Governors America Corp GAC Product Application Guide 2021 – Electronic Governor Systems for Diesel, Natural Gas & Propane Engines

Description

GAC Product Application Guide — 2021 Edition

This is the complete Governors America Corp Product Application Guide for 2021 — a 233-page technical reference that shows exactly which GAC electronic governor components fit which engines, with real installation notes from the field. If you service, repower, or maintain diesel, natural gas, or propane engines and need to convert a mechanical governor to electronic control, or replace an existing GAC system, this guide is the single most useful document you can have on the bench.

The guide is organised by engine manufacturer, with each section listing the recommended GAC actuator, speed controller, magnetic speed pickup, and accessory kits for specific engine models. It also includes full cross-reference tables that let you match GAC part numbers to Ambac, Barber Colman, Cummins, Deutz, Heinzmann, Iveco, MAN, Mitsubishi, MTU, Scania, SDMO, Volvo, and Woodward part numbers — so you can find the right replacement without guesswork.

File Details

• Manual type: Product Application Guide
• Brand: Governors America Corp (GAC)
• Title: GAC Product Application Guide
• Edition / Date: 2021
• Language: English
• Page count: 233
• File format: PDF

Chapters Covered

• Overview & About This Guide
• About Inline Diesel Fuel Injection Pumps
• GAC Governor Basic Terms
• GAC Governor Features
• Arrow A-32 and A-42 Engines
• BEML BSA6D170 Engine
• Caterpillar Engines (3054, 3304, 3306, 3406, 3408, 3412, 3512, 3516, and more)
• Chevrolet 350 in³ and 454 in³ Engines (Natural Gas or Propane)
• Combined Heat and Power Solution
• Cummins Engines (NT, KT, QST30G, B4.5T, KT38, B, C, 6BT, 4A2.0/4A2.3/4AT2.3, 3A1.4/3A1.7, 4B, VT1710, KTTA-50, KT855NA)
• Detroit Engines (3-71 through V16-149, DDEC)
• Deutz Engines (616, 620, 912/913, 1011/2011, 1012/1013, 1015, 2008, 12L513, EMR Interface)
• Doosan D1146T Engine
• Ford 300 in³ and 460 in³ Engines (Natural Gas, Propane, NA, Turbocharged)
• Hatz 1B and 35W Series Engines
• John Deere Diesel Engine with CAV-DPA Rotary Pump
• Kirloskar 6SL8800TA and DV Series Engines
• Komatsu SAA 170-G3 and Gen Set
• Kubota Various Diesel Engines (D722, V2203, V3800DIT, D905, D1005, D1105, V1305, V1505, D1503M, D1703M, D1803M, V2003M, V2403M, V3300, V3800)
• Limmat 12 Cylinder Marine Engine
• Lombardini / Kohler KDW1003 and LDW 2004 Engines
• MAN Diesel 0824, 0826, 2842, 2866 Engines
• Military — John Deere 40457F151 and 6068TF151 Generator
• Mitsubishi L3E, S4L2 Engines
• Mitsubishi Heavy Industry S6R2 (Volvo D30), S4S/S6S, S12A2/S12R/S16R, L-Series/K-Series, S6A3/S6B3/S6R
• MTU 183, 447 Engines
• Marine Propulsion / Generator Drive
• Noell 6 Cylinder Crane
• Perkins 3.1524, 4.236, 1004, 1006, 1300, 1306, 2006, 2800, 3008, 3012, 4000 Series
• Dorman 6 SETCA 2 / Perkins 4006 TAG2
• Vista A with Delphi DPA
• Scania D9, D11, DSC 14, DSI 14, DSC1000, 12 Liter Gas, S6, Sanfirden Bio Gas
• Volvo TD 420, TAD 420, TAD 520, TAD 531, TAD 720, TAD 731, D30, D34A, D49A, D65A, TD/TWD610, TD/TWD710, TAD721, 730, 740, TD1010, TD1030
• Wanco Light Tower
• Wisconsin Motors TM27 Engines
• Xichai Variable Speed Forklift
• Cross References and GAC Replacements (Ambac, Barber Colman, Cummins, Deutz, Heinzmann, Iveco, MAN, Mitsubishi, MTU, Scania, SDMO, Volvo, Woodward)

Overview & About This Guide

The opening section explains how the guide is organised and what it is for. It covers the basic types of mechanical governors used on inline diesel fuel injection pumps — min-max governors and variable speed controllers — and explains how GAC electro-magnetic proportional pump-mounted actuators replace them. There is a clear table showing which GAC actuator series (100, 103, 110, 175, 176, 180, 275, 295, ALR) matches which GAC speed controller and what type of fuel pump each is designed for. This is the section that tells you where to start if you have never specified a GAC system before.

