Advanced Full Text Search - REHS4636 - Generator Set Control (GSC) and AC Transformer Box (ATB) Replacement (4490)

6/22/2017 Advanced Full Text Search - REHS4636 - Generator Set Control (GSC) and AC Transformer Box (ATB) Replacement{4490}
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Special Instruction
Generator Set Control (GSC) and AC Transformer Box (ATB) Replacement{4490}
Media Number -REHS4636-01 Publication Date -21/11/2008 Date Updated -21/11/2008
i03277690
Generator Set Control (GSC) and AC Transformer Box (ATB)

Replacement{4490}
SMCS - 4490
Engine:
3516B (S/N: 7RN1-UP; CPA1-UP; BMB1-UP; BPJ1-UP; FDN1-UP; 6HN1-UP; GAR1-UP;
PBR1-UP; GZS1-UP; GZT1-UP; 1NW1-UP; 2JW1-UP; 8NW1-UP; FDX1-UP; GZY1-UP)
3208 (S/N: 30A1-UP; 5YF1-UP)
3304 (S/N: 83Z1-UP)
3306 (S/N: 85Z1-UP)
3306B (S/N: B8D1-UP; 2AJ1-UP; 8NS1-UP; 9DS1-UP; LRW1-UP)
3412 (S/N: 2WJ1-UP; 4BZ1-UP)
3412C (S/N: BAK1-UP; 5FL1-UP; DJN1-UP; 9EP1-UP; TFT1-UP; BCW1-UP; LRY1-UP)
3412E (S/N: TGC1-UP)
3508 (S/N: CNF1-UP; 1ZF1-UP; 5XM1-UP; 3LS1-UP; 5PW1-UP; 96Y1-UP; 23Z1-UP; 69Z1-
UP; 70Z1-UP)
3508B (S/N: CNB1-UP; 4GM1-UP; 6PN1-UP; 2HW1-UP; 5KW1-UP; BGX1-UP)
3512 (S/N: 3YF1-UP; CMJ1-UP; 6PM1-UP; FDR1-UP; 3MS1-UP; 6WW1-UP; 50Y1-UP; 24Z1-
UP; 66Z1-UP; 67Z1-UP)
3512B (S/N: CMC1-UP; FDE1-UP; BLF1-UP; PTF1-UP; BRK1-UP; PTM1-UP; 8RM1-UP;
6WN1-UP; 1PW1-UP; 4AW1-UP; 5AW1-UP; 6GW1-UP)
3516 (S/N: CMD1-UP; 4XF1-UP; 4MJ1-UP; 5SJ1-UP; CAL1-UP; 7KM1-UP; GZR1-UP; 3NS1-
UP; 8TW1-UP; GZX1-UP; 29Z1-UP; 72Z1-UP; 73Z1-UP)
C18 (S/N: DKE1-UP)
G3304 (S/N: 37Y1-UP)
G3306 (S/N: JCA1-UP; 4DL1-UP; CNR1-UP; 07Y1-UP)
G3406 (S/N: 4FD1-UP; R7E1-UP; 1RK1-UP; KAR1-UP)
G3408 (S/N: 6NB1-UP; 6RJ1-UP; 78Z1-UP)
G3408C (S/N: 3WR1-UP; BAZ1-UP)
G3412 (S/N: R7A1-UP; 7DB1-UP; 3NK1-UP; KAP1-UP)
G3412C (S/N: 6ZM1-UP; 5KR1-UP)
G3508 (S/N: 4WD1-UP; 2JF1-UP; 9TG1-UP; CPJ1-UP; 2TJ1-UP; CPS1-UP; CPY1-UP; CAW1-
UP)
G3512 (S/N: 4KC1-UP; 5JD1-UP; 7NJ1-UP; CRN1-UP; CSP1-UP)
G3516 (S/N: ZBA1-UP; 3RC1-UP; 8LD1-UP; CPG1-UP; 4EK1-UP; CSZ1-UP; ZAZ1-UP; 25Z1-
UP)
Electric Power Generation:
SR4 (S/N: 5NA1-UP; 6DA1-UP; 6SA1-UP; 9AB1-UP; 9EF1-UP; 8HG1-UP; 9FG1-UP; 3KJ1-UP;
