11142912 Mercury OWNERS MANUAL (GRAY 135/150/175/200)

Table 1
Tools Needed Quantity
4C-6594 Timing and Fuel Setting Tool 1
6V-3075 Dial Indicator 1
5P-4814 Collet Clamp 1
5P-7263 Indicator Contact Point 1
8T-1000 Electronic Position Indicator 1 The governor actuator linkage must be adjusted in order to synchronize the actuator travel with the travel of the engine's fuel control linkage.Note: Before the adjustment of the actuator linkage is made, the fuel injectors must be correctly synchronized. See the subject Fuel Injector Synchronization.
Illustration 1 g00559366
Governor Actuator Linkage
(1) Governor Actuator. (2) Synchronizing pin. (3) Angle of installation. (4) Governor terminal shaft. (5) Governor control housing. (6) Shaft. (7) Rod assembly. (8) Lever. (Y) Location for dial indicator. (Z) Location for synchronizing pin.
Remove the two plugs from location (Y) and from location (Z) on governor control housing (5).
Remove synchronizing pin (2) from the storage location in the governor control housing. Install the synchronizing pin in the governor control housing at location (Z) without the spacer. Tighten the synchronizing pin to the following torque. ... 10 2 N m (7 1 lb ft)
Rotate shaft (6) in the "Fuel On" direction until the flat surface of the fuel stop lever contacts synchronizing pin (2). Hold the shaft in position. Dead weights are recommended.
Either a 4C-6594 Timing and Fuel Setting Tool or an 8T-1000 Electronic Position Indicator is acceptable to use. One of these tools will be installed in the threaded hole at location (Y) of the fuel control housing.
For the 4C-6594 Timing and Fuel Setting Tool, install the 5P-4814 Collet Clamp in the threaded hole at location (Y). Slide the 6V-3075 Dial Indicator with the 5P-7263 Indicator Contact Point into the 5P-4814 Collet Clamp. When the contact point seats against the fuel stop lever, slide the indicator inward or slide the indicator outward until the indicator dial reads +5.00 mm (+0.197 inch). Tighten the collet in order to hold the indicator in position. The indicator is now ready to be used.
For the 8T-1000 Electronic Position Indicator, install the 5P-4814 Collet Clamp in the threaded hole at location (Y). Slide the 8T-1002 Probe with the 5P-7263 Indicator Contact Point into the 5P-4814 Collet Clamp until the 8T-1002 Probe sleeve bottoms in the 5P-4814 Collet Clamp. Tighten the collet enough to hold the probe in position. Attach the probe to the 8T-1001 Electronic Indicator. Turn the indicator "ON" and set the indicator to measure millimeters. With the indicator "ON", touch the negative "-" button. Then touch the zero button. The indicator is now ready to be used.
Remove synchronizing pin (2) from the governor control housing and install the pin into the storage location. Install the plug in the threaded hole at location (Z).
Remove rod assembly (7).
Rotate governor terminal shaft (4) to the minimum fuel position. Then hold the governor terminal shaft in place.
Install lever (8) on shaft (4) so the centerline of the lever is 40.7 degrees from the vertical centerline. This is shown by angle (3).
Adjust rod assembly (5) between the control housing lever and the actuator lever (4). Use the appropriate procedure that follows.
If the 8T-1000 Electronic Position Indicator is being used, adjust the rod assembly until the 8T-1001 Electronic Indicator displays a reading of −9.50 mm (−0.374 inch). Secure the rod assembly in place with the locknuts. Ensure that each rod end on the rod assembly has the same amount of thread engagement.
If the 4C-6594 Timing and Fuel Setting Tool is being used, adjust the rod assembly until the 6V-3075 Dial Indicator displays a reading of −4.50 mm (−0.177 inch). Secure the rod assembly in place with the locknuts. Ensure that each rod end on the rod assembly has the same amount of thread engagement.
Personal injury or death can result from flying objects generated by engine overspeed. The engine could overspeed as a result of improper linkage assembly, adjustment, or governor deadband. Be prepared to stop the engine by activating the engine air shut-off or closing the air off to the air inlets.
The definition of governor deadband is the total amount of travel between the point of actual fuel shutoff and the actual "FUEL OFF" position. When the 8T-1001 Electronic Indicator is used and when the reading of the maximum actuator "FUEL OFF" is more positive than −9.50 mm (−0.374 inch), the governor deadband can be eliminated. −8.75 mm (−0.344 inch) is an example of a reading that is more positive than −9.50 mm (−0.374 inch). When the 6V-3075 Dial Indicator is used and when the reading of the maximum actuator "FUEL OFF" is more positive than −4.50 mm (−0.177 inch), the governor deadband can be eliminated. −3.75 mm (−0.148 inch) is an example of a reading that is more positive than −4.50 mm (−0.177 inch). This can cause an engine overspeed.
Remove the plug from location (Z). Remove synchronizing (2) from the storage location in the governor control housing, and install the pin at location (Z) without the spacer. When the 8T-1001 Electronic Indicator is used, ensure that the indicator still reads a value of 0.00 mm (0.000 inch). When the 6V-3075 Dial Indicator is used, ensure that the indicator still reads +5.00 mm (+0.197 inch). If the indicated reading is not correct, repeat Step 3 through Step 9. If the indicated reading is correct, continue with the procedure. If the 6V-3075 Dial Indicator is used, adjust the dial indicator in order to read 0.00 mm (0.000 inch). This must be done before continuing the procedure.
Check the fuel setting. See the subject Fuel Setting Check.
Remove the dead weight from the actuator terminal shaft.
Remove synchronizing pin (2) from location (Z) and install the plug. Install the synchronizing pin and install the spacer in the storage location.
Remove all tooling from location (Y) in the governor control housing. Install the plug at location (Y).
Before starting the engine, put a mark on the governor actuator's position indicator at the point of minimum governor travel. This is the engine's stopped position.
The engine may overspeed