INDEX

1. Introduction.
¾ Inputs & Outputs.
¾ Key Switch and Starter Protection Features.
¾ Digital Display and Scan Push Button.

2. Diagnostics and Fault Indication.

3. Part Number Information.

4. Connector Pin Details.

5. Wiring Diagram.

6. OEM Connector.

7. Specifications

8. Trouble Shooting.

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1.INTRODUCTION

Electronic Control Panel

Parameter LEDs sensor Fault Other Fault lamps

Scan
Push button Key switch front
Engine Harness OEM
Scanning Window connector connector
For digital display.

FRONT REAR SIDE

The above sketches show general form / shape of the Electronic Control Panel
(ECP).

The panel housing is fabricated from MS sheet and powder coat painted. The
front plate is an aluminium plate coated with a plastic film, which bears legend for
each of the scan parameter LEDs, as well as the fault lamps.

The ECP is a set of two electronic subassemblies housed in this enclosure.

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Following inputs/ outputs are connected to the ECP by a bunch of wires or
Wiring Harness via 2 connectors on the rear of the ECP. (See connector
details).

Inputs

1. Battery supply
2. Coolant Water Temperature sensor
3. Auxiliary Temperature Sensor (Intake Manifold temperature Only on KTA-38
–G5 and KTA-50-G8 engines.)
4. Oil pressure sensor
5. Engine speed sensor i.e. Magnetic Pick up
6. Oil pressure safety control
7. Low Coolant Water Level switch (only on KV engines)
8. Scan Push button
9. Key switch
10. Remote Start

Auxiliary temperature sensor (intake manifold temperature sensor) to monitor

LTA performance with two pump, two loop systems, is supplied only with KTA-
38-G5 and KTA-50-G8 engines. The Low coolant water level switch is supplied
only with KV series engines.

Outputs

1. Fuel Shut Down Coil

2. Starter Magnetic Switch
3. LLOP alarm relay driver
4. HWT alarm relay driver
5. AUX alarm relay driver
6. Charging Alternator “W” terminal.

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Key Switch and Starter Protection Features.

Key switch is used to turn on / off the 24 VDC battery supply to the ECP, to start
the engine and to stop the engine.

Turning ON the key switch will start the scanning of engine parameters, and will
open the Fuel shut down valve if no active High Water Temperature or Low
Coolant Water Level fault exists. Also the electronics in the panel looks for any
sensor fault / shorted LUB oil pressure safety control and indicates any fault
appropriately as described in detail in the diagnostic section.

When the key switch is taken to the spring loaded “START” position, the starter
solenoid will turn ON, causing the STARTER to engage the flywheel ring gear
and rotate the engine.

As the engine fires and picks up speed, the starter solenoid is de-activated
automatically, thereby disengaging the starter from the flywheel ring gear, thus
protecting the starter from “OVERCRANKING”.

As long as the engine is running, taking the key switch to “START” position will
not activate the starter solenoid. This feature prevents the starter damage that
can be caused by an attempt to engage the starter with flywheel ring gear when
the engine is already running.

There is also a built in timer mechanism that prevents starter damage due to
over-cranking. After 5 seconds from the instance the key is turned to “START”
position, the starter solenoid will automatically de-activate and will remain de-
activated at least for 5 seconds, even if the key remains in start position.

The starter interlock is speed based and not Lubricating Oil Pressure based as in
many other schemes, and therefore is independent of possible delays in oil
pressure build up.

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Digital Display and the SCAN push button.

The ECP has a 4 digit digital display to indicate

Battery Voltage VOLTS Volts

Coolant Water Temperature WT °C
Lubricating Oil Pressure LOP KG/cm2
Engine speed RPM RPM
Engine hours HOURS hours
Auxiliary temperature AUX °C

The row of green LEDs on the left side of display is used to indicate which
parameter is being indicated at any given moment. Screen printed in front of
each of these LEDs, is the name of the parameter that the Display will indicate
when that LED is lit.

There are two modes of operation of the display.