4SJ1-UP; 5NJ1-UP; 6EJ1-UP; 7AJ1-UP; 2MM1-UP; 4LM1-UP; 6JM1-UP; 6YR1-UP; 7YR1-
UP; 8DR1-UP; 8ER1-UP; 9CR1-UP; 9DR1-UP; 1MS1-UP)
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SR4B (S/N: 5CK1-UP; 6PK1-UP; 8GK1-UP; 2DM1-UP; 2FN1-UP; 3FN1-UP; 3HN1-UP; 6SN1-
UP; 7DN1-UP; BGG1-UP; BGK1-UP)
Generator Set:
3406C GEN SET (S/N: C2G1-UP; C5G1-UP; C8G1-UP; KPS1-UP; 8FS1-UP; 9ES1-UP; LRX1-
UP)
3406E GEN SET (S/N: 8AZ1-UP)
3412 GEN SET (S/N: 81Z1-UP)
3412C GEN SET (S/N: BAX1-UP)
3456 GEN SET (S/N: CCB1-UP; C1G1-UP; C3G1-UP; C4G1-UP; CAH1-UP; C2T1-UP; CBX1-
UP)
C18 GEN SET (S/N: G4C1-UP; STD1-UP; STM1-UP; EKW1-UP; C6C1-UP)
3406 GEN SET (S/N: 4ZR1-UP)
Power Module:
PM3412 (S/N: CAJ1-UP)
PM3456 (S/N: B3G1-UP)
PM3508 (S/N: BLM1-UP; BPY1-UP)
PM3512 (S/N: BRF1-UP; BNR1-UP)
PM3516 (S/N: CAC1-UP; BPD1-UP)
Introduction
This Special Instruction provides information about the equipment and the procedures that are necessary in
order to replace or to upgrade the "Generator Set Control" (GSC) that has been installed for Caterpillar
generator sets. The GSC is located in the Electronic Modular Control Panel II (EMCP II).
This Special Instruction also provides information about the equipment and the procedures that are necessary
in order to replace or upgrade the AC Transformer Box (ATB) that has been installed for Caterpillar
generator sets. The ATB+ is located in the Electronic Modular Control Panel II (EMCP II).
The GSC+ is the replacement for the "Generator Set Control" (GSC). The ATB+ is the replacement the AC
Transformer Box (ATB).
Note: The ATB cannot be used with GSC+. The ATB MUST be replaced by the ATB+ in order to be
compatible with the GSC+.
The instructions and the warnings in this publication must be read and understood before the installation of
the GSC+ or the ATB+.
The GSC+ direct replacement features are as follows:
1. Power Metering
Total Real Power (kW)
Total Reactive Power (kVAR)
Power Factor
Rated Power (Percent kW)
Total Energy Output (kWHr)
2. Additional Display Components
Power Meter Key and Display
Spare Fault Indicators
3. Additional Generator Protection