GAC Governor Basic Terms & Features

Before diving into engine-specific applications, the guide defines every term you need to understand the rest of the document. You get plain-English explanations of number of teeth and RPM calculation, rated speed, variable speed, crank termination RPM, pulse-width modulation (PWM) with a duty-cycle diagram, overspeed protection, light force, reverse acting, electronic fuel control (EFC), fuel ramp, isochronous, droop, droop percentage, PID control loops, gain, stability, dead time, starting fuel, speed ramp, idle, AUX input, speed trim, speed switches, soft coupling, lead circuit, dual gain, dead time compensation (DTC), multi-PID, fuel limit, dither, temperature compensation, and foot pedal input. This section alone is worth the price of the guide because it gives you the vocabulary to specify, install, and tune a GAC governor system correctly.

Caterpillar Applications

One of the largest sections in the guide. Covers the 3054 engine with the ADC100-24 actuator and ECC328 speed controller (no magnetic pickup required — uses genset frequency). The 3304 and 3306 engines with ADD225GSC-24 or ADC225GS-24 actuators and ESD5500E speed controller. The 3406 engine with the 225 Series actuator, ESD5111/ESD5500E/EEG6500 speed controller, MSP6720 magnetic speed pickup, and KT230 installation kit. The 3408 with natural gas, using the ACB2001 actuator, ESD5330 speed controller, ICM200-4 ignition control module, CL600/CL601 ignition coils, SPW100 spark plug wires, and SPG100-002 spark plugs. The 3412 engine with ADC225GS-24, ESD5111/ESD5500E/ESD5550. The 3512 and 3516 engines with ACB2001 actuator and ESD5330 speed controller. There is also a detailed application note for a tugboat in Iceland running two Caterpillar 3516 V16 engines with two ACB2001 actuators and two ESD5330 controllers, including how the fuel racks were modified and how the engines are balanced with a single potentiometer.

Cummins Applications

The Cummins section covers NT and KT engines with PT pump and EFC fuel system or PT pump with mechanical governor (ADB120E4 or ADC225JS-12/24 actuator, ESD5522E/ESD5120/ESD5119/ESD5160/EEG6500/EDG6000/ESD2210/ESD5111/ESD5500E/ESD5500-II/ESD5550 speed controller, EAM100 interface module, plus optional load sharing and auto synchroniser modules). The QST30G with Bosch in-line fuel injection pump and Bosch EDC governor is covered in detail — you need two ADD175F actuators, two ESD5111 or ESD5221 controllers, a DDM101 dual driver module, a 5/8″-18 thread magnetic speed pickup, a CH1204 harness, two KT197 Bosch EDC governor adaptor kits, two STE101 K-type thermocouples, two CH1243 feedback sensor mating harnesses, and two CH1215 actuator harnesses. The section includes a photo of the ADD175F mounted on a QST30 fuel injection pump with the KT197 installation kit. Other Cummins engines covered include the B4.5T (with ESD2349-12 and FP100 electronic foot pedal for a 10-ton Taylor Machine Works forklift), KT38 (two ADB120E4 actuators, two ESD5221 controllers, two RSC671 speed ramping controllers for a tugboat in Cook Inlet, Alaska), B engine with CAV DPA, C engine with Bosch inline and RSV, 6BT with Bosch inline, NT/KT with EFC system, 4A2.0/4A2.3/4AT2.3, 3A1.4/3A1.7, 4B with Zexel A, 4B and 6BT with Stanadyne rotary pump, VT1710 irrigation engine (dual ATB652T2F14-24 actuators, ESD5111, DDM101 dual driver module, STE101 thermocouples), and the KTTA-50 C.I.L. diesel electric locomotive (ADB120E4, LCC107B speed controller with overspeed sensing, start fuel adjustments, speed selects, and excitation control). There is also an application note for the KT855NA naturally aspirated natural gas engine with ATB652T2N-12/24 throttle body and ESD5526E speed controller.

