes
are available to the user using the service tool.
Data Link
Convertor
Feature
Trim
= Reference Speed
= Droop
To ECPG
4-4
d. Alarm Relay / Lamp Drivers

Four (4) output drivers are provided to annunciate the
specific engine protection alarm conditions that have
occurred. Individual output of these drivers can be used
to drive either a lamp or a relay. Following relay / lamp
drivers are provided :
Engine Warning conditions :
(1) High Coolant Temperature
(2) Low Lube Oil Pressure
(3) Engine Overspeed / High Intake Air Temp.
shutdown
(4) Customer output.
HCT ALARM
G
LLOP ALARM
OS/HIGH IMT ALARM
CUSTOMER
SELECTION
OUTPUT
OEM INTERFACE PANEL
H
I
A
B
A1;
J
E
OEM CONNECTOR "B

ON CONTROLLER
Each relay / lamp driver is capable to handle a rated

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

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

OFF position.
5-1
SECTION 5
ECPG - FAULT CODE INFORMATION
Page
ECPG Fault Code Information ............................................................................................................................... 5-2
ECPG Fault Response Threshold ......................................................................................................................... 5-5
5-2
Electronic Control Panel + Governor (ECPG)

Fault Code Information
Engine
Protection/
System Fault
Default
Fault Response
Fault Description
Effect (Only when fault is active)
135
System
Warning
Engine Lube Oil Pressure sensor signal is

shorted high
No engine protection for Lube Oil Pressure.

No effect on engine performance.
141
System
Warning
Engine Lube Oil Pressure sensor signal is

shorted low
No engine protection for Lube Oil Pressure.

143
Engine
Protection
Warning
Engine Lube Oil Pressure has dropped below the

warning threshold for Low Lube Oil Pressure
Low Lube Oil Pressure warning relay driver is

energized. No effect on engine performance.
144
System
Warning
Engine Coolant Temperature sensor signal is

shorted high
No engine protection for Coolant Temperature.

145
System
Warning
Engine Coolant Temperature sensor signal is

shorted low
No engine protection for Coolant Temperature.

146
Engine
Protection
Warning
Engine Coolant Temperature has exceed the

warning threshold for High Coolant Temperature
High Coolant Temperature warning relay driver is

energized. No effect on engine performance.
151
Engine
Protection
Shutdown
Engine Coolant temperature has exceed the

shutdown threshold for high Coolant Temperature
Engine will shutdown.
153
System
Warning
Engine Intake Air Temperature sensor signal is

Shorted high
No engine protection for Intake Air Temperature.

154
System
Warning
Engine Intake Air Temperature Sensor signal is

shorted low
No engine protection for Intake Air Temperature.

Fault
Code
Fault
Code
Engine
Protection/
System Fault
Default
Fault Response
Fault Description
155
Engine
Protection
Warning
Engine Intake Air Temperature has exceed the

warning threshold for High Intake Air Temperature
High Intake Air Temperature warning relay driver

is energized. No effect on engine performance.
234
Engine
Protection
Shutdown
Engine Speed Signal indicates that engine speed

is greater than Overspeed threshold
Engine will shutdown. Fuel Shut-Off Valve

(S.D. Coil) is de-energized (valve closed).
Overspeed shutdown relay driver is energized.
235
Engine
Protection
Shutdown
Engine Coolant Level has dropped below the

shutdown threshold for Low Coolant Level.
359
System
Warning
Engine cranked but failed to start
No effect on engine performance
415
Engine
Protection
Shutdown
Engine Lube Oil Pressure has dropped below the

shutdown threshold for Low Oil Pressure
441
System
Warning
Low voltage has been detected for battery

during engine crank.
Engine may not crank. Possible loss of ECPG

functionality.
1411
System
Warning
Speed Bias Analog Input signal is shorted high
The Speed Bias Analog Input signal feature will

be disabled. Possible loss of engine
performance.
1416
System
Warning
Engine fail to shutdown
Engine failed to stop even after a stop command

was issued by the system. No engine
protection feature.

5-3
5-4

Engine
Protection/
System Fault
Default
Fault Response
Fault Description
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.
3116
System
Warning
Fuel Actuator PWM signal is close to maximum

for long enough time due to possibly stuck
actuator or insufficient fuel supply.
Possible loss of engine performance at

higher loads.
3118
System
Warning
Powerdown hardware within ECPG malfunctioning.
1) No effect on engine performance.

2) ECPG will not powerdown. Potential
battery drain.
Fault
Code
5-5
ECPG FAULT RESPONSE THRESHOLD

Engine Parameter
Fault Response (default values)
Threshold (default values)
Engine Overspeed
Shutdown
110% of rated RPM for 1500 RPM

110% of rated RPM for 1800 RPM
Warning
90oC (194 oF)

93oC (199 oF)
Shutdown
96oC (205 oF)
High Intake Manifold Temperature

Warning
Warning
75oC (167 oF)
Low Lube Oil Pressure Warning
Warning
RPM
0
500
1100
1500
Threshold (bar)
0
0.5
1.0
2.7
Low Lube Oil Pressure Shutdown
Shutdown
RPM
0
500
1100
1500
Threshold (bar)
0
0.3
0.6
2.4
Low Coolant Level
Shutdown
Low Coolant Level
High Coolant Temperature Warning
High Coolant Temperature Shutdown
5-6
NOTES
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6-1
SECTION 6
TROUBLESHOOTING
Page
Fault Code 135 ...................................................................................................................................................... 6-2
Fault Code 141 ...................................................................................................................................................... 6-3
Fault Code 143 ...................................................................................................................................................... 6-4
Fault Code 144 ...................................................................................................................................................... 6-6
Fault Code 145 ...................................................................................................................................................... 6-7
Fault Code 146 ...................................................................................................................................................... 6-8
Fault Code 151 .................................................................................................................................................... 6-10
Fault Code 153 .................................................................................................................................................... 6-12
Fault Code 154 .................................................................................................................................................... 6-13
Fault Code 155 .................................................................................................................................................... 6-14
Fault Code 234 .................................................................................................................................................... 6-15
Fault Code 235 .................................................................................................................................................... 6-16
Fault Code 359 .................................................................................................................................................... 6-17
Fault Code 415 .................................................................................................................................................... 6-18
Fault Code 441 .................................................................................................................................................... 6-20
Fault Code 1411 .................................................................................................................................................. 6-21
Fault Code 1416 .................................................................................................................................................. 6-22
Fault Code 1438 .................................................................................................................................................. 6-23
Fault Code 3111 .................................................................................................................................................. 6-24
Fault Code 3112 .................................................................................................................................................. 6-25
Fault Code 3113 .................................................................................................................................................. 6-26
Fault Code 3115 .................................................................................................................................................. 6-27
Fault Code 3116 .................................................................................................................................................. 6-28
Fault Code 3118 .................................................................................................................................................. 6-29
6-2
TR
OUBLESHOO
TING
TROUBLESHOO
OUBLESHOOTING
Fault Code
135
Reason
Engine Lube Oil Pressure sensor signal is shorted high.
Cause
Lube Oil Pressure sensor