Reverse Power
Overvoltage and Undervoltage
Overfrequency and Underfrequency
Overcurrent
A complete GSC+ upgrade procedure can provide additional features. A complete GSC+ upgrade procedure
will require additional wiring and modifications. Refer to the "GSC+ Upgrade Procedure" section within this
document for a description of the features and required modifications.
Illustration 1 g01546094
Location of the system components on the EMCP II panel. (Front View of a Closed Panel)
(1) Generator Set Control (GSC) that is to be replaced by the GSC+
(2) Optional Governor Switch (GS) or Optional Speed Potentiometer (SP)
(3) Diagnostic Reset Switch (DRS)
(4) Engine Control Switch (ECS)
(5) Optional Alarm Module (ALM) or Optional Synchronizing Light Module (SLM).
(6) Part Number for the GSC Film
(7) Optional Panel Light Switch (PLS)
(8) Emergency Stop Push Button (ESPB)
(9) Voltage Adjust Rheostat (VAR)

Location of the System Components on the EMCP II Subpanel. (Front View of Open Panel).
(10) Auxiliary Terminal Strip (AUX)
(11) Optional Electronic Governor (EG)
(12) Optional Reverse Power Relay, Optional Overcurrent Relay, or Optional Overvoltage Relay
(13) AC Transformer Box (ATB) that is to be replaced by the ATB+
(14) Circuit Breaker 2 (CB2)
(15) Starting Motor Magnetic Switch 1 (SMMS1)
(16) Optional Starting Motor Magnetic Switch 2 (SMMS2)
(17) Optional Auxiliary Relay (AUXREL)
(18) Resistor Assembly for Altronics Interface Box (RA)
(19) Battery Negative Post High Current (GPHI)
Location of the System Components on the Interior of the EMCP II Panel (Top View of the Panel with the Door Open).
(1) Generator Set Control (GSC) that is to be replaced by GSC+
(2) Optional Governor Switch (GS) or Optional Speed Potentiometer (SP)
(3) Diagnostic Reset Switch (DRS)
(4) Engine Control Switch (ECS)
(5) Optional Alarm module (ALM) or Optional Synchronizing Light Module (SLM)
(7) Optional Panel Light Switch (PLS)
(8) Emergency Stop Push Button (ESPB)
(9) Voltage Adjust Rheostat (VAR)
(20) Relay Module (RM), part of GSC
Reference
ReferenceSystems Operation Testing and Adjusting, SENR5809, "Electronic Modular Control Panel II
(EMCP II) for MUI Engines"
(EMCP II) for PEEC Engines"
(EMCP II) for Electronic Unit Injector (EUI) Engines"
ReferenceService Manual, SENR6588, "Programmable Relay Control Module (PRCM)"
ReferenceOperation and Maintenance Manual, SEBU6874, "Customer Communications Module for Diesel
Engines"
ReferenceService Manual, SENR5832, "Electronic Modular Control Panel II+ (EMCP II+) for MUI
Engines"
ReferenceService Manual, RENR1254, "Electronic Modular Control Panel II+ (EMCP II+) For PEEC
Engines"
Recommended Tools
Table 1
Recommended Tools
Qty Part Number Description
1 1U-5804 Crimp Tool

1 9U-7246 Connector Repair Kit
1 121-9587 Wire Removal Tool
1 (each) None 11 mm (0.4375 inch) socket, extension, and ratchet wrench

1 None Straight blade screwdriver
1 None
11 mm (0.4375 inch) open end wrench
1 None
4 mm (0.1575 inch) hex wrench
1 None
31.75 mm (1.25 inch) open end wrench
1 None Wire stripper and wire cutter
Required Parts
Table 2
Required Parts
Qty Part Number Description
1 118-0175 EMCPII+ Electronic Control (ATB+)
All of the replacements require the ATB+.

Choose one of the following GSC+ modules based on the application.
Applications that are not 3508 based
1 118-2070 EMCPII+ Electronic Control (GSC+, BASIC)

3508 based applications
1 243-5065 EMCPII+ Electronic Control (GSC+, BASIC)
Gas based applications

1 137-5525 EMCPII+ Electronic Control (GSC+, GAS)
1 236-4558 EMCPII+ Electronic Control (GSC+, GAS, ADEM III Applications (1))
(1) "Advanced Diesel Engine Management" (ADEM) is a type of Caterpillar electronic control.
GSC+ Direct Replacement Procedure

1. Start the engine of the generator set prior to initiating the upgrade procedure. Verify that all systems
are operational. Repair any faults that are logged prior to the conversion.
2. Shut down the generator set. Record all of the set point information that is necessary to reprogram the
GSC+. Also, be sure to:
Record the current hour meter reading.
Record the wire connections that are on the ATB terminal strip (13) .
Record the calibration values that are located on the barcode. The barcode is located on the side
of the ATB module.
Record the wire connections that are on the relay module (20) .
3. If a battery charging system is installed, then disconnect the AC source from the battery charging
system. Disconnect the battery system by either turning the battery disconnect switch to the OFF
position or remove the ground wire from the negative terminal of the batteries.
4. Locate the ATB terminal strip (13). Refer to Illustration 2. Use a straight blade screwdriver in order to
disconnect all of the AC wiring that is connected to the ATB terminal strip (13). Disconnect the eight
pin Deutsch connector that is connected to the ATB terminal strip.
5. Remove the four locknuts that secure the ATB module (13) to the EMCP II subpanel. A 11 mm
(0.4375 inch) socket, an extension, and a ratchet wrench are needed in order to remove the four
locknuts.
6. Install the ATB+ module in the former location of the ATB module (13). Refer to Illustration 2. Verify
that all four locknuts are installed. Torque the locknuts from 5.7 N·m (50 lb in) to 8.2 N·m (73 lb in).
Front view of the ATB+ terminal strip. The dash lines represent optional features. Refer to Table 3 for the wiring guide.
7. Reconnect the AC wiring (30, 31, 32) to the ATB+ terminal strip at the same points as on the original
ATB. Install three fuses into the fuse block of the ATB+ terminal strip. If possible, use the fuses from
the original ATB terminal strip. Refer to Illustration 4.
Table 3
ATB+ Terminal Strip Wiring Guide
Call Out Number Wire Number