SCAN MODE: The display changes from one parameter to the next after
displaying each parameter for 2 seconds. After displaying the last parameter the
display rolls over to the first parameter and scanning goes on until the key switch
is ON.

CONTINUOUS DISPLAY MODE: The scanning can be stopped and any desired
parameter can be viewed in continuous mode as follows.

Press the scan button.

Release the button as soon as the scanning enters the desired parameter as
indicated by the lighting of the LED corresponding to that parameter.

The display will now keep displaying the chosen parameter.

To start scanning again push the SCAN button momentarily and release.

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2.DIAGNOSTICS AND FAULT INDICATORS
Following diagnostic and fault indicators are provided on the ECP.

Parameter Legend Fault Condition

Sensor Fault SENSOR FAULT Open/Short

High Water Temperature HWT Above 95 ° C
Low Lub Oil Pressure LLOP below 1 Kg/cm2
Over Speed OS Above 1650 rpm for 10
Seconds
Low Coolant Water Level LCWL Level below sensor
AUX Temperature High AUX AUX temp above 68 °C
Charging Failure CHARGE No charging current
Oil Pressure Safety Control OIL SW FAULT Shorted safety control

Sensor Fault

Just below the row of green Parameter LEDs there is a red LED, which indicates
sensor faults. While scanning parameters if the corresponding sensor is found
faulty, the sensor fault LED glows while scanning that particular parameter.
Simultaneously, if the sensor is open, then the Display Window will indicate ‘O ’.
(O followed by three blanks). Similarly if the sensor is found shorted, then the
Display Window will indicate ‘ S ‘. (S followed by three blanks).

High Water Temperature (HWT):

When the engine water temperature exceeds beyond 95° C the engine will shut
down and the HWT LED will keep glowing until the fault is acknowledged by turning
off the panel

Over Speed (OS):

When the engine speed goes beyond 1650 RPM and remains there for more than
10 seconds, the engine trips. Momentary overshoots of engine speed during start
up or those due to sudden load throw off will therefore not result in spurious engine
tripping. The OS LED will keep glowing until the fault is acknowledged by turning off
the panel.

Low Lub Oil Pressure (LLOP):

The engine shuts down when the LLOP safety control opens and LUB oil pressure
goes below 15 PSI. The LLOP LED will keep glowing until the fault is
acknowledged by turning off the panel

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Low coolant water level (LCWL): When the water level in the Expansion tank /
Radiator goes below the desired level the engine is made to shut down. The LCWL
LED will keep glowing until the fault is acknowledged by turning off the panel

When any of the above mentioned faults occur the engine will not fire (since the
Supply to the shut down coil is cut off) until the panel is reset. To reset the panel,
Turn the panel OFF by moving the key switch to OFF position. Restart the engine
After attending the fault.

There are four more diagnostic LEDs and associated events other than those
mentioned above. They are as follows

Charge:

This LED glows when there is no charging current flowing to the battery. Hence this
LED glows when the engine is not running. When the engine starts running and the
charging alternator starts supplying charging current to the batteries this LED will go
off.

Oil SW Fault:

The LUB oil pressure safety control is normally open. When oil pressure develops
the safety control changes over and closes. However, a shorted LUB oil pressure
safety control can go undetected. To detect this potentially dangerous fault, a
diagnostic LED has been added here.

This LED glows if, a shorted LUB oil pressure safety control is detected when key
Switch is turned on, but the engine is yet to be started. The logic that is used here is
that, with engine at stand still and the panel powered up, the LUB oil pressure
safety control should be open and with the engine running and LUB oil pressure
developed, the LUB oil pressure safety control should be closed.

