Kohler 275547 User manual

R
INSTRUCTIONS
T T --- 7 2 7
7/90
Throttle Repair Kits --- 275547, 275548, 275549, 275550
for 20---180 ROZJ Generator Sets
Standby Generator Sets
The throttle repair kits replace the governor
throttle spring with a linkage or bracket which
holds the governor throttle lever in the
full---open position. (See Service Bulletin 496.)
Observe the following safety precautions during
kit installation. Reference the appropriate
installation drawing to identify and assemble
components.
WARNING
Accidental starting can cause death or serious
personal injury. Turn Generator Master Switch
to OFF position, disconnect power to battery
charger, and remove battery cables (remove
negative lead first and reconnect it last) to
disable generator set before working on any
equipment connected to generator. The
generator set can be started by automatic
transfer switch or remote start/stop switch
unless these precautions are followed.
WARNING
Exposed moving parts can cause severe injury.
Keep hands, feet, hair, and clothing away from
belts and pulleys when unit is running. Replace
guards, covers, and screens before operating
generator set.
CAUTION
Hot parts can cause personal injury.
Do not touch hot engine parts. An engine gets
hot while running and exhaust system
components get extremely hot.
NOTE
Do not adjust governor fast idle adjusting screw
during kit installation. Changingposition offast
idle screw will affect engine speed and require
that the governor be adjusted.
INSTALLATION
1. Disconnect engine battery cables (negative
lead first) to disable generator set.
2. Disconnect spring from governor throttle
lever and spring bracket. Discard spring.
3.1 20---100ROZJ Models
a. Remove hardware securingspring bracket to
engine block. Remove and discard spring
bracket. Reference the appropriate
installation drawing in Figure 1 or Figure 2
to determine what hardware should be
retained for installation of new bracket.
b. Attach mounting bracket to engine block
with screws, washers and spacers (if used ---
see parts list). Torque to 28 ft. lbs. (40 Nm).
R

2
c. Assemble rod and ball joint linkage as shown
in installation drawing. Attach linkage to
governor throttle lever with hardware
indicated in Figure 1 or Figure 2. Do not
connect linkage to mounting bracket until
next step.
d. To correctly set throttle rod length, rotate
throttle lever clockwise until lever stops
against the fast idle adjusting screw. Rotate
throttle lever an additional 10 degrees
clockwise then attach ball joint on free end
of rod to mounting bracket. When properly
adjusted, the spring on the throttle lever will
be slightly extended. See Figure 3.
3.2 125---180ROZJ Models
a. Remove hardware securing throttle lever to
governor shaft. Remove and discard throttle
lever and mounting screws.
b. Attach throttle bracket (275546) to governor
shaft with screws and washers as shown in
Figures 4 and 5. Torque to 28 ft. lbs. (40 Nm).
When installed, the throttle bracket should
contact the governor stop screw to hold the
throttle in the full---open position against the
idle speed adjusting screw. DO NOT
CHANGE POSITION OF IDLE SPEED
ADJUSTING SCREW.
4. Reconnect generator starting battery,
negative lead last.
5. Start generator set. Using a tachometer or
frequency meter on controller (if equipped),
check engine full load speed. Engine speed
should be 1800 rpm at 60 Hz and 1500 at 50
Hz operation. If engine speed is incorrect,
refer to the generator service manual for
governor adjustment procedure.
Kit No. 275548 50---60ROZJ
Kit No. 275547 20---40ROZJ
Figure 1. Throttle Repair Kits for 20---60ROZJ

3
Figure 2. Throttle Repair Kit 275549 for 80---100ROZJ
Description Qty. Kit 275547 Kit 275548 Kit 275549 Kit 275550
(20---40ROZJ) (50---60ROZJ) (80---100ROZJ) (125---180ROZJ)
N u t , l o c k 1 / 4 2 X --- 1 0 1 --- 7 X --- 1 0 1 --- 7 X --- 1 0 1 --- 7
Spacer 13/32 x 3/4 x 1---1/2 2 X---400--- 5 X---400--- 181
S c r e w , H . C . 3 / 8 --- 1 6 x 2 --- 3 / 4 2 X --- 6 2 3 8 --- 9 X --- 6 2 3 8 --- 8
N u t , h e x 1 / 4 --- 2 8 2 X --- 8 1 --- 2 X --- 8 1 --- 2 X --- 8 1 --- 2
Stud 1 253424 253424 253424
Ball joint 2 271097 271097 271097
Mounting bracket 1 275543 275526 276521 275546
Washer, lock 1/4 2 X --- 2 0 --- 1
Screw,H.C.M6x1x16 2 X---6049---2
PARTS LISTING
Figure 3. Throttle Repair Kit Installed --- Typical (20---100ROZJ)
276521
X --- 6 2 3 8 --- 8 ( 2 )
X --- 4 0 0 --- 1 8 1 ( 2 )

4
Figure 4. Throttle Repair Kit 275550 for 125---180ROZJ
Figure 5. Throttle Repair Kit Installed (125---180ROZJ)