30 T1-GEN T1/U
31 T2-GEN T2/V
32 T3-GEN T3/W
33 T0-GEN-T0
34 50-TS1-50 (Optional)
38 80-VRTS-6
39 82-VRTS-7
40 T11-SLR1-A (Optional)
41 T13-SLR2-A (Optional)
42 H21
43 H22
44 H23
45 80-VAR-1
46 82-VAR-2
47 Pigtail and Deutsch Plug
(47) Pigtail and Deutsch plug with 8 wire harness
Pin Number Wire Number

1 P10-GSC-10 (VAN OUT)
2 P11-GSC-11 (VBN OUT)
3 P12-GSC-12 (VCN OUT)

4 P4-GSC-4 (IA OUT)
5 P5-GSC-5 (IB OUT)
6 P6-GSC-6 (IC OUT)

7 P16-GSC-16 (AC GROUND)
8 No Connection
8. Wire the generator leads to the ATB+ in the same way as the ATB. There should NOT be a "T0" (33)
wire for the "Direct Replacement Procedure". Refer to Illustration 5.
Note: Verify that the jumpers connections (50) are made between H21 (42), H22 (43), and H23 (44).
Refer to Illustration 5.
ATB+ generator wiring configuration (No "T0" wire for direct replacement procedure).
9. Program the set point P032. P032 must be set to the delta generator configuration type. Set point P032
is on the GSC+. The value "1" equals the delta configuration.
If external potential transformers are required, then refer to the EMCPII+ service manual for more
information on setup and information about programming.
Note: Ignore the ATB+ chassis ground wire that is on pin eight of the Deutsch connector and that is
connected to pin 17 of the GSC. The ATB+ chassis ground wire is not used on the EMCP II+.
10. If no SLM (5) is installed in the panel, then the unused L1 wire and the L3 wire must be left
disconnected. The unused L1 wire and the L3 wire must be properly insulated. These wires must be
left available for possible future use.
11. If an optional "Synchronizing Light Module" (SLM) (5) is installed in the panel, then remove the L1
wire and L3 wire that is connected to the TS1 that is in the generator terminal box. Provide a direct
connection from TS1 to the SS-4 terminal connection and to the SS-6 terminal connection respectively
that is on the SLM (5).
Note: The T11 (40) wire and the T13 (41) wire must be connected to the synchronizing light resistors
SLR1 and SLR2 of the SLM.
Note: The EMCP II subpanel may possess an optional control unit (12). The control unit (12) can be a
reverse power relay, an overcurrent relay, or an overvoltage relay. The control unit (12) is replaced by
the protective relaying programming in the GSC+ and the ATB+. If a control unit is installed,
disconnect all of the wires to the control unit (12). Insulate the unused wiring. Refer to the EMCPII+
service manual for information about protective relay programming and about the process to configure
the generator protection on the GSC+.
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12. Document the wiring scheme and label the wiring scheme that is on the GSC relay module (20).
Disconnect all of the wiring to the GSC relay module (20).
Note: A 4 mm (0.1575 inch) Hex wrench, a straight blade screwdriver, and either a 11 mm (0.4375
inch) open end wrench or a 11 mm (0.4375 inch) socket, extension, and ratchet wrench are needed in
order to remove the components that are discussed in these procedures.
13. Disconnect the 40 pin connector plug that is connected to the GSC control (1) .
14. After all the wiring is disconnected, then loosen the six locknuts that are on the back of the generator
set control mounting flange. The mounting flange holds the GSC (1) in place on the panel face.
15. Install the new GSC+ in place of the original GSC (1). Tighten the six locknuts that mount the GSC+
to the panel face. The six locknuts must be torqued from 5.7 N·m (50 lb in) to 8.2 N·m (73 lb in).
16. Connect the 40 pin connector to the GSC+ (1). Tighten the 40 pin connector.
17. Install all shield grounding terminals to the stud of the GSC+ (1) .
18. Connect the wiring to the relay module (20) exactly as the wiring was for the original GSC. Ensure the
relay module fuses are installed on the GSC+ (1) from the original GSC.
Note: When either the GSC+ or the ATB+ is replaced, the calibration values that are written on the
ATB+ bar code sticker must be programmed into the GSC+. The calibration values are needed in order
to ensure accurate voltage and accurate current values. Refer to the EMCPII+ service manual for
instructions that relate to programming the GSC+ and ATB+ voltmeter and ammeter.
19. Attach the appropriate GSC+ film graphic.
Three different film graphics are available for the GSC+. Film graphic part numbers (6) can be found
on the EMCPII + as shown in Illustration 1. Determine the correct film graphics. Refer to Table 4.
Table 4
GSC Film Graphic Replacement
GSC Film Graphic Part Number GSC+ Film Graphic Part Number
130-9716 335-8640
4P-6407 335-8638 or 335-8639 (1)