short
OK
Engine harness defective
OK
ECPG Malfunctioning
Effect (Only when fault code is

active
Warning
No engine protection for Lube Oil
Pressure. No effect on engine
performance.
Correction
Inspect the sensor for damaged,
corroded, bent, broken, expanded or
pushed back pins. If sensor pins are
found damaged, replace the sensor.
Also inspect the sensor for dirt,
debris, moisture in or on the sensor
pins.
If observed, flush the dirt, debris,
moisture from the sensor pins.
Check the lube oil pressure sensor
as per sensor specification. If it is
not as per sensor specification,
replace the sensor.
Check the sensor supply voltage
between pin G and pin J of engine
harness. If no sensor supply voltage
is observed, check the engine
harness for continuity.
Check supply voltage = 5V if the lube
oil pressure sensor signal wire
(pin H) is shorted to + 5V sensor
supply wire pin G in the engine
harness. If short is observed in the
harness, repair the wires, that have
short circuits or replace the engine
harness.
Replace the ECPG.
Fault Code
141
Reason
Engine Oil pressure sensor signal is shorted low.
Cause

open
OK
OK
ECPG Malfunctioning
6-3

active)
Warning
No engine protection for Lube Oil
Pressure. No effect on engine
performance.
Correction
Inspect the sensor for damaged,
corroded, bent, broken, expanded or
pushed back pins. If sensor pins are
found damaged, replace the sensor.
pins.
not as per sensor specification,
replace the sensor.
harness. If no sensor supply voltage
is observed, check the engine
harness for continuity.
Check supply voltage = 5V if the lube
oil pressure sensor signal wire
(pin H) is shorted to + 5V sensor
supply wire pin G in the engine
harness. If short is observed in the
harness, repair the wires, that have
harness.
Replace the ECPG.
6-4
Fault Code
Reason
Engine Oil Pressure has dropped below the warning
threshold for low lube oil pressure.
143
Cause
Insufficient lube oil in engine

active)
Warning
Low lube oil pressure warning relay
driver is energized.
Correction
Check the dipstick calibration.
Check the oil level in the engine.
Add oil if level below dipstick mark.
OK

not at correct location on
engine
Check the mounting location of lube

oil pressure sensor on engine. Refer
to engine specification. If location is
incorrect, relocate sensor and
check operation.
OK
Lube oil diluted with fuel or

coolant
OK
Full flow lube oil filter(s)

plugged
Check for fuel or coolant

contamination in the lube oil.
If contaminated, remove the cause.
Drain all the oil in engine and fill the
fresh lube oil in the engine.
Replace lube oil filter(s).
OK
Lube oil suction tube broken

or tube seals leaking
Remove oil sump. Inspect/replace

the suction tube.
OK
Malfunction lube oil pressure

regulator in lube oil filter
head.

suction tube.
OK
Lubricating oil pump

malfunction
Inspect lubricating oil pump. repair

or replace the pump if necessary.
Fault Code
Reason
Engine Oil Pressure has dropped below the warning
threshold for low lube oil pressure.
143
Contd.
Cause
Lube oil pressure sensor

defective
6-5

active)
Warning
Low lube oil pressure warning relay
driver is energized.
Correction
not as per specification, replace the
sensor.
OK
Sensor getting + 5 V supply

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

connector A and engine harness
(pin G, pin H or pin J). If no
continuity is observed, repair the
wires that have short circuits or
replace the engine harness.
Replace the ECPG.
6-6
Fault Code
Reason
144
Engine coolant temperature sensor signal is shorted high.
Cause
Coolant Temperature
sensor short
OK
OK
ECPG Malfunctioning

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

sensor signal wire (pin N) shorted
to + 24 V battery supply in the
engine harness. If short is observed,
repair the wires that have short
circuits, or replace the engine
harness.
Replace the ECPG.
Fault Code
Reason
145
Engine Coolant Temperature sensor signal is shorted low.
Cause
Coolant Temperature
sensor open
OK
OK
ECPG Malfunctioning
6-7

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

sensor signal wire (pin N) shorted
to ground in the engine harness. If
short is observed, repair the wires
that have short circuits, or replace
the engine harness.
Replace the ECPG.
6-8
Fault Code
Reason
Engine Coolant Temperature has exceeded the warning
threshold for high coolant temperature
146
Cause
Coolant Level low

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

high
Disconnect underhood air. Check

for air recirculation from radiator
entering air cleaner
OK
Radiator/Heat Exchanger
fins obstructed or damaged
Check fins for damage and debris.
OK
Pipe coupling or hose

collapsed
Check the pipe coupling or hose if

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

viscous fan malfunction
Check fan RPM.
OK
Radiator Cap Malfunction
Check / replace radiator cap.
Fault Code
Reason
Engine Coolant Temperature has exceeded the warning
146
Contd.
Cause
Loss of Raw water supply
to HE
6-9

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

or damaged (internal)
Inspect radiator and clean if

necessary.
OK
Water pump malfunctioning
Check the water pump and replace

it if incase found defective.
OK
Coolant Temperature
sensor defective

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

(+ 12 V) between pin N and pin A
of engine harness. If not, repair the
wires that have short circuits / open
circuits or replace the engine
harness.
Replace the ECPG.
6-10
Fault Code
Reason
151
Engine coolant temperature has exceeded the shutdown

Cause
Coolant Level low

active)
Shutdown
Engine will shutdown
Correction
Check level. Add coolant, if
necessary.
OK
Intake Air temperature too

high
Disconnect underhood air. Check

for air recirculation from radiator
entering air cleaner
OK
Radiator/HE fins
obstructed or damaged
Check fins for damage and debris.
OK
Pipe coupling or hose

collapsed
Check the pipe coupling or hose if

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

viscous fan malfunction
Check fan RPM.
OK
Radiator Cap Malfunction
Check /replace radiator cap.
Fault Code
151 Contd.
Reason
Engine coolant temperature has exceeded the shutdown
Cause
Loss of Raw water supply
to HE
6-11

active)
Shutdown
Engine will shutdown
Correction
Check the raw water flow pressure
and see whether it is in the
specified limit.
OK
Radiator core obstructed

or damaged (internal)
Inspect radiator and clean if

necessary.
OK
Water pump malfunctioning
Check the water pump and replace

it if incase found defective.
OK
Coolant Temperature
sensor defective

sensor as per sensor specification.
replace the sensor.
OK
OK
ECPG Malfunctioning

