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275 Series

Integrated Pump Mounted Electric Actuator


1 SELECTION CHART MATING HARDWARE
ACTUATOR TYPE CONNECTOR DESCRIPTION
SYSTEM CONNECTOR MODIFICATIONS ACB, ADB EC1000 Military - Straight
VOLTAGE

Connectors
ACB, ADB EC1010 Military -90
Heavy Duty Feed-
24 Multi Oil Drain
Product No. MIL Packard Bearing back ADD EC1300 Packard
VDC VDC Fitting
Retention Sensor
ADD EC1310 Packard
ACB275 AB Position Sensor
ACE275K EC1515
ACB275C Military - Straight 12 ft [3.6m]
ACB, ADB CH1203
ACB275H

Harnesses
ACB, ADB CH1210 Military - 90 12 ft [3.6m]
ACE275H-24 Packard 6 ft. [1.8m]
ADD CH1215
ACE275HD-24 AB Position
ACE275k CH1515
ACE275J-24 Sensor 6 ft [1.8mm]
ACE275K

ACB275F 3 OUTLINES & DIMENSIONS


Dimensions: [mm]
ADDITIONAL NOTES
in
Designed specifically for MTU with a sand cast house and VIEW 2
VIEW 1
ACB275C aluminum cover plate. Installation requires bearing retainer kit
kt3000-mt or kt7000 - mt
[86.61] 6
90.50 [86.61] 3.41 68.28 2
90.50 3.56
Features a compression style oil drain fitting that accepts a 10 3.41 [57.15] 2.69
ACE275J-24 mm diameter tubes, for engines with high crankcase pressure 46.75
3.56 46.75
1.84
[57.15] 2.25 35.97
2.25 1.42
1.84 29.67
29.67 1.17
1.17
CAMSHAFT BEARING RETAINER KITS
P3000 Pump KT275 23.53
23.53 0.93
0.93
P7000 Pump KT276 26.72 MIL CONNECTOR SHOWN
[112.63]
26.72 1.05 MIL CONNECTOR SHOWN
1.05 [112.63] 4.43
Bosch RP21 Pump with RB Plate KT278 4.43

Bosch RP21 Pump KT278-1 180.80


180.80 7.12
7.12

2
38.62 31.65
103.71 38.62 1.52
31.65 19.05
1.25
SPECIFICATIONS 103.71
4.08
4.08 1.52
41.52
1.63
1.25
41.52
1.63
R .75

PERFORMANCE 19.05
19.05
.75
.75

Force 13.2 lb. Max (58.7 N)


Operating Stroke 0.79 in. Max (20mm) 29.03
19.05 164.34
19.05 14.78
29.03 1.14 109.98 0.75
14.78 0.58
1.14 0.75 6.47 0.58
ELECTRICAL POWER INPUT 109.98
4.33
4.33 164.34
6.47
46.99
1.85
68.85
Operating Voltage 12 or 24 VDC
VIEW 3 2.71

Normal Operating Current 3.0 Amps @ 12 VDC


1.5 Amps @ 24 DVC NOTE Military connec- [86.61] 68.28
90.50 tor shown. ACE 3.41 2.69
Maximum Current (Continuous) 9.0 Amps @ 12 VDC 3.56
Versions have a 16in [400mm]
46.75
[57.15]
2.25
35.97
1.42
4.5 Amps @ 24 VDC 1.84
harness which29.67exits from bot-
ENVIRONMENT tom. 1.17

Operating Temperature Range -40F to +185F (-40C to +85C) 4 X .25

23.53
Relative Humidity Up to 100% 0.93
26.72 65.00
All Surface Finishes Fungus Proof and Corrosion Resistant 1.05
MIL CONNECTOR SHOWN
[112.63]
4.43
2.56

PHYSICAL
180.80
Dimensions See Outline & Dimensions 7.12
38.62 19.05 65.96
Weight 11 lb (4.9 kg) 103.71 1.52
31.65
1.25 R .75 2.60
4.08 41.52
1.63
Directly on RP, P 3000 and P 7000 Bosch
fuel injection pumps in place of the mechan-
Mounting ical governor. Requires camshaft bearing
19.05 29.13
.75 1.15
retainer kit. See section 4 for more info.