Detroit, Deutz, and Other Major Brands

Detroit engines from the 3-71 through V16-149 are covered with ADD225, ADB225, ADC225, ACB2001 actuators and ESD5111, ESD5500E, ESD5330 speed controllers. The DDEC engines use the EAM104 interface module for isochronous parallel operation with GAC auto synchroniser and precision load sharing. Deutz coverage includes the MWM 616 Series (ACB275H S1 and ACB275G4-24), 620 engines (ACE295-24), 912/913 engines (ADE176AA Series), 1011 and 2011 Series gen-sets (ACD110-12/24), 1012 and 1013 engines (ADD180G with KT188, ESD5111 or ESD5500E), BF6M1015GCP-FIMS natural gas engine (full GAC FIMS fuel and ignition management system with ATB552T2N-12 throttle body, AFR210 integrated venturi mixer control, MX60-STM mixer, SCI100 speed sensor, RPR104 zero pressure gas regulator, ICM200-6 ignition control module, CL602 ignition coil, BK601 coil bracket, SPG100-002 spark plugs, SPM200-1B MAP sensor, STE101 exhaust gas temperature sensor, SOX102 O2 sensor, SPO100 oil pressure sensor, STC101 coolant temperature sensor, GR104 trigger wheel, SCI103 Hall effect sensor), 1015 engines (ACE275H-24 or ACE275J-24 with ESD5500E and KT275 mounting kit, or ACD175A with KT197 for EDC pump), 2008 engine with Delphi pump (ADD103B), 12L513 engines (ACE275, ESD5221, RSC671 for an Alaskan hovercraft), and Deutz engines with EMR interface module (EAM114).

Perkins, Volvo, Scania, MTU, and More

The Perkins section is extensive: 3.1524 with Stanadyne (ADC100, ESD2244/ESD5120/ESD5522E/ESD5570, MSP6728C, EC1350), 4.236 with Stanadyne CAV (ADC100 or ADD120S, same controllers, KT190 mounting kit), 1004 with Stanadyne rotary pump (ADC100, same controllers, MSP6728C or MSP6723C with M16x1.5 thread), 1006 with Stanadyne CAV (ADC100 or ADD120S, same controllers, KT190), 1300 Series (EAM115 interface module), 1306 with Bosch “P” pump (ACD175A, MSP6724 with 3/4-16 UNF, KT275), 2006 with Bosch “P” pump (ACE275HD-24, MSP6728 with 5/8-18 UNF, KT275), 2800 Series (EAM113 interface module), 3008 with Bosch “P” pump (ACE275HD-24 or ACD175A, KT275), 3012 Series (ADD225S-24, MSP6728C), 4000 Series methane power generation (RPR102 zero pressure gas regulator, MXSB44-STM venturi mixer and fuel control valve, ATB552T2N2-24/ATB652T2N2-24/ATB753T3N214-24 actuator throttle body, AFR210 venturi mixer control/engine speed controller, SOX103 O2 sensor, STE101 exhaust gas temperature sensor, ICM200-6/8 ignition control module, CL600 ignition coils, SPW100 spark plug wires, GR104 camshaft trigger wheel, SC1010 camshaft sensor), and the Dorman 6 SETCA 2 / Perkins 4006 TAG2 (ACB2001, ESD5330 or ESD5340). Volvo coverage includes the TD 420, TAD 420, TAD 520, TAD 531, TAD 720, TAD 731 engines (ADD180G-12/24, ESD5500E/ESD5111/ESD5500-II/ESD5550), D30 (MHI S6R2) engines (ADC225S-24 with Volvo part number 3838271, ESD5500E with Volvo part number 3817999, MSP6827C), D34A/D49A/D65A marine engines (ACB2001, ESD5330, MSP6728C), TD/TWD610, TD/TWD710, TAD721, 730, 740, TD1010, TD1030 engines (ACB275H-24 or ACD175A-24, ESD5500E, MSP6728C, KT275 or KT276), and TAD 520/720 engines (ADD225). Scania covers D9, D11, DSC 14, DSI 14 (ADC225S-24, ESD5131 or ESD5500E, MSP675), DSC1000 Series engine control system (ACE275K-24, DSC1004 controller with cranking fuel and crank termination adjustments, speed ramping, fully programmable via GDS software, fuel mapping based on RPM and boost pressure, temperature dependent start fuel, temperature dependent torque curve, fault codes and logging, load sharing/synchroniser input, droop or isochronous selection, oil/air/exhaust temp measurement), 12 Liter Gas Engine (ATB652T3N1-24), S6 Engine (EAM127 interface module), and Sanfirden Bio Gas Engine — Scania SGI-12-ST (ATB T2 65mm bore diameter high temperature/sealed actuator with optional position feedback sensor, ESD5526E speed controller, anti-wind-up circuit, switchable droop control, start fuel control, speed ramping, soft coupling, over-speed control switch). MTU coverage includes the 183 diesel-electric locomotive (ACB275H, SSW675 speed switch, LCC109B accessories), 447 engine (ADC225S-24, EDG5500), and marine propulsion/generator drive (EGS104B speed controller, LSM201 load share modules, SYC6714 synchronisers, ACE275H actuator).