(1) Graphic Film part number 335-8638 adds Oil Temperature (optional) to the five default parameter indicators.
20. There are no modifications that are needed for the optional "Customer Communication Module"
(CCM) data link, unless the EMCP II+ is installed for an application that involves multiple EUI
engines. In the multiple EUI engines application, the engines are connected to a single CCM that is on
the same data link. If the preceding application exists, the following procedure must be completed.
a. Locate the 40 pin panel wiring connector that mates to the GSC+. Extract the wire that is in
location 19 from the 40 pin panel wiring connector. Use the 121-9587 Wire Removal Tool .
b. Move the wire to location 21.
c. Extract the wire that is in location 20 from the 40 pin panel wiring connector. Use the 121-9587
Wire Removal Tool .
d. Move the wire to location 22.
e. The new location of these wires is designated as the CCM data link. The CCM data link will be
available on the auxiliary terminal strip (10). The CCM data link will communicate to the CCM.
The former location 19 and location 20 will be used for the Caterpillar DataLink (CDL). The
CDL will be used for communication with additional Caterpillar electronic controls such as
ADEM. If the generator set incorporates a local CDL network, then the local network must be
connected to the 40 pin panel wiring connector. The local network must be connected to the
CDL+ that is on pin 19 and the CDL- that is on pin 20. Use the 9U-7246 Connector Repair Kit
in order to install the pins.
21. An additional spare fault input (SW4) is available for use with the GSC+ replacement. This function is
available for customer input connection via the 40 pin Deutsch connector. The SW4 input is available
on pin 29 of the 40 pin Deutsch connector. The same guidelines and the same application requirements
for the utilization of spare inputs SW1, SW2, and SW3 apply to SW4.
Note: Refer to the EMCP II+ service manual for further information regarding the use and the
programming of SW4.
For a direct replacement only, skip the "GSC+ Upgrade Procedure" section and continue with the
"Programming and Startup" section.
GSC+ Upgrade Procedure