(+ 12 V) between pin N and pin A
of engine harness. If not, repair the
wires that have short circuits / open
circuits or replace the engine
harness.
Replace the ECPG.
6-12
Fault Code
Reason
153
Engine Intake air temperature sensor signal is shorted high.
Cause
sensor short
OK
OK
ECPG Malfunctioning

active)
Warning
No engine protection for Intake Air
Temperature. No effect on engine
performance.
Correction
Check the Intake Air Temperature
sensor.
Check if the Intake Air Temperature

sensor signal wire (pin S) is
shorted to + 24 V battery supply in
the engine harness. If short is
observed, repair the wires that have
harness.
Replace the ECPG.
Fault Code
Reason
154
Engine Intake Air Temperature sensor signal is shorted low.
Cause
sensor open
OK
OK
ECPG Malfunctioning
6-13

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

sensor signal wire (pin S) shorted
to ground in the engine harness. If
short is observed, repair the wires
that have short circuits or replace
the engine harness.
Replace the ECPG.
6-14
Fault Code
Reason
Engine Intake Air Temperature has exceeded the warning
threshold for high intake air temperature.
155
Cause

Sensor defective.
OK
LTA Pump failure

active)
Warning
High intake air temperature
warning relay driver is energized.
Correction
Check the nominal resistance with
DMM (Digital multimeter) of Intake
Air temperature sensor by referring
sensor specification.
replace the sensor.
Check for LTA pump working. If not,

replace the pump. Also check LTA
raw water pump operation.
OK
Incorrect engine installation

or mechanical problem
OK
ECPG Malfunctioning
Check :
- CAC plumbing.
- Engine compartment
temperature
- Lack of insulation on exhaust
manifold or turbocharger.
Replace the ECPG.
Fault Code
Reason
Engine speed signal indicates that engine speed greater
than overspeed threshold.
234
Cause
Incorrect calibration
OK
Fuel Actuator stuck in open

position
6-15

active)
Shutdown
Overspeed shutdown relay driver is
energized.
Correction
Use proper calibration and check
engine overspeed limit is set
sufficiently higher than the rated
engine speed.
Clean or replace the fuel actuator.
OK
Fuel actuator getting +24V

battery supply continuously
OK
Check other engine related

factors referring to engine
T & R Manual
If +24 V supply is present on

actuator,
1) check the engine harness for
actuator connection shorting to
supply voltage.
If short, repair the wires that have
short circuits or replace the
engine harness.
2) If supply voltage is still present
on actuator, replace the ECPG.
Refer T & R Manual.
6-16
Fault Code
Reason
Engine coolant level has dropped below the shutdown
threshold for low coolant level.
235
Cause
Coolant is low

active)
Shutdown
Correction
Check the coolant level.
Add coolant, if necessary.
OK
Coolant level sensor faulty
OK
Inspect the coolant level sensor for

damaged, corroded, bent, broken,
expanded or pushed back pins. If
sensor pins are found damaged,
replace 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
359
Reason
Engine cranked but failed to start
6-17

active)
Warning
Cause
Fuel in the tank is low
Correction
Add fuel.
OK
Fuel filter choked
Clean or replace the fuel filters.
OK
Fuel inlet restriction

excessive
Inspect the fuel line and remove the

obstructions and clean the line.
OK
Check air in the fuel. Tighten the
fuel line connections. Tighten filter.
Check tank stand pipe
Air in fuel
OK
Fuel shut off valve not getting

the + 24 V battery supply
OK
Fuel Shut Off Valve not

operating
Check the engine harness for FSO

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

sticky
Check the engine harness for

actuator connection, short or open,
if faulty, repair the wires that have
short circuits / open circuits or
If voltage is still not preset, replace
the ECPG.
Check the fuel actuator coil
resistance. If as per specification,
check actuator for stickiness. If
sticky, clean / replace the actuator.
If coil resistance not as per
specification, replace the actuator.
6-18
Fault Code
Reason
415
Engine Lube Oil Pressure has dropped below the shutdown

threshold for low oil pressure
Cause
Incorrect Oil level

active)
Shutdown
Correction
Check the dipstick calibration.
Check the oil level. Add oil if
necessary.
OK
Lube Oil pressure sensor

not at correct location
Check location. Refer to engine

specification. Relocate sensor, and
check operation.
OK
Lube Oil diluted in the

engine with fuel or coolant
Check for fuel or coolant

contamination in the engine oil. If
contaminated remove the cause.
Drain the oil. Fill the fresh oil.
OK
Full flow Lube Oil filter

plugged
Replace oil filter.
OK
Oil suction tube broken or

tube seals leaking.

suction tube.
OK
Malfunction Oil pressure

regulator in Oil Filter head.

suction tube.
OK
Lubricating Oil pump

malfunction
Inspect lubricating oil pump.

Replace or repair the pump if
possible.
Fault Code
Reason
415
Contd.
Engine Lube Oil Pressure has dropped below the shutdown

threshold for low oil pressure
Cause

defective
6-19

active)
Shutdown
Correction
not as per specification, replace the
sensor.
OK
Sensor getting + 5 V supply

harness. If not, check the engine
harness.
OK
OK
ECPG Malfunctioning

connector A and engine harness
(pin G, pin H or pin J). If no
continuity is observed, repair the
wires that have short circuits or
Replace the ECPG.
6-20
Fault Code
441
Reason
Low voltage has been detected during engine crank
Cause
Battery charge low

active)
Warning
1) Engine may not crank.
2) Possible loss of ECPG
functionality.
Correction
Check electrolyte level and specific
gravity of battery cells. If low,
charge or replace the battery.
OK
Battery rating too low
Replace battery with correct rating.
OK
ECPG Malfunctioning
Replace the ECPG.
Fault Code
1411
Reason
Speed Bias Analog Input signal is shorted high.
Cause
The Speed Bias Analog Input