29.03 19.05 55.17


1.14 14.78 2.17
109.98 164.34 0.75 0.58
4.33 46.99
6.47 1.85
68.85
2.71

275 Series Integrated Pump Mounted Electric Actuator 01.27.16 PIB 2030 F
1 2016 Copyright All Rights Reserved
LINK ASSEMBLY
INSTALLING THE ACTUATOR

VIEW 1
1. Remove the four screws that fasten the top cover (with label) to the actua-
tor and expose the linkage used to connect the actuator to the fuel rack.
2. Remove the screw that attaches the ball bearing rod end to the lever. Do
not remove or loosen the lever from the actuator shaft.
3. The opposite end of the linkage must be attached to the top of the fuel
rack with the screw and lock nut provided. Tighten the screw and nut
securely to 4.0 4.5 Nm. The linkage is preset to a specific length and
locked. Any adjustment of rack travel must be made using the slot on the
actuator lever.
4. The gasket supplied in the installation parts kit fits between the actuator
and pump. Clean the mounting surfaces of the actuator and the pump on
one side of the gasket to the actuator. A small amount of gasket sealant,
such as RTV silicone, is recommended for the pump side of the gasket.
5. Loosen the two M8 hex nuts that hold the lower mounting bar to the
actuator.
VIEW 2
6. Place the actuator over the rack and linkage. Fit the lower part of the
actuator onto the bearing retainer plate. Attach the actuator to the pump
with four M5 22mm screws and washers through the upper mounting
holes. Tighten these screws securely to 9 Nm so that the gasket is com-
pressed evenly.
7. Push the lower mounting bar against the bearing retainer plate and tight-
en the two M6 nuts onto the studs that are in the pump to 10 Nm.
8. Tighten the two M8 nuts on the studs that hold the mounting bar onto the
actuator to 20 Nm.
9. The linkage attached to the fuel rack must be free when moved from shut
off to full fuel. Pull the linkage fully away from the pump. Push the linkage
1mm toward the pump and attach it to the slot in the actuator lever with
the M5 screw, two flat washers and locking nut. Tighten securely to 4 Nm.
The fuel rack should be 1mm or less away from its internal physical stop.
The zero fuel stop of the system will now be provided by the actuator
instead of inside the fuel pump.

VIEW 3
10. Manually move the actuator lever and linkage through its full range of
motion. No binding should be noticed. The actuator operating lever &
assembly must not contact the inside of the housing.
11. A maximum fuel stop adjustment is located on the actuator lever. The set
screw and lock nut may be adjusted to limit the travel of the fuel rack.
12. Push the linkage to the full fuel position and operate the manual shut
off to insure that the shut off lever correctly contacts the stop plate and
forces the linkage to zero fuel.
13. After the maximum fuel delivery has been adjusted on an engine or dyna-
mometer, the top cover may be installed. Place the special sealing screw
4 INSTALLATION in the lower left hand corner. Lockwire the two covers together to prevent
tampering.
If the pump is equipped with a mechanical governor, it must be
WARNING
removed. GAC recommends that the modification be done by a
qualified fuel injection shop. The following steps are a generalized procedure.
PREPARING THE FUEL INJECTION PUMP
1. Remove the rear housing of the mechanical governor and disconnect the
governor assembly from the fuel rack.
2. Remove the flyweight assembly.
3. Remove the intermediate governor housing, this leaves only the rack and
camshaft protruding from the housing.
4. Install the appropriate camshaft bearing retainer kit. This kit includes the
correct shims to ensure that the retainer plate rests on the bearing and
also prevents oil from leaking out around the camshaft. See page one for
retainer kits. See PIB2031 for retainer kit installation details.
5. Located on the pump between the fuel rack and the camshaft, the oil hex
plug may be removed to allow any oil, leaking from the fuel rack, to drain
back into the pump.
NOTE Removal of oil from the mechanical governor is required.
275 Series Integrated Pump Mounted Electric Actuator 01.27.16 PIB 2030 F
2 2016 Copyright All Rights Reserved
5 WIRING 6 TROUBLESHOOTING
The EC1000 or EC1010 electrical connector that mates with the actuator must The engine should be equipped with an independent shut
CAUTION
be pre-wired in a configuration to match the system voltage. Cable Harness- down device to prevent overspeed which can cause equip-
es CH1203, CH1215, & CH1515 are available from GAC. Refer to MATING ment damage or personal injury.
HARDWARE in the Specifications Section.
If the governor system fails to operate, make the following tests at the actuator
CABLE HARNESS mounted connector while moving the actuator through its stroke.