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3.PART NUMBER INFORMATION.
ECP:

For engines with 142 teeth on flywheel ring gear: 3414797

For engines with 118 teeth on flywheel ring gear: 4053453

Engine Wiring Harness

1MW 4054729
KV16 4054727
KV12 4053890
V28 4053889
K6 4053888
N4.8G 4053456
855 Series 4052728
743 Series 4053886
495 Series 4053887

OEM connector: : 4054744

Coolant Water Temperature Sensor : 3865346

Connector Water Temperature Sensor : 3823256
LUB Oil Pressure Sensor : 3392445
Magnetic Pick Up : 3875360
Intake Manifold Temperature Sensor (AUX) : 3865345
Low Coolant Water Level (LCWL) Switch : 3046031
Low LUB Oil Pressure Switch : 3056344
Adapter for Coolant Water Temperature Sensor : 4053490
Adapter for Intake Manifold Temperature Sensor : 4053490

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4. Connector Pin Details:
Engine Connector (19 pin)

SR no. PIN Descriptions.

1 A Battery Negative 24 VDC.
2 B ECP MPU -ve.
3 C Shut down coil –ve (extra).
4 D Shut down coil +ve.
5 E Starter magnetic switch.
6 F ECP actuator (Future scope).
7 G LLOP safety control.
8 H Oil pressure sensor.
9 J Oil pressure sensor.
10 K LLOP safety control.
11 L Battery positive 24 VDC.
12 M ECP actuator (Future scope).
13 N Water temperature sensor.
14 P Water temperature sensor.
15 R Low coolant water level signal.
16 S Optional sensor.
17 T ECP MPU +ve.
18 U Optional sensor.
19 V ‘W’ terminal of alternator.

OEM Connector (10 pin)

SR no. Letter Descriptions.

1 A Battery –ve
2 B Future Expansion
3 C Future Expansion
4 D Remote Start
5 E Relay driver output AUX alarm
6 F Relay driver output LLOP alarm
7 G Relay driver output HWT alarm
8 H Future Expansion
9 I Future Expansion
10 J Remote stop

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Data Link Connector (9 pin)

SR no. Letter Descriptions.

1 1 Data Positive.
2 2 Data negative.
3 3 Open.
4 4 Open.
5 5 24 Volts Positive.
6 6 Open.
7 7 Open.
8 8 Ground.
9 9 Open.

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5.WIRING DIAGRAMS:
Without EFC Governor and One Starter : 4054713

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With EFC Governor and One Starter : 4054714

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With EFC Governor and Two Starters : 4054715

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6.OEM connector

OEM connector Wiring Diagram: OEM responsibility on the right hand side of
the dashed line representing the 10-pin OEM connector as the boundary.

BATTERY NEGATIVE
REMOTE START
AUX ALARM RELAY DRIVE
LLOP ALARM RELAY DRIVE
HWT ALARM RELAY DRIVE
A
Use remote start N/O
Contact to connect 24VDC
to start.
D
E R
F R
G R

REMOTE STOP J

1. Alarm Relay Drivers: Following figure shows the internal arrangement of the
alarm relay driver circuit. In order to prevent damage due to accidental short
circuits, a 150 ohms 5 watt resistor is used in series with the transistor switch
in the ECP electronics.

+24 VDC

Trigger 150 ohms connector

logic 5 watt resistor pin E(or F or G)

Use suitable relays as shown in OEM connector wiring diagramRas

OR use suitable interface circuits to make use of the alarm relay driver outputs.

Recommended relay: O/E/N 57 DP -12 - 1C6

Coil 12 VDC 150 ohms

2. Remote start: Apply 24 volts DC (with respect to battery negative) through an

external contact at Pin D of the 10-pin OEM connector to start the engine. Note
that the Starter magnetic switches (2 Nos. in case of KV engines) will draw
current from this 24 V source. The cables and the contact must therefore be
appropriately rated. Recommend 10 amps capability.

3. Remote stop: Apply 24 volts DC at the pin J of the 10-pin connector, for
sufficient time to stop the engine from a remote external contact. This input will
not draw more than 10 mA from the 24 V source.

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7.Specifications:
Overall Dimensions: All dimensions in millimeters.
90

212.74

158.76 212

238 72

FRONT REAR SIDE

Weight: 2.7 kg approx.

Mounting:

Separately mounted on a suitable stand near the engine OR

If mounted directly on the engine, use mounting arrangement capable of

damping the vibrations (as measured on the panel front, top and side), to less
than 3G(Acceleration), 250 microns (displacement).