The full capabilities of the GSC+ and ATB+ can be obtained by performing the "GSC+ Upgrade Procedure".
The following steps are necessary in order to obtain the complete set of the GSC+ features and the ATB+
features. In addition to the GSC+ replacement and the ATB+ replacement, the features will require further
modifications and wiring changes.
GSC+ Full Upgrade Features.
1. L-N per phase voltage
2. Additional power metering
Per phase real power
Per phase power factor
3. Additional GSC+ outputs
Programmable spare relay
Optional relay driver module
kW level output
4. Install the ATB+ module. Refer to the procedure that begins in Step 6 through Step 9 of the "GSC+
Direct Replacement Procedure".
After the ATB+ has been installed into the same location as the ATB, the ATB+ can be wired as a wye
configuration or a delta configuration. If the generator wiring is a wye configuration, then a connection
from the ATB+ (13) terminal strip location H21 (42), H22 (43), and H23 (44) to the generator neutral
(T0) must be made. The generator neutral (T0) is wired to H23 (33). The wire should be a minimum of
16 gauge. Refer to Illustration 6.
If the generator is wired in a delta configuration, then the additional "T0" wire should NOT be added.
Note: Some power metering values are unavailable with a delta configured generator.
ATB+ Generator Wiring Configuration
5. Program the set point P032 on the GSC+. The set point must be programmed in order to set the
generator configuration type to what is being used. Zero (0) will set the generator configuration type to
the wye configuration. One (1) will set the generator configuration type to the delta configuration. If
external potential transformers are required, refer to the EMCPII+ service manual for more
information on setup and information on programming.
6. If required, install a 102-0050 Temperature Sensor Group into the engine oil gallery. Use a 1 1/4 inch
open end wrench in order to install the sensor.
Note: If a generic "cut-to-length" harness is used, connect a three pin Deutsch connector to the mating
connector that is on the sensor. Route the wire harness back down the engine, inside of the existing DC
engine harness conduit. Route the wire harness through the generator terminal box and then up inside
of the EMCP panel. The sensor harness should be routed in the DC harness conduit in order to avoid
electrical noise that can exist in the AC panel harness. Secure the harness with cable straps to existing
harness in order to avoid vibration fatigue. Connect the three wires from the sensor harness. Refer to
Table 5.
Table 5
Connection Of Three Wires From Sensor Harness (1)
(From) Sensor Pin (Use) Part Number

(To) Panel Connection Point Part No. Description
Auxiliary Terminal Strip SV+ Spring Spade Terminal

A 5P-1475
Auxiliary Terminal Strip SV- Spring Spade Terminal

B 5P-1475
GSC 14 (on pin 40

C 8T-8730 Connector Socket
connection)
(1) This connection requires the use of the 9U-7246 Connector Repair Kit , the 1U-5804 Crimp Tool , a combination wire
stripper and wire cutter, and a straight blade screwdriver.
7. The "Programmable Spare Relay" (PSR) contacts are available for customer use by making the
appropriate connections to relay module terminals. Refer to Table 6. The relay contacts are rated at 10
amperes at 24 VDC and 110 VAC for resistive loads. The contacts are rated at 5 amperes at 24 VDC
and 7.5 amperes at 110 VAC for inductive loads. The RM37, RM38, RM25, and RM26 are located on
the rearward side of the GSC+ (1) module.
Table 6
Programmable Spare Relay Connections
Terminal Connections
RM37 PSR1 IN
RM38 PSR2 IN
RM25 PSR2 NO OUT
RM26 PSR1 NC OUT
Note: Refer to the EMCP II+ service manual for additional information regarding electrical
connections and programming the GSC+ control (1) in order to activate this function.
8. An optional "Relay Driver Module" (RDM) output is available for use with the EMCP II+ control. The
RDM option provides nine additional outputs for remote control through the CCM. The RDM outputs
can be connected to an optional relay board or connected directly to horns, lamps, or other devices. For
installation, the serial data link must be connected to the 40 pin Deutsch connector on pin 30 of the
GSC+ (1). The operation of the RDM is controlled through the GSC+ by the CCM.
Note: For additional information concerning the program set points in order to operate the CCM
programmable output, refer to the EMCP II+ service manual.
9. A programmable kW level output is now available with the GSC+. The kW level output is a 100
milliamperes sinking output. In order to utilize this function, a connection to the 40 pin Deutsch
connector on pin 34 of the GSC+ control is required.
Note: For programming, operation, and application information, refer to the EMCP II+ service
manual.
Programming and Startup

