175 Series

Electrical Actuator
1 INTRODUCTION Installation Kits
KT153
Description
175 Series Installation Kit - Motorpal Pump PP#M10P1i
GAC’s 175 Series Integrated Pump Mounted Actuators are field proven pro-
portional actuators designed to mount directly to fuel injection Bosch “P” style KT197
175 Series Installation Kit - Bosch EDC Governor Housing - Mounting
or similar pumps to achieve an integrated proportional servo fuel package. The Plate, Linkage, Gasket and Installation Hardware
design is versatile with numerous options and mounting kits available in order to 175 Series Installation Kit For Bosch RS/RSV Governor / Right Hand
adapt to other fuel pumps. See below. KT175-RS-R
Rack / Mounts Actuator Directly to Intermediary Mechanical Governor
Housing - Adapter Plate, Linkage,
2 SELECTION CHART Gasket and Installation Hardware

175 Series Installation Kit - For Zexel RS/RSV Governor / Right Hand
Rack / Mounts Actuator Directly to Intermediary Mechanical Governor

Connection-2
Kit (Included)

Bearing Bore

Lever to Link
KT175-RS-R-Zexel

Heavy Duty
Installation
Connector

Protective
Feedback

Housing - Adapter Plate, Linkage, Gaskets (Governor Housing and

Included

Retainer
Position

Bearing
Sensor
Mating

Return
Spring
12 Volt

24 Volt

Plug-1
Actuator) and Installation Hardware
Product
175 Series Installation Kit - For Bosch ‘A’ size Pump with a Right
Hand Rack / Mounts Actuator Directly onto an Adapter Plate. In-
KT175A-R
cludes Adapter Plate, Linkage, Gaskets, Bearing Retainer, Shims and
2x Installation Hardware
ACD175A-12 ■ KT283 ■
Bearing
175 Series Installation Kit - For Bosch ‘A’ size Pump with a Right
2x
ACD175A-24 ■ KT283 ■ Hand Rack / Mounts Actuator Directly onto an Adapter Plate. In-
Bearing
KT175A-R-SA cludes Adapter Plate, Linkage, Gaskets, Bearing Retainer, Shims and
1x Installation Hardware.
ADD175A-12 ■ KT289
Bearing For Mounting ADD175SA-24 Actuator with Internal Return Spring

1x 175 or 275 Installation Kit - Bosch P 3000 Series Camshaft Bearing

ADD175A-24 ■ KT289 KT275
Bearing Retainer Kit - Plate, Gasket, Seal, Shims and Installation Hardware
1x
ADD175HD-24 ■ KT289 ■ ■ 175 or 275 Installation Kit - Bosch P 7000 Series Camshaft Bearing
Bearing
KT276 Retainer Kit - Plate, Gasket, Seal, Shims and Installation Hardware
1x
ADD175F-12 ■ ■ KT289
Bearing
ACD175A Installation Kit - Spare for BYC Asimco Pumps (Included
1x KT283
ADD175F-24 ■ ■ KT289 with Actuator) - Hardware, Gasket, Shutoff Plate, Spring
Bearing
ADD/ADE175 Series Installation Kit - Spare for Bosch-Style Pumps
Direct
ADD175SA-24 ■ ■ KT270 ■ (Included with Actuator) - Hardware, Gasket, Shutoff Plate, Spring,
Link KT289
Retainer, Linkage / Note - KT289 includes all of KT283 (BYC ASIM-
1x CO installation kit) plus Retainer and Linkage
ADE175A-12 ■ ■ KT289
Bearing