Signal shorted to high
OK
Source of signal delivering

Speed Bias voltage from
O.E.M. equipment stuck to
high.
6-21

active)
Warning
The Speed Bias Analog Input Signal
feature will be disabled.
Correction
Check the O.E.M. harness for short
circuit the signal wire to + 5 V or
+ 24 V battery supply.
the O.E.M. harness.
Isolate the ECPG. Check and

rectify the source of signal from
O.E.M. equipment.
If problem still persists, replace the
O.E.M. source of signal equipment.
OK
ECPG malfunctioning
Replace the ECPG.
6-22
Fault Code
1416
Reason
Engine fail to shutdown
Cause
Fuel Shut Off valve
permanently ON after
turning the key switch from
Run position to Off
position.
OK
Fuel Shut Off valve is in

manual override mode

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

override screw on fuel shutoff valve
is out to maximum travel.
OK
Fuel Shut Off valve

malfunctioning
OK
Engine fuel drain line

restricted
Check that the Fuel Shut Off valve

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

reroute engine fuel drain line.
OK
Engine injector(s)
malfunctioning or injector(s)
O-ring(s) damaged.
Please refer T & R manual of the

engine for mechanical and fuel
systems repair problems.
Fault Code
1438
Reason
Engine fail to crank
Cause
MPU not operative (fault
occurs even if engine cranks)
6-23

active)
Warning
Correction
Refer to Speed Signal Lost fault
diagnosis. See fault code 3115.
OK
Battery connections are

broken, loose or corroded
Clean and tighten the Battery

connections.
OK
Battery charge low
Check electrolyte level and specific

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

component Malfunctioning.
OK
Check whether engine drive

unit engages
OK
Engine starting Motor pinion

or ring gear on pinion
damage
Check if +24 V battery supply appears at starter magnetic switch during

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

cylinder
Check intake or exhaust valve

operation.
6-24
Fault Code
Reason
Speed Bias Analog Input signal is shorted low.
3111
Cause

Signal shorted to ground

active)
Warning
signal feature will be disabled.
Possible loss of engine
performance.
Correction
Check the O.E.M. harness for short
circuit the signal wire to ground.
the O.E.M. harness.
OK
Source of signal delivering

Speed Bias voltage from
O.E.M. equipment stuck to
low.
Isolate the ECPG. Check and

rectify the source of signal from
O.E.M. equipment.
If problem still persists, replace the
O.E.M. source of signal equipment.
OK
ECPG malfunctioning
Replace the ECPG.
Fault Code
3112
Reason
Speed Raise switch is shorted High
6-25

active)
Warning
The Speed Raise Switch feature will
be disabled.
Cause
Correction
The Speed Raise Switch on

the A.M.F. or Customer
panel shorted to high.
Check the speed raise switch on the

A.M.F. or customer panel for short.
If short is observed, repair or replace
the switch.
OK
OEM harness defective
OK
ECPG malfunctioning
Check the O.E.M. harness for

speed raise input short to +24 V
battery supply. If short circuit is
observed, repair the wires that have
short circuits or replace the O.E.M.
harness.
Replace the ECPG.
6-26
Fault Code
3113
Reason
Speed Lower switch is shorted high

active)
Warning
The Speed Lower Switch feature will
be disabled.
Cause
Correction
The Speed Lower Switch

on the A.M.F. or customer
panel shorted to high.
Check the speed lower switch on the

A.M.F. or customer panel for short.
If short is observed, repair or replace
the speed lower switch.
OK
O.E.M. harness defective
Check the O.E.M. harness for

speed lower input short to + 24 V
battery supply. If short circuit is
observed in the O.E.M. harness,
repair the wires that have short
circuits or replace the harness.
OK
ECPG malfunctioning
Replace the ECPG.
Fault Code
Reason
Speed signal was lost while engine running.
3115
Cause
Loose MPU connection
6-27

active)
Shutdown
Correction
Check whether MPU connector is
properly secured to the engine
harness.
OK
MPU coil resistance as per

sensor specification
OK
MPU tip damaged
Check the resistance of the MPU

coil. Refer sensors specifications, if
not within specification, replace the
MPU.
Check the tip of the MPU for

damage.
If the tip is damaged, replace the
MPU.
OK
Gap between MPU tip and

engine flywheel ring gear
teeth more than the engine
specification
Check the gap between MPU tip

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

Connector A (Pin B and Pin T)
and MPU connector.
If no continuity is observed repair
the wires or replace the engine
harness.
If continuity is observed and the
problem still persists, replace the
ECPG.
6-28
Fault Code
3116
Reason
Fuel actuator PWM signal is close to maximum for long
enough time due to possibly stuck actuator or insufficient
fuel supply.
Cause
Fuel is not available

active)
Warning
Possible loss of engine performance
at higher loads.
Correction
Check the engine fuel supply and
ensure that air lock has not
occured.
OK
Fuel filter(s) choked
Check the fuel filter(s) and clean or

replace it, if necessary.
OK
Fuel Actuator sticky
Remove the fuel actuator located on

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

supply
Check the engine harness for short

circuits or open circuits.
For short circuits : If short or open
circuits observed between
Connector A and actuator
connector, repair the wires that have
short or open circuits or replace the
engine harness.
For open circuits : Check the
continuity between Connector A
(pin F and pin M) and the fuel
actuator connector. If no continuity
is observed, repair the wires or
If continuity is observed, and the
problem still persists, replace the
ECPG.
Fault Code
3118
Reason
Powerdown hardware within ECPG malfunctioning
Cause
Powerdown hardware within
ECPG failed
6-29

active)
Warning
1) No effect on engine performance.
2) Potential battery drain.
Correction
Replace ECPG
6-30
NO
TES
NOTES
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7-1
SECTION 7
ECPG INSTALLATION
Page
Installation ............................................................................................................................................................ 7-2
Magnetic Pick up .......................................................................................................................................... 7-2
Actuator ....................................................................................................................................................... 7-3
Actuator Removal from the Housing ............................................................................................................. 7-5
Actuator Housing .......................................................................................................................................... 7-5
ECPG Controller ........................................................................................................................................... 7-6
Power Source ............................................................................................................................................... 7-7
Isolating Grounding ....................................................................................................................................... 7-7
Replacement of Parts ................................................................................................................................... 7-8
Removal of I/O Board ................................................................................................................................. 7-10
Removal of CPU Board .............................................................................................................................. 7-10
7-2
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.
7-3
Tighten the locknut down on the flywheel housing.