Cross References & GAC Replacements

One of the most valuable parts of the guide for anyone doing retrofits or replacements. The cross-reference tables let you look up a part number from another manufacturer and find the GAC equivalent. Coverage includes Ambac (AGB, AGD, AGK, AGL, AGS, AL3000, AL3001, AR3100, AR3200, CU671, CW673, EC50, EC5000, EC501, EC5100, EC5111, EC60, ECD67, ESC61, ESC63, LS671, LS672, LS7000, LSM672, LSM675, RSC671, SSW674, SSW675, SSW676, SWA674, SWA675, SYC6714, SYN671, TP501, TP502, TP503, and many more), Barber Colman (DPG2100 through DPG2401, DYNC series, DYN series, DYNA series, DYNT series, DYNZ series, LAM100, and more), Cummins (3019635, 3001817, 3020987, 3052504 through 3052509, 3037359, 3032733, 3063504, 3063505, 3044189, 3044196, 3081313, 3005810, 3014107, 3014195, 3039571, 8836, 213272, 213273, 3003916, 3005811, 3008316, 3015105, 3017418, 3628381, ITM050, ITM051), Deutz (1231 4175, 1231 4288, 1230 7878, 0423 3541, 0423 3456, 0423 3463, 0428 1525 KV-12, 0428 1524 KV-24, 02113598, 0421 26060, 301622, 302990, 302991, 0422 3844, 1231 6257, 0422 6301, 0423 3140, 0423 3464, 0427 1898, 1230 5436, 1230 4578, 1502 2476, 1232 0916, 1509 8057, 1509 6247, 1232 0621, 1509 6246, 0427 1795, 0419 1545, 0427 1897, 0422 3457, 0422 3846, 303089, 0422 3959, 302979, 302981, 1231 4423, 1231 6259, 1231 6113, 302972, 302987, 302583, 302997, 302938, 302977, 302978, 302664, 302969, 302973, 303082, 30301, 302974, 302976, 302982, 0423 3576, 0424 3577, 0427 1793, 302983, 302984, 302985, 1232 0622, 1232 0623, 04233807, 1232 0914, 0422 4032, 0422 4035, 0422 4956, 0427 1801, 1509 8058, 1509 8059, 1232 3417, 1232 3419, 0423 3161, 1232 0620, 0419 1541, 1232 2066, 1203 6768, 1215 3968, 1215 7759, 1221 3833, 1221 3883, 1221 3885, 1231 4176, 04323142, 1232 0983, 302970, 302994), Heinzmann (KG1/2, KG6/10, KG16/30/40, KG64/90, KG2000, AC3, DC2/DC6, DC8, DC9, DC12, StG 4002, StG 2005 DP, StG 2040 DP, StG 1/StG 2, StG 6-01, StG 6-02V, StG 10, StG 16/StG 2080, StG 2005, StG 2010, StG 2040, StG 3005/StG 3010, LA 25/LA 30, LA 35), Iveco (8018971, 8021744, 8015587, 8018556, 8018674, 8029133, 8078971, 8037141, 8045581, 8045582, 5802139004, 5801383709, 5801407573, 8017472, 8018675, 8018557, 8023045, 8030357, 87974507, 5802139002, 8014335, 8018673, 8030061, 8018343, 8018386), MAN (51.11610-6026, 51.11610-6025, 51.11610-6028, 51.11610-7131, 51.11610-7159, 51.11610-7132, 51.11610-7133, 51.11610-7134, 51.11610-7135, 51.11610-1023, 51.27120-7032, 99.25413-6117, 51.25435-7007, 51.25435-6010, 51.25435-6011, E 51.11610-6029, E 51.11605-0199, E 51.11610-6017, E 51.97601-0286), Mitsubishi / Mitsubishi Heavy Ind (242538, 3838271, 242295-BP, 3817999, 242537, 3818000), MTU (001-061-23-00, 000-538-32-60, 000-538-55-60, 000-538-56-60, 001-530-16-12, 000-532-01-10, 000-532-50-64, 000-533-29-88, 001-061-09-03, 001-061-10-03, 000-061-10-03, 000-535-62-33, 000-538-57-60, 003-531-86-18, 003-531-76-18, 003-531-84-18), Scania (1349 380, 1359 295, 1359 400, 1349 569, 1373 879, 1373 881, 1300 298, 1300 300, 1349 570, 1359 216, 1359 296, 1359 299, 1359 403, 1359 404, 1412 222, 1412 223, 1423 086, 1432 252, 1432 254, 1480 890, 1480 891, 1534601, 1534603), SDMO (30604011001, 30604011201, 30604020701, 30604020901, 30604015401, 30604007101, 30604012201, 30604021001, 30604020801, 30604005401, 31101043101, 31613096301, 30604020011NE), Volvo (358 9408, 383 8271, 382 7267, 383 4900, 863 616, 866 167, 383 7082, 358 6281, 382 5454, 881 676, 881 677, 881 616, 873 979, 873 738, 873 747, 881 665, 865 414, 863 617, 873 796, 873 797, 873 798, 382 6107, 383 9296, 865 233, 866 169, 382 5233, 358 9140, 863 618, 382 5810, 862 207, 866 812, 382 5151, 874 370, 358 6975, 358 6282, 358 6789, 383 4933), and Woodward (8290-051, 8290-052, 8290-061, 8290-054, 8290-038, 8290-060, 8290-067, 8290-071, 8290-046, 8290-075, 8290-140, 8290-186, 8290-175, 8290-138, 8290-184, 8290-172, 8290-069, 8290-073, 8290-044, 8290-077, 8290-189, 8290-190, 8290-064, 8290-041, 8290-059, 8290-057, 8290-058, 8290-039, 8290-068, 8290-072, 8290-047, 8290-076, 8290-070, 8290-074, 8290-045, 8290-078, 8256-022, 8256-017, 8290-141, 8290-187, 8290-174, 8290-139, 8290-185, 8290-158, 8290-142, 8290-021, 8290-016, 8290-118, 8256-021, 2301A, DPG2100, DPG2200, EPG512, EPG524, EPG1712, EPG1714, DYNC 70000-001-0-12, Dyna 70025, A459 8, SA-4506-24, Dyna8000, DC11020-000-012, DC11028-300-024, Dyna8200, DC12000-000-012, DC12003-000-024, 8405-089, DynaPlus4, DynaPlus8, UG8-UG40, ProAct Model I, ProAct Model II, LSM, L-Series ITB, F-Series ITB, Flo-Tech ITB, ProAct ITB — Large Bores).