1. After all hardware installation has been completed, connect the battery lead, or turn the disconnect
switch to the ON position. Provide power to the EMCP II+ panel on by turning the ECS (4) to the
STOP and COOLDOWN position.
Once the GSC+ is powered on, perform all the set point programming as documented in the EMCP II+
service manual. Use the set points from the original GSC for most of the information. The default set
points for the GSC+ are the same as the GSC, but several new set points on the GSC+ must be
configured.
Note: Reference the EMCP II+ service manual for information regarding power metering, protective
relaying, and other additional functions that are available with the EMCP II+ system.
2. Once the programming of the GSC+ has been completed, the control is ready for validation.
a. Start the generator set by moving the ECS switch (4) to the START/RUN position. The
generator set should start and run at the rated speed.
b. Once the generator set is at the rated speed, verify that all of the displayed functions are
operating at the correct values. Ensure that no fault codes or diagnostic codes are active.
c. After determining the unit is correctly operating, validate the shut down and the fault condition
operation of the EMCP II+ control according to the EMCP II+ service manual. If problems
occur, refer to the EMCP II+ service manual for assistance in troubleshooting the generator set
and repair of the generator set control system.
3. After validation of the EMCP II+ control, the engine can be shut down and then returned to normal
service.
Copyright 1993 - 2017 Caterpillar Inc. Thu Jun 22 2017 16:57:56 GMT-0300 (Hora oficial do Brasil)
All Rights Reserved.
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6/22/2017 Advanced Full Text Search - REHS4636 - Generator Set Control (GSC) and AC Transformer Box (ATB) Replacement{4490}

Generator Set Control (GSC) and AC Transformer Box (ATB)

The GSC+ direct replacement features are as follows:

Total Real Power (kW)

Total Reactive Power (kVAR)

Rated Power (Percent kW)

Total Energy Output (kWHr)

2. Additional Display Components

Power Meter Key and Display

Spare Fault Indicators

3. Additional Generator Protection

Overvoltage and Undervoltage

Overfrequency and Underfrequency

(1) Generator Set Control (GSC) that is to be replaced by the GSC+

(2) Optional Governor Switch (GS) or Optional Speed Potentiometer (SP)

(3) Diagnostic Reset Switch (DRS)

(4) Engine Control Switch (ECS)

(6) Part Number for the GSC Film

(7) Optional Panel Light Switch (PLS)

(8) Emergency Stop Push Button (ESPB)

(9) Voltage Adjust Rheostat (VAR)

(10) Auxiliary Terminal Strip (AUX)

(11) Optional Electronic Governor (EG)

(13) AC Transformer Box (ATB) that is to be replaced by the ATB+

(14) Circuit Breaker 2 (CB2)

(15) Starting Motor Magnetic Switch 1 (SMMS1)

(16) Optional Starting Motor Magnetic Switch 2 (SMMS2)

(17) Optional Auxiliary Relay (AUXREL)

(18) Resistor Assembly for Altronics Interface Box (RA)

(19) Battery Negative Post High Current (GPHI)

(1) Generator Set Control (GSC) that is to be replaced by GSC+

(2) Optional Governor Switch (GS) or Optional Speed Potentiometer (SP)

(3) Diagnostic Reset Switch (DRS)

(4) Engine Control Switch (ECS)

(7) Optional Panel Light Switch (PLS)

(8) Emergency Stop Push Button (ESPB)

(9) Voltage Adjust Rheostat (VAR)

(20) Relay Module (RM), part of GSC

ReferenceService Manual, SENR6588, "Programmable Relay Control Module (PRCM)"

1 1U-5804 Crimp Tool

1 121-9587 Wire Removal Tool

1 (each) None 11 mm (0.4375 inch) socket, extension, and ratchet wrench

1 118-0175 EMCPII+ Electronic Control (ATB+)

All of the replacements require the ATB+.

Applications that are not 3508 based

1 118-2070 EMCPII+ Electronic Control (GSC+, BASIC)

1 243-5065 EMCPII+ Electronic Control (GSC+, BASIC)

Gas based applications

GSC+ Direct Replacement Procedure

Record the current hour meter reading.

Call Out Number Wire Number

(47) Pigtail and Deutsch plug with 8 wire harness

Pin Number Wire Number

2 P11-GSC-11 (VBN OUT)

3 P12-GSC-12 (VCN OUT)

5 P5-GSC-5 (IB OUT)

6 P6-GSC-6 (IC OUT)

19. Attach the appropriate GSC+ film graphic.

4P-6407 335-8638 or 335-8639 (1)

b. Move the wire to location 21.

d. Move the wire to location 22.

GSC+ Upgrade Procedure

GSC+ Full Upgrade Features.