Temperature:

Operating temperature: up to 70 degrees C.

Washing and cleaning:

Do not splash water or other liquids directly on the panel. Use dry cloth first to
remove dust. The surfaces may then be wiped clean with a damp cloth.

Supply Voltage:

Operating Voltage: 18 VDC to 30 VDC with AC ripple less than 1 V RMS.

Current consumption: (nominal at 24 VDC)

ECP: 0.6 Amps, SD Coil: 0.8 Amps, Starter Magnetic Switch: 2.3 Amps each.

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CAUTION:

1) Battery supply should never be disconnected with key switch turned ON.
Turn Key switch OFF before removing any cables from battery or any other
cables, harness, connectors for maintenance, cleaning, troubleshooting
etc.

DO NOT OPERATE THE PANEL ON ANY SOURCE THAT DOES NOT

SATISFY THE SUPPLY VOLTAGE AND CURRENT SPECIFICATION.

2) The body of the ECP is required to dissipate heat to ambience. Direct

exposure to sun may result in malfunctioning.

MAKE PROVISION FOR PREVENTING DIRECT EXPOSURE OF THE ECP TO

SUN OR OTHER EXTERNAL HEAT SOURCES.

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8.Trouble Shooting:
1. No LEDs light OR they light intermittently when Key switch is turned
ON.

Tech. - Note: When the key switch is turned ON, the OIL SW FAULT lights for a
few seconds and goes OFF if the oil pressure safety control is OK. The panel
immediately enters the scan mode. The PARAMETER LEDs light one by one at
an interval of 2 seconds, displaying the values of the respective parameters one
by one.

Possible Causes and Remedies:

- The engine harness connector (19 pin) may be loose or not connected.
Turn the key switch OFF. Tighten the 19-pin engine harness connector
securely.
- Engine harness wire A OR L broken OR loose OR the lugs broken.
Repair the wire connections.

2. Engine does not CRANK, display fades while key switch is turned to
“START”

Tech. - Note: The engine panel draws relatively very small current when the Key
switch is turned on. However, when one attempts to start the engine, the starters
would draw a much higher current. If the batteries are weak, then the battery
voltage will drop to a very low value and the engine will not crank. If batteries are
so week as to drop below 10 VDC then the display will appear to fade.

Possible Causes and Remedies:

- Batteries are very weak

Use properly charged batteries.

3. Engine Fires and stops in few seconds, LLOP indication lights.

Tech. – Note: The ECP has a built in mechanism which provides for the function
of auto-bypass for the low lub oil pressure safety control for 5 seconds OR until
the key switch is in “START” position.

If the oil pressure safety control is faulty i.e. STUCK OPEN OR the harness
connector is not secured in position at the safety control, then an attempt to
“START” will result in engine firing up but subsequently stopping in a few
seconds.

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Check if oil pressure display also indicates low oil pressure, or very slow build up
of oil pressure. Check for leakage.

To check on these aspects, press the scan button and release it when the
PARAMETER LED corresponding to lub oil pressure lights. This will display the
lub oil pressure in continuous mode.

Turn the manual over-ride screw on the SD coil in, and start the engine to check
the time it takes for the engine to develop lub oil pressure. If the oil pressure
does not build up to more than 1 kg / cm2 in 5 seconds, AND/OR the oil pressure
remains lower than normal, check for leakages.

If lub oil pressure is OK, clean the safety control connector contacts, reconnect,
and try again.

Data Link:

The data link is intended to be used to connect single or multiple ECPs to

- A host computer acting as a supervisor for facilitating data

acquisition and logging.

- A PC based service tool

The data link is an RS-485 connection. An RS-485 to RS-232 convertor is

required for connecting the data link to a PC’s RS –232 serial communication
port.

The format of data that is available via data link and the communication protocol
information will be supplied on request to CIL Marketing division.

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9. PHOTOS
Front side:

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Rear side:

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I/O assembly:

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Display assembly:

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