Why This GAC Application Guide Belongs on Your Bench

If you work on diesel, natural gas, or propane engines — whether in a shop, on a farm, in a marine application, or in power generation — you already know that governor problems are some of the most frustrating faults to diagnose. A hunting engine, a genset that won’t hold frequency, a engine that surges under load, or a governor that won’t respond at all can bring an entire operation to a standstill. The difference between guessing and fixing it right is having the correct application data: which actuator fits your injection pump, which speed controller works with your actuator, which magnetic speed pickup matches your flywheel ring gear teeth, and which installation kit you need to mount it all without fabricating brackets.

This GAC Product Application Guide gives you exactly that, engine by engine. Instead of calling a dealer and hoping they have the right information, or searching forums for a part number that may or may not be correct, you can open this guide and find the specific GAC components recommended for your engine — often with an application note showing a completed installation, the actuator mounting location, the linkage setup, and the speed controller settings. That means fewer wrong parts, less downtime, and a governor system that works the way it should.

For fleet managers and OEMs, the cross-reference tables are invaluable. If you have an engine with an Ambac, Barber Colman, Woodward, Heinzmann, or other governor that is obsolete or hard to source, you can look up the original part number and find the GAC replacement. That keeps older equipment running without a complete repower.

For technicians doing conversions from mechanical to electronic governing, the guide provides the full picture: actuator selection, controller selection, wiring and harness part numbers, magnetic speed pickup options, mounting kits, linkage components, and configuration notes. The application notes show real installations on tugboats, locomotives, hovercraft, generator sets, forklifts, wood chippers, yachts, and irrigation pumps — proof that these systems work in the field, not just on paper.

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