Plug the electrical connection into the pickup, when
required.
Install the main generator, if it was removed.
When the flywheel gear teeth pass the pickup, an A.C.

voltage is induced. One cycle is induced for each gear
tooth.
If the pickup signal is less than 2.5 volts A.C. when

cranking the engine, screw the pickup in 1/8 to 1/4 turn.
b. Actuator
Two O rings are used for mounting the actuator in the
housing.
1) Part number : 3865398 Seal O Ring
2) Part number : 3042542 Seal O Ring
7-4
Two O rings and four Allen screws and washers are

used to clamp the housing on the fuel pump. The actuator
cable is used to connect actuator terminals to a connector
in the engine harness at connector A at pin F & pin M.
Caution
Actuator is a delicate part and should be handled with
care, while removing, cleaning or putting back in the
housing.
Installation
Lubricate the two-barrel O rings with clean engine oil.
Insert the actuator in the housing and rotate it clockwise
till it is inserted completely. Using a 1,1/4-inch spanner,
tighten the actuator, (torque of 5.6 Nm).
Connect the connector to the actuator. The connector is

keyed, so that it connects in one direction only.
7-5
c. Actuator removal from the housing

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

There is a 10-micron fuel screen in the inlet side of the
actuator; the filter screen should be periodically cleaned.
Pull the two smallest fuel filter windows outwards. Hold
the actuator in both the hands, with the connector pointed
outwards. Pull the two fuel filter windows which are
smallest outwards, the fuel filter screen opens. Clean
the filter screen with shop air at pressure ~1Kg/cm2
(0.980 bar). Snap the filter back into place by pushing
the filter windows together.
d. Actuator Housing
The actuator housing is mounted on the fuel pump as
per following procedure:
Retrofitting preparation:
a) Remove the copper tube/rubber hose connecting the
fuel shutoff valve to the injectors from the fuel
shutdown valve side.
b) Remove the shutdown valve with the O ring.
c) Remove the fuel pump return line along with the
elbow, if used.
d) Remove the tacho drive, if it is on the top of the
pump.
e) Plug it with an aluminum plug.
f)
Clean the top of the fuel pump. The fuel pump is

ready for mounting the actuator housing.
Note: In case of retrofitting, the fuel pump needs

recalibration along with the actuator housing, using proper
code for calibration.
Fuel Pump
7-6
1.
Place the actuator housing with two O rings, these

O rings act as a face seal in fuel outlet and fuel
return path respectively.
2.
Clamp the housing on the fuel pump using four Allen

screws. Torque of 5.6 Nm (50.4 in-lb) should be
given.
3. Mount fuel shutoff valve on the actuator housing as

per standard procedure.
4.
Connect the fuel pump return line on the actuator

housing.
5.
Connect the copper tubing going to injectors from

the fuel shut off valve.
e. ECPG Controller
&&&&
Normally all ECP-G controllers are engine mounted on a

bracket with the help of four vibration isolators. If it is
not so, then a suitable provision for mounting the controller
needs to the provided by the user. It can be fixed on a
bracket or on a separate stand near the alternator. The
controller should be mounted such that the front and rear
sides are accessible and convenient for any kind of
adjustment and connections. The mounting place should
be such that, the cable routing length is not more than
the length of the extension cable provided.
The mounting location should be such that the controller
is not directly exposed to Sun, heat, humidity, water,
while in operation.
Four mounting holes are provided on the ECPG to connect
it on vibration isolators.
Warning
To avoid personal injury, or death, it is important
that all electrical equipment be properly bonded or
grounded. All metallic parts that could become
energized under abnormal conditions must also be
properly bonded or grounded.
f.
Power Sour
ce
Source
The ECP-G is designed to operate between 20 and 30

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

ground system, where electrical system ground is not
connected to battery (-ve), take into consideration the
following :
1) The load sharing / paralleling equipment interfacing
to the ECPG should have the same grounding
method and is isolated electrically.
2) Starter wiring harness, battery charging alternator
and other components like free wheeling diode must
be designed to operate properly when connected
using the grounding method being implemented.
7-7
7-8
h. Replacement of Parts
ed Cummins
(T
o be perf
ormed b
y authoriz
(To
performed
by
authorized
personnel only)
This section describe the procedure for removal and
installation of circuit boards and parts that are contained
in the ECPG.
Turn off or remove AC power from the battery charger
and then remove the negative (-) battery cable from the
set starting battery. This is to make sure that the set will
not start while working on it and to avoid circuit board
damage caused by voltage spikes when removing and
replacing circuit board connectors.
CAUTION
Always disconnect the battery charger from its AC
source before disconnecting the battery cables.
Otherwise, disconnecting the cables can result in
voltage spikes high enough to damage the DC control
circuits of the set.
1) Turn the key switch to off position.
OFF
2) Remove the two mating connectors in the harness

from Connector A and Connector B.
CA
UTION
CAUTION
ENGINE
HARNESS
OEM
HARNESS
No user serviceable parts inside ECPG. Do not

attempt to ope the ECPG enclosure while battery and
ECPG harness is connected to ECPG. P
otential risk
Potential
of electrical shock.
3) Remove the six Phillips head screws (M5 x 50 mm)
on the back of the plastic enclosure.
7-9
4) Gently pull out the rear plastic enclosure half. This

gives access to the two boards and the flat ribbon
cable.
5) The plastic enclosure houses the two printed circuit

boards,
(1) CPU Board,
(2) Input/Output (I/O) Board.
I/O board
26 pin FRC cable
CPU board
6) Remove the 26 pin FRC cable from the I/O and CPU
board by pulling out the locking wedges and gently
pulling out the flat ribbon cable. Take care not to
bend the pins.
7) Remove the 14 pin FRC cable from the I/O and CPU
board by pulling out the locking wedges and gently
pulling out the flat ribbon cable. Take care not to
bend the pins.
26 pin FRC cable
7-10
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.
8-1
SECTION 8
APPENDIX
Page
Appendix-A - Operating, Electrical & Environmental Specifications ....................................................................... 8-2
Appendix-B - Glossary of Power Terms ................................................................................................................. 8-3
Appendix-C - Electrical Wiring Diagram ................................................................................................................. 8-9
Wiring diagram for Engines with Single Starter ............................................................................................. 8-9
Wiring diagram for Engines with Two Starter ............................................................................................... 8-10
Appendix-D - ECPG Sensor Specifications ......................................................................................................... 8-11
Appendix-E - List of Replacement Parts .............................................................................................................. 8-12
Customer Literature Comments ........................................................................................................................... 8-13
8-2
Appendix - A
OPERATING, ELECTRICAL & ENVIRONMENTAL SPECIFICATIONS
Operation
Governor Mode .................................................................................. Isochronous to 6% Droop
Governor Gain Adjust ........................................................................ 0.9 to 1.1
Frequency Adjust Range .................................................................... 4Hz
Power
Nominal Operating Voltage ................................................................ +24VDC
Operating Voltage Range ................................................................... +20 to +32VDC
Maximum Continuous Voltage ........................................................... +32VDC
Ground Polarity ................................................................................. Negative Ground
Nominal Operating Current ................................................................. 1.5A @ +24VDC
Maximum Operating Current .............................................................. 4.5A @ +18VDC
Sleep Mode Operating Current ........................................................... 100mA (nominal)
Ready Mode Operating Current .......................................................... 850mA (nominal)
[ECPG On & Engine Not Running]
Environmental
Ambient ECPG Housing Operating Temp. ......................................... 0 to 70C (0 to158F)
Storage Temperature ......................................................................... 0 to 70C (0 to158F)
Vibration Limits ................................................................................. 20-100Hz, 93.6mm/sec:
Physical
Dimensions (Including Heat Sink; ...................................................... 314 mm (L) x 264 mm (H) x 118.3 mm (D)
excluding mounting brackets) ............................................................ (12.34 x 10.37 x 4/64)
Weight ............................................................................................... 2.53 kg (5.596 lbs.)
Housing Enclosure ............................................................................ Glass Filled Plastic
Heat Sink Metal ................................................................................. Aluminum
Protection
Reverse Polarity Protection ............................................................... +28VDC Maximum
Electrical Interface Characteristics
Lamp/Relay Driver Supply
Supply Voltage .................................................................................. +12VDC Nominal @ 80 mA
Lamp/Relay Drivers
Driver Type. ....................................................................................... Low-Side (switched GND/Open)
Driver Voltage Rating ......................................................................... +24VDC Nominal
Maximum Sink Current (Driver On) .................................................... 80mA
Analog (Adjustable) Inputs
Nominal Input Voltage Adjustment Range .......................................... 0-5VDC
Maximum Input Voltage ..................................................................... 5VDC
Speed (Frequency) Bias Reference & Voltage Supply
0-5 VDC Reference Voltage ............................................................... +5VDC
8-3
Appendix - B
GLOSSARY OF POWER TERMS
A.C. - See Alternating Current.
Alternating Current - Electrical current which repeatedly
varies from zero to a positive maximum value to zero to
a negative maximum value and back to zero at a periodic
rate. Since the applied voltage continually reverses
polarity, the resultant current flow alternates in direction
within the circuit.
Capacitance - The property of a device which resists