ADE175A-24 ■ ■ KT289
1x
Bearing
3 SPECIFICATIONS
2x PERFORMANCE
T732012023 ■ KT289 ■
Bearing
Net Force 6.2 lb-ft (27.5 N)
NOTE 1 To protect paint or other debris from entering main shaft bore.
2 The standard connection is one bearing rolling on link piece pro- Max Operating Stroke 0.80 in (21 mm)
vided in KT289. Two bearings are sometimes needed to accommodate rank Response Time (10-90%, 2-19 mm) 35 msec
height variances across different fuel pump models. Lever assembly on ADD-
175SA-24 is designed to work with specially modified rack and linkage, consult ELECTRICAL POWER INPUT
GAC for details. Operating Voltage 12 VDC or 24 VDC
3 OEM part number for Lovol brand engines.
4.0 A (12 VDC)
Nominal Operating Current
Others: Select models have GAC logo embossed on top cover. On some mod- 2.0 A (24 VDC)
els, lock washers are used in place of flat washers to tighten down the covers. 5.8 A (12 VDC)
Max. Continuous Current
Contact GAC if special accommodation is needed. 3.1 A (24 VDC)

Item Model Number 7.2Ω (12V)

Nominal Coil Resistance
2.0Ω (24V)
Actuator Mating Connector EC1300
ENVIRONMENTAL
ADD Packard Actuators - Connector Kit Replacement /
EC1310 Operating Temperature -40 to 257°F (-40 to 125°C)
(2 Terminal)
Actuator Mating Cable Harness (6 ft.) [1.8m] CH1215 Relative Humidity Up to 100%

ADD175F-12/24 Position Feedback Sensor Mating Connector EC1523 Vibration Heavy Duty HD version:
Random vibration: 31grms vertical,
ADD175F-12/24 Position Feedback Sensor Harness, 6 Ft. (1.8m) CH1243 17grms transversal, 12grms longitudinal
@ 20-2000Hz

ADD175F-12/24 Position All other variants:

Feedback Sensor Mating 21g peak @ 100-2000Hz
Connector EC1523

Shock 20g @ 11 msec

CH1243 SN120
PIN SIGNAL All Surface Finishes Fungus Proof and Corrosion Resistant
Harness Sensor

A +5V RED GREEN PHYSICAL

B GND BLACK BROWN Dimensions See Section 4
C OUT WHITE WHITE
Weight 4.75 lb (2.2 kg)

1 175 Series Electric Actuator 4.30.2018 PIB 2050 G

© 2018 Copyright All Rights Reserved
 4 DIMENSIONS 7. Insert a ball end hex wrench through the access point located on the
operating lever (17) and tighten the left lower mounting screw (15) a
few turns.
Dimension Units
8. Pull the operating lever outward and slide the ball end hex wrench into
[xx.x] -------- [mm] the space between the operating lever and the access point in the hous-
xx.x --------------- in ing of the actuator and tighten the right lower mounting screw.
9. Once these two screws are fully engaged (do not tighten at this time)
into the pump housing, insert two additional M6 X 16 mm long screws
(15) and spring washers (16) into the top two mounting holes of the ac-
R tuator and thread into the pump housing.
10. Torque all four mounting screws to 5-6 NM.
11. Verify that the fuel rack assembly moves in and out freely inside the
upper cavity of the actuator.
12. Carefully loosen screw (11) and (20) over the slotted portion of the ad-
justment plate so that the operating lever bearing assembly (21) can be
STEEL REAR
moved away from the fuel rack connection link.
13. Ensure that the fuel rack is as far out of the pump as possible.
14. Rotate the operating lever (17) out from the actuator until it stops (the
armature of the actuator will be in contact with the lower cover (9) and
hold in this position.
R
15. Rotate the adjustment plate and lever bearing assembly (21) in towards
the fuel rack so that contact between the bearing and rack connection
link is made. Continue to push in an additional 1 to 2 mm. While holding
5 PREPARATION this position torque the operating lever assembly shaft screw (11) and
screw (20) to 4-6 NM.
If the fuel injection pump is equipped with a mechanical governor, it must be re- 16. Inspect the assembly to ensure all screws are tight and the fuel rack
moved. GAC recommends that this modification be performed by a qualified fuel moves smoothly without any binding. Push in the fuel rack manually to
injection service facility. The following procedure lists the general steps required the full fuel position and rotate the fuel shut off lever (22) to minimum fuel
to remove the mechanical governor. to confirm that the shut off lever contacts the metal plate (6) on the fuel
NOTE rack connector assembly and forces the fuel rack to minimum position.
The mechanical governor will release oil during removal.
17. The operating lever has a maximum fuel adjustment set screw (23)
1. Remove the rear housing from the mechanical governor and disconnect which can be used to restrict the fuel rack travel.
the governor linkage from the pump fuel rack. Remove the flyweight as-
When installed, the cover must not hit the internal operating lever
sembly. A special tool is required. NOTE
or the maximum fuel adjustment screw. Torque the cover screws to
2. Remove the intermediate governor housing. This leaves only the rack 2-3 NM. Check for any oil leaks. Lock-wire the lower screws for tamper resis-
and camshaft protruding from the pump. tance.
3. Install the appropriate adapter plate to provide the transition required from Setting high fuel levels may cause the maximum fuel adjusting
CAUTION
the actuator to the mounting holes formerly held by the governor housing. screw to hit the top cover, which can change the minimum fuel
This plate must have countersunk holes for the mounting screws. position. This could lead to a dangerous condition. When setting fuel levels
above 17mm, insure that the adjusting screw does not contact the top cover
6 INSTALLING THE ACTUATOR
at minimum level. Make sure that the cold start magnet is de-energized when
adjusting the actuator with the cold start option.

