854357 Volvo.Penta Relay

Illustration 1 g00668020
Make sure that the left hand threads in the end of the throttle shaft are clean. Thread Tool (A) into the throttle shaft. Tighten Tool (A) until the shoulder on Tool (A) bottoms out against the end of the throttle shaft.
Install throttle lever (1) on Tool (A) .Note: Throttle lever (1) and the tolerance ring should not be reused after being removed from the governor. A new 4P-3539 Throttle Lever and a new 4P-3537 Tolerance Ring are required. Apply a light machine oil to the bore of the throttle lever and the outside of the tolerance ring after the tolerance ring is seated on the throttle shaft. This will reduce the force that is required to press the throttle lever into position.
Install Tool (E) on Tool (A) and put Tool (F) in position.
Install thrust bearing (D), washer (C) and nut (B) on Tool (A) .Note: High idle screw (2) must be backed out all the way.Note: The governor fuel ratio control must be connected to a regulated air supply of 140 to 210 kPa (20 to 30 psi) during the adjusting procedure.
Increase the speed of the calibration bench to the "THROT LEV PRESS" rpm that is specified in the TMI.
Illustration 2 g00668244
Loosen screw (3) in the adjustable arm assembly. Use a 1U-7579 Hex Wrench to rotate the throttle shaft counterclockwise. Stop rotating the throttle shaft when the governor output is within the range for "THROT LEV PRESS" that is specified in the TMI.Note: Use a hex wrench to rotate the throttle shaft. Do not exceed a governor output of 0.0 mm (0.0 inch) when the throttle shaft is rotated. Before the throttle lever is pressed onto the throttle shaft, rotating the throttle shaft too far in the FUEL ON direction may cause the internal governor linkage to come loose from the pivot shaft linkage. If the internal governor linkage becomes disconnected, the governor will not pass the remainder of the adjusting procedure. The governor must be disassembled and the linkage must be reconnected. Refer to the Disassembly and Assembly section in this manual. Repeat this procedure beginning with Step 1, after the governor has been reassembled.
Illustration 3 g00668482
Use a hex wrench to tighten setscrew (3) on arm (E) while the throttle shaft is held in position. Tightening setscrew (3) will lock the throttle shaft in position.
Illustration 4 g00668541
Rotate the throttle shaft with two thumb screws (4). The two thumb screws will adjust the governor output to the final position. Keep both thumb screws tight against arm (E). When the setscrew is released the throttle shaft will be locked in position.
Decrease the speed of the calibration bench until the governor output becomes positive. When the governor output becomes positive, adjust the speed of the calibration bench to the "THROT LEV PRESS" rpm that is specified in the TMI. If the governor output is not within the range that is specified in the TMI, repeat Steps 6 through 9, if necessary.
Illustration 5 g00668613
Maintain the "THROT LEV PRESS" rpm on the calibration bench. Verify that high idle screw (2) is backed out and that throttle lever (1) is rotated fully in the counterclockwise direction so that the throttle lever touches the rear housing face. Hold the throttle lever in this position.Note: The throttle lever should sit squarely on the shaft and against the housing face. Make sure that the throttle lever is not in a bind.
Illustration 6 g00668569
Tighten nut (B) until block (F) bottoms out against throttle shaft (1) .
Loosen the setscrew on Tool (E) .
Rotate the throttle lever fully counterclockwise so the high idle bump on the throttle lever touches the rear housing face. Decrease the speed of the test bench until the governor output is positive. Return the speed of the test bench to the "THROT LEV PRESS" rpm that is specified in the TMI. Note the governor output.
If the governor output is within the range for the "THROT LEV PRESS" that is specified in the TMI, the throttle lever is correctly positioned. Proceed with the standard governor adjustment procedure. Refer to the Testing and Adjusting, "Governor (Type) - Adjust" section in this manual.
If the governor output is not within the range for the "THROT LEV PRESS" that is specified in the TMI, the throttle lever must be removed and a new lever must be installed with the correct orientation. Repeat this entire procedure after the throttle lever is installed.