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

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

capacitance. A typical capacitor consists of two
conducting surfaces separated by an insulating material.
A capacitor stores electrical energy, blocks the flow of
D.C. and permits the flow of A.C. to a degree largely
dependent on the capacitance and the frequency of the
applied A.C.
Circuit - An electrical path through which an electric
current may flow from a voltage supply to a load and
return. A closed or complete circuit is one where current
is flowing. An open circuit is where the path has been
disrupted, such as an open switch or circuit breaker, thus
stopping current flow.
Circuit Breaker - A protective device for opening a circuit
where current flow exceeds a predetermined value.
Circulating Current - Also called Cross Current. Current
which flows between paralleled generators, most apparent
with no external load on the paralleled generators.
Circulating current is caused (1) by unequal excitation of
the generators (reactive current, which may be reduced
by changing the voltage regulator adjustment or
connections); and (2) by unequal power from the engines
that are driving the generators real current (and power)
which can be eliminated by governor adjustments.
Conductor - A wire cable, bus, or other device intended
to distribute current from the supply to the load.
Technically, a conductor is any device which will permit
the flow of current.
8-4
Contactor - A device for opening and closing an electric

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

current to flow in one direction, but not in the other. In
alternating current circuits, a diode will permit one half
cycle to flow but will resist the flow of the opposite half
cycle of current. Thus, alternating current is converted
to direct current by a diode.
Direct Current (D.C.) - An electric current that flows in

one direction only. Conventional direct current is defined
as flowing from positive to negative in the circuit outside
the source (example: a battery or combination of diodes).
Conventional current flows in the direction of the arrow
through a diode.
Direct Current I
Applied Voltage V
Distribution Panel A control panel containing circuit
breakers, transfer switches, and other control devices
which distribute the electrical power, such as from a
generator set to the loads.
Double Pole Switch - A switch which has two sets of
contacts which operate on two independent circuits at
the same time.
Typical Alternating Current

or Voltage Cycle
D.C. - See Direct Current.
Typical Double Pole Switch Shown as a
Single Throw Type in the Off Position
E - Symbol used to represent electrical potential (voltage).

Earth Ground - An intentional connection made between
the earth and the metallic frame of electrical equipment
as a means to eliminate possible voltage hazards to
personnel. Earth Ground also serves, in some cases, to
reduce electrical interference in sensitive circuits such
as television and radio equipment.
EMI - An abbreviation for the term electromagnetic
interference which is sometimes caused by SCR type
devices and evident in radio and television operation.
Energy - The capability of performing work.
Frequency - The number of complete cycles of alternation
current per unit of time. Typically, frequency is expressed
in cycles per second or Hertz (Hz).
Frequency Droop - A decrease in steady state frequency
output of a generator caused by an increase in load. This
decrease in frequency from the no load frequency is
expressed as a percentage of the full load frequency or:
(FNL - FFL) X 100

%F Droop =
FFL
Where: % F Droop = Percent Frequency Droop
FNL = No Load Frequency
FFL = Full Load Frequency
Frequency droop may be used to provide governor
stability and for load sharing between paralleled generator
sets.
Frequency Meter - An instrument designed to measure
the frequency of an alternating current system.
Gain - The increase in signal power that is produced by
an amplifier, usually given as the ratio of output to input
voltage, current, or power. In generator set systems, a
low gain setting on the electric governor or voltage
regulator provides a relatively small signal to correct
variations of frequency or voltage. The frequency and/or
voltage may wander or be slow in recovering to stable
conditions after a load change. A high gain setting provides
a relatively large signal to correct variations of frequency
and/or voltage. If the gain is set too high, the electric
governor or voltage regulator may over-correct.
8-5
This may produce unacceptable hunting of the frequency

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

Voltage Caused by Inductive Load
8-6
Inductor - A device possessing the property of

inductance. An inductor stores electrical energy, passes
D.C., and opposes the flow of A.C. to a degree largely
dependent on the inductance and the frequency of the
applied A.C. A typical inductor consists of a coil of wire.
In Phase - Alternating currents or voltages are in phase
with respect to each other if they cross through zero and
reach their positive and negative maximum values
together.
Insulation - A non-conductive material such as rubber
or plastic intended to prevent current from flowing.
Technically, insulation is any material which stops the
flow of current.
Isochronous - As it applies to engine governors,
maintaining constant steady state speed regardless of
the load within the rating of the engine. Thus, a generator
set is said to be isochronous if the frequency remains
the same regardless of load.
Normally Closed (Symbol N.C.) - As applied to a
magnetically operated device such as a valve or the
contacts of a relay, Normally Closed indicates that the
valve or the relay contacts are closed when no power is
supplied to the operating magnet.
Normally Open (Symbol N.O.) - As applied to a magnetically operated device such as a valve or the contacts of
a relay, Normally Open indicates that the valve or the
relay contacts are open when no power is supplied to the
operating magnet.
Ohm - The unit of measure of electrical resistance. One
ohm of resistance will allow a current of one ampere to
flow with an applied potential of one volt.
Ohmmeter - An instrument for measuring electrical
resistance.
Ohms Law - A fundamental law expressing the
relationship between voltage, current, and resistance in
electrical circuits. The law states that E = IR or voltage
is equal to current times resistance.
Open Circuit - 1) A circuit that does not provide a
complete path for the flow of current. 2.) A condition of
an electrical circuit caused by the breaking of continuity
of one or more conductors of the circuit; often an
undesired condition. 3) An arrangement of conductors

