808220 Mercruiser BUSHING

DI ENGINE Any adjustment to the governor must be made only by a person approved by Caterpillar or by a Caterpillar Dealer.(1) Torque for nut ... 9 3 lb. ft.(12 4 N m)(2) 6N8793 Spring:Length under test force ... .750 in.(19.05 mm)Test force ... .45 .03 lb.(2.00 0.13 N)Free length after test ... 1.65 in.(41.9 mm)Outside diameter ... .370 in.(9.40 mm)
INSTALL SPRING WASHERS AS SHOWN(3) Seat. Install a spring washer, flat washer and spring washer between seat (3) and spring (4) as shown.(4) 9L6448 Spring for the governor:Color code ... one green stripe, one yellow stripePut force on spring of ... 4.00 lb.(22.24 N)Then add more force to make spring shorter by: ... .900 in.(22.86 mm)Total test force ... 16.60 .30 lb.(73.00 1.50 N)Free length after test ... 2.24 .03 in.(56.9 0.8 mm)Outside diameter ... 1.39 in.(35.3 mm)(5) 9M6303 Spring:Length under test force ... .180 in.(4.57 mm)Test force ... 10.0 1 lb.(44.5 4.4 N)Free length after test ... .344 in.(8.74 mm)Outside diameter ... .480 in.(12.19 mm)(5) 8N6579 Spring for low idle performance: Length under test force ... .250 in.(6.35 mm)Test force ... .60 .03 lb(2.62 0.13 N)Free length after test ... .545 in.(13.84 mm)Outside diameter ... .437 in.(11.11 mm)(6) Diameter of the outer surface of the cylinder (new) ... 1.5000 .0005 in.(38.100 0.013 mm)Bore in the gear (new) ... 1.5020 .0005 in.(38.151 0.013 mm)(7) Put marks in alignment on pinion-stop-and gear before installing dowel (PC Engine).(7) Install two dowels in governor drive gear to a dimension of (DI Engine) ... .31 .02 in.(7.9 0.5 mm)(8) Bore in the bearing (new) ... .8765 .0015 in.(22.263 0.038 mm)Diameter of the gear, at the hub (new) ... .8735 .0005 in.(22.187 0.013 mm) (9) Distance from the face of the plate to the bearing for the governor drive assembly ... .020 .010 in.(0.51 0.25 mm)(10) Dowel installation: Angel A must be ... 54 10°Dimension B must be ... .31 .02 in.(7.9 0.5 mm)(11) Install dowels to get a dimension of ... .22 .02 in.(5.6 0.5 mm)
CONTROL SHAFT BEARINGS(12) Bore in the governor control shaft bearings (new) ... .6205 .0015 in.(15.761 0.038 mm)Diameter of the governor control shaft (new) ... .6189 .0003 in.(15.720 0.008 mm)(13) Distance between the bearings for the governor control shaft ... 2.385 .005 in.(60.58 0.13 mm)(14) Distance from the face of the housing to the end of the bearing for the governor control shaft ... 1.708 .006 in.(43.38 0.15 mm)
SHUTOFF SHAFT BEARINGS(15) Bore in the shutoff shaft bearing (new) ... .5005 .0005 in.(12.713 0.013 mm)Diameter of the shutoff shaft (new) ... .4975 .0005 in.(12.637 0.013 mm)(16) Torque for insulator ... 40 5 lb. in.(4.5 0.6 N m)(17) Needle bearing.(18) Distance from center of bolt hole to outside end of needle bearing (17) ... 3.656 .010 in.(92.86 0.25 mm)(19) Distance from end of needle bearing (17) to inside of sleeve bearing ... 3.885 .010 in.(98.68 0.25 mm)Install seals as shown.