All hardware needed to attach the actuator to the pump is located in both kits With the fuel pump operating on the engine, the maximum fuel setting screw can
KT283 and KT289, which are supplied with the actuator. The following installa- be adjusted to provide specific horsepower. Once this setting is made torque the
tion instructions will refer to figures located on the next page. locknut (24) on the fuel adjustment screw to 5-6 NM.

1. Place the spring seat (1) over the fuel rack and slide it to the body of the Rotate the manual shut off lever (22) to the stop position and ensure that the fuel
fuel pump (see Figure 1-1). Slide the fuel rack return spring (2) over the is completely shutoff and the engine stops. With the engine shut down, install
fuel rack and against the spring seat. the upper chamber cover (8) and o’ring seal (25) by first applying Loctite 222 to
the six screws (26, 27) provided.
2. Attach the rack connection link assembly (4, 5, 6, 7) to the fuel rack with
two M5 X 10 mm long retaining screws (3) that include patches of Loctite
adhesive. Torque the screws to 3-4 NM.
7 WIRING
3. Remove the upper actuator cover (8) and o’ring seal (25). The 175 Series Integral Electric Actuator is prewired for 12 or 24VDC operation.
Use the included cable harness or make up a cable harness to connect the
4. Clean the actuator to pump adapter mounting surface so that it is free
actuator to the speed control unit.
of any debris.
Do not use the 175 Series actuator on a 32-volt system.
5. Insert two M6 X 16 mm long screws (15) and spring washers (16) WARNING
Contact the factory for assistance.
through the lower mounting holes inside the upper actuator cavity (see
Figure 1-3). The engine should be equipped with an independent shut down
CAUTION
device to prevent overspeed, which can cause equipment dam-
6. Align the gasket (29) as shown in (Figure 1-4) and install it over the two
age or personal injury.
screws and carefully slip the actuator over the fuel rack assembly until
the two lower screws just start to meet the fuel pump mounting holes.

Alternate the turning of following mounting screws so that

IMPORTANT
the actuator is aligned properly with the pump adapter plate.

175 Series Electric Actuator 4.30.2018 PIB 2050 G

2 © 2018 Copyright All Rights Reserved
8 DIAGRAMS

KT275 or KT276

Mounting Kits KT289 & KT283

KT283 is specific to the BYC (Asimco) fuel injection pump where the retainer
and link are already included with the fuel pump. KT289 comes with the re-
tainer and link, giving the customer a choice of whether or not to use the two
included components.
KT283 KT289
Link X
Retainer X

Link
(KT289)

Retainer
(KT289)

175 Series Electric Actuator 4.30.2018 PIB 2050 G

3 © 2018 Copyright All Rights Reserved