and equipment that depends upon lack of continuity for
operation, as open-circuit telegraphy; a circuit in which
continuity is incomplete or interrupted.
Oscillogram - The permanent record produced by an
oscillograph, or a photograph of the trace produced by
an oscilloscope.
Oscillograph - A measurement device for determining
waveform by recording the instantaneous values of a
quantity such as voltage as a function of time.
Oscilloscope - An instrument primarily for making visible
the instantaneous value of one or more rapidly varying
electrical quantities as a function of time or of another
electrical or mechanical quantity.
Oscilloscope, Dual Beam - An oscilloscope in which
the cathode-ray tube produces two separate electron
beams that may be individually or jointly controlled.
Parallel Connection - An electrical connection in which
the input of one element is connected to the input of
another element. The output connections are similarly
connected together thus providing two or more paths for
current to flow.
Parallel Connection
Parallel Operation - The method by which two or more
generators having the same voltage and frequency
characteristics are connected to a common load.
Permanent Magnet Generator - A generator which uses
permanent magnets to create a magnetic field. As applied
to Cummins Generators: a permanent magnet generator,
within the main generator, supplies the power to the
voltage regulator which in turn supplies the power to the
exciter field. The permanent magnet generator still
supplies power during a short circuit of the main generator.
This permits the main generator to sustain high short
circuit currents. The output of the permanent magnet
generator is electrically isolated from the main generator
output and is not adversely affected by main generator
output waveform distortion such as from SCR type loads.
PMG - See Permanent Magnet Generator.

Polarity - An electrical term which indicates the direction
in which current flows in a conductor. In a direct current
system, current flows in the same direction. In an
alternating current system, current changes direction as
the polarity of the A.C. voltage source changes.
Potential - Another term to indicate voltage.
Potential Difference - The difference in voltage between
two points in a circuit.
Power - Defined as the rate of performing work.
Mechanical power is measured in horsepower or kilowatts.
Electrical power is measured in Kilowatts.
Power Factor - The ratio of the true power (KW)
requirements of a load to the apparent power (KVA)
requirements of a load. The combined loads applied to a
power source may have a resistive, capacitive, or
inductive effect.
Resistive loads such as incandescent lighting or resistive
heating elements cause no shift in the voltage/current
wave forms and are, therefore, unity (1.0) power factor
loads.
Inductive and capacitive loads, however, cause the
voltage and current waveforms to shift with respect to
one another. These types of loads are commonly called
power factor loads (i.e., the power factor is less than
1.0).
See INDUCTANCE and CAPACITANCE for more
information.
Power factor is frequently multiplied by 100 and expressed
as a percentage.
8-7
Resistor (Symbol R) - A device or component designed

to have a definite amount of resistance. Resistors are
used in circuits to limit current flow or to provide a voltage
drop.
Resistor, Fixed - A component which is used to control
voltage and current by introducing a constant resistance
of known value into the circuit.
Resistor, Variable - Similar to a fixed resistor except
the resistance value can be adjusted. The voltage adjust
rheostat is a variable resistor.
Rheostat - A variable resistor.
Series Connection - An electrical connection in which
the input of one element is connected to the output of
another element providing only one path for current to
flow.
Series Connection
Short Circuit - An abnormal connection (including an
arc of relatively low resistance, whether made
accidentally, or intentionally, between two points of
different potential in a circuit. Equipment, not protected
by fuse or circuit breakers, may be damaged by a short
circuit.
Single Pole Switch - A switch which has only one set
of contacts.
The formula for power factor is:

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

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

a Single Pole Type in the Off Position
8-8
Speed Droop - A decrease in steady state speed of an

engine due to an increase in applied load. This decrease
in speed from the no load speed is expressed as a
percentage of full load speed or:
(SNL - SFL) X 100

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

Ampere to flow through a resistance of one Ohm.
Voltage - Electrical potential or pressure which forces
current to flow through a circuit.
Voltage Dip - A temporary reduction in voltage generally
resulting from an increase in load.
Voltage Droop - A decrease in steady state voltage of a
generator due to an increase in load applied. This decrease
in voltage from the no load voltage is expressed as a
percentage of the full load voltage or
(VNL- VFL) X 100

%VDroop =
VFL
Where: % VDroop = Percent Voltage Droop
VNL = No Load Voltage
VFL = Full Load Voltage
Voltmeter - An instrument designed to measure electrical
potential or voltage.
LCL
+ Ve
26
33E
+ Ve
25
STARTER 45
26
EARTH WIRE
BATTERY 24 V.D.C.
- Ve + Ve
36
39E
25
LOW COOLANT
LEVEL SENSOR
35 +Ve
ALTERNATOR
- Ve
36
-Ve
GND
OUTPUT
+5V
ECPG ACTUATOR
SHUT DOWN COIL
- Ve
45
17
38
35
39E
38
17
E
MAGNETIC
SWITCH
39E
DATALINK
START
INTAKE
AIR TEMP.
SENSOR
MAG.
PICK-UP
COOLANT TEMP.
SENSOR
A1;
-Ve
CIRCUIT NO.
B,T
SHIELDED
1 SQ. MM
CABLE
P.V.C. 95 SQ. MM
1 SQ. MM
200
11
26,45
G,H,J,N,P,S,U,R
1.5 SQ. MM
4.5 SQ. MM
30
14
AMP.
CAPACITY WIRE GAUGE
25,33E,38,17
G,E,V,A,L,F,M
39E,D
19 PIN CONNECTOR
WIRING DIAGRAM FOR ENGINES WITH SINGLE STARTER
S0.C7A5L0E
WIRING DIAGRAM FOR ENGINES WITH SINGLE STARTER
1. 24 VOLT NEGATIVE GROUND SYSTEM
2. TURN THE STARTING KEY SWITCH

TO START POSITION TO CRANK
THE ENGINE.