#16 Gauge (1.5 mm) 12 Volt System TROUBLESHOOTING TEST


#18 Gauge (1.0 mm) 24 Volt System Energize the actuator to full fuel (follow steps in control unit publication and
manually move the actuator through its range using the stop lever. No binding
Fabricate a cable harness to connect the speed control unit to the actuator. or sticking should occur. If the actuator passes three tests, the problem is else-
The recommended wire size of the cable harness is: where in the system. Refer to the troubleshooting section the speed control
units literature.
Larger gauge wire will be necessary for cable lengths greater than
NOTE
12ft. (4m). MILITARY CONNECTOR
12 Volt 24 Volt
to Actuator Terminal A to Actuator Terminal A MEASURING THE RESISTANCE
on Speed Control Unit on Speed Control Unit
TERMINALS RESISTANCE
A ADD RESISTOR FOR
F
A
B F B A to B 2.5 Ohms
Jumper B to C For Multi
32 V
OPERATION
Voltage ONLY
Only
ACB275C
E & ACB275H
C WIRING E C C to D 2.5 Ohms
D D ACE275K WIRING

* SEE NOTE BELOW A to C


FEEDBACK SENSOR Infinity
(Female Receptacle)
to Actuator Terminal B to Actuator Terminal B A to Housing Infinity
Aon Speed Control Unit A on Speed Control Unit
F F
B
To B C to Housing Infinity
Control Unit To
E E Control Unit E to F Infinity
D C C
D
MILITARY CONNECTOR
12 VOLT OPERATION
A TO C For 32 V operation, wire the connector24as shown for 24 V operation PACKARD
Harness CONNECTOR
B TONOTE
D VOLT OPERATION
and
A AND D TO ACTUATOR add aOF1.5 ohm, 25 V resistor in series
TERMINALS B TO C with pin A of the actua-
SPEED CONTROL UNIT A AND D TO ACTUATOR TERMINALS
tor connector and the corresponding output terminal of the speed control unit. MEASURING THE RESISTANCE
TERMINALS RESISTANCE
ADB275F / ACB275F WIRING TO SPEED CONTROL UNIT
A to B (12V) 2.5 Ohms
ACTUATOR TERMINALS
A to B (24V) 2.5 Ohms

F A A to Housing Infinity
B SENSOR GROUND
E
B to Housing Infinity
C SENSOR SIGNAL TO SPEED CONTROL UNIT
POSITION SENSOR TERMINALS
D SENSOR POWER
(14 VOC MAX)
SHIELD GROUND

FEED BACK SENSOR

ACE275K WIRING HARNESS


FEEDBACK SENSOR
(Female Receptacle)
PIN SIGNAL
1 +5V
2 GND
t
4 OUT

The ACB275F & Harness


ACE275K version of the actuator includes a rack position sen-
sor. A GAC speed control unit that includes fuel management electronics is
required to interface with this sensor. See the appropriate speed control unit
literature for wiring information.

275 Series Integrated Pump Mounted Electric Actuator 01.27.16 PIB 2030 F
3 2016 Copyright All Rights Reserved