8-9
APPENDIX - C
ELECTRICAL WIRING DIAGRAMS
8-10
WIRING DIAGRAM FOR ENGINES WITH TWO STARTERS

WIRING DIAGRAM FOR ENGINES WITH TWO STARTERS
D
SHUT DOWN COIL

19 PIN CONNECTOR
-Ve
A
B
ECPG ACTUATOR
G
H
J
K
L
M
35 +Ve
R
36
-Ve
P
LOW COOLANT
LEVEL SENSOR
33E
OUTPUT
DATALINK
START
+ Ve
R
A1;
AIR INTAKE
TEMP.
SENSOR
T
U
25
V
V
+5V
GND
- Ve
B
C
G
H
J
K
L
M
N
P
S0C.A7L5E0
R
S
T
U
V
COOLANT TEMP.
SENSOR
CIRCUIT NO.
26
A
36
25
38
35
45
17
STARTER
17
39E
EARTH WIRE
45
- Ve
- Ve + Ve
26
17
17
STARTER 45 39E
26
+ Ve
38
E
38
38
MAGNETIC
SWITCH
BATTERY 24 V.D.C.
AMP.
CAPACITY WIRE GAUGE
G,E,V,A,L,F,M
39E,D
14
1.5 SQ. MM
25,33E,38,17
30
4.5 SQ. MM
1. 24 VOLT NEGATIVE GROUND SYSTEM
G,H,J,N,P,S,U,R
11
26,45
200
EARTH WIRE
B,T
2. TURN THE STARTING KEY SWITCH

TO START POSITION TO CRANK
THE ENGINE.
1 SQ. MM
P.V.C. 95 SQ. MM
SHIELDED
1 SQ. MM
CABLE
ALTERNATOR
8-11
APPENDIX - D
DATALINK
ECPG CONNECT
OR
CONNECTOR
RS-485 Serial Communication Standard
Retaining capscrew torque=1 Nm [9 in-lb]
SHORT CIRCUIT TO EXTERNAL VOLTAGE

ALL CONTINUITY CHECKS
OK if < 1.5 VDC
OK (no open circuit) if < 10

ALL SHORTS TO GROUND
ESS circuits
ECPG POWER SUPPLY
20 to 32 VDC
OK (no short circuit) if > 10M
All other circuits

OK (no short circuit) if > 100k
ECPG SENSOR SPECIFICA

TIONS
SPECIFICATIONS
OIL PRESSURE SENSOR
Torque = 14 Nm [124 in-lb]
ALL TEMPERA
TURE SENSORS
TEMPERATURE
Torque = 15 Nm [133 in-lb]
Pressure
(kPa)
Pressure
[psia]
Voltage
(VDC)
Temperature
(oC)
Temperature
(oF)
Resistance
()
0
207
414
621
827
0
30
60
90
120
0.5
1.5
2.5
3.5
4.5
0
25
50
75
100
32
77
122
167
212
30k to 36k
9k to 11k
3k to 4k
1350 to 1500
600 to 675
ENGINE SPEED SENSOR

Torque = 34 to 47 Nm [25 to 35 ft-lb]
Coil Resistance = 750 to 1600
8-12
APPENDIX - E
LIST OF REPLACEMENT PARTS
Sr. No.
Part name
Part Number
ECP-G Assembly
1
2
3
4
5
6
ECP-G Assembly
Key switch
Parameter selection push button
Toggle switch (for Idle/Rated mode selection)
Vibration Isolator
Mounting bracket
4083935
504975
4071721
3875362
3229922
4084240
Sensors
1
2
3
4
5
6
7
8
9
Coolant temperature sensor

Air Intake temperature sensor
Coolant level sensor
Adapter for Coolant temperature sensor
Adapter for Air intake temperature sensor
Magnetic pick up
Lube Oil Pressure sensor adaptor (V 28 engine)
Lube Oil Pressure sensor adaptor
(495, 743, 855 series engines)
3865346
3408345
3408560
4072714
4084218
4084219
3879986
4104562
3814448
Actuator and Actuator housing

1
2
3
4
5
Fuel Actuator with O ring

Fuel actuator housing
Fuel actuator filter screen
Fuel actuator O rings (1)
Fuel actuator O rings (2)
3330601
4071944
3867393
3865398
3642542
Harness
1
2
3
4
5
6
7
8
9
Engine harness
KT/KTA 1150/KTA 19 G4/G3 engines
NT 495
NTA 495
NT/NTA 743
NT/NTA 855
VT/VTA 28
Extension harness 10 meters
Extension harness 5 meters
OEM harness
4084232
4085697
4085698
4085700
4085692
4085693
4072993
4072992
4054744
8-13
Customer Literature Comments

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Please fold and staple.
8-14
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will be
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Addressee
PERMIT No. 176

Ex-Servicemens Colony P.O.
PUNE - 411 038.
To,
Marketing Division,
Cummins India Limited
Kothrud, Pune - 411 038.
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ECP 4083935 - O&m - Ecpg

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Operation & Maintenance Manual for ECPG

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

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

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

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

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

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

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

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

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

Operation & Maintenance Manual for ECPG

Operation & Maintenance Manual for ECPG

Operation & Maintenance Manual for ECPG

About the Manual

Operation & Maintenance Manual for ECPG

To The Owner and Operator

Operation & Maintenance Manual for ECPG

General Safety Instructions

Operation & Maintenance Manual for ECPG

General Repair Instructions

Operation & Maintenance Manual for ECPG

CLEAN the part or assembly.

Operation & Maintenance Manual for ECPG

Operation & Maintenance Manual for ECPG

Earth Safety Ground

This symbol may be used in

Operation & Maintenance Manual for ECPG

Ingress Protection - Dust-Protected &

Auto Mains Failure

Ingress Protection - Dust-Protected &

American Wire Gage

Coolant Temperature Sensor

Electronic Control Panel

Electronic Control Panel with Governor

Low Lube Oil Pressure

Erasable Programmable Read Only

Engine Speed Sensor

Original Equipment Manufacturer

Oil Pressure Sensor

Fuel Shutoff Valve

G-Drive Original Equipment

Pounds Per Square Inch

Revolutions Per Minute

High Coolant Temperature

Pulse Width Modulator

Operation & Maintenance Manual for ECPG

Operation & Maintenance Manual for ECPG

Important Reference Numbers

ECPG Sr. No.

Engine Serial Number

Engine Control Parts List (CPL) Number

Engine Oil Type and Viscosity

Filter Part Numbers:

Belt Part Number (Alternator)

Operation & Maintenance Manual for ECPG

The illustrations included in this manual are intended to

Illustrations showing connector contact positions for

Illustrations showing connector contact positions for

Connector Fuel Actuator

Operation & Maintenance Manual for ECPG

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

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

Operation & Maintenance Manual for ECPG