Edition : 1

OPERATION & MAINTENANCE

MANUAL

Komatsu Diesel Generator : EGS-6 Series

EGS90 (B, BS) - 6 EGS570 (B, BS) - 6

EGS120 (B, BS) - 6 EGS630 (B, BS) - 6
EGS160 (B, BS) - 6 EGS650 (B, BS) - 6
EGS240 (B, BS) - 6 EGS760 (B, BS) - 6
EGS300 (B, BS) - 6 EGS850 (B, BS) - 6
EGS360 (B, BS) - 6 EGS1000 (B, BS) - 6
EGS380 (B, BS) - 6 EGS1050 (B, BS) - 6
EGS500 (B, BS) - 6 EGS1200 (B, BS) - 6

Blank : Open Type

B : Bonnet (Weatherproof) Type
BS : Bonnet & Soundproof Type

Serial No : 60001 and up

 QUICK REFERENCE
Component model and its serial number.

COMPONENT MODEL SERIES NO

Generator Set
Engine
Alternator

FOREWORD
This manual describes procedures for lubrication, maintenance, checking and
adjustment of power generator system. It will help the operator or anyone realizes
peak performance through effective, economical and safe machine maintenance.

Please read this manual carefully before carrying out any maintenance on the machi
Please continue studying this manual until proper maintaining procedure is complete
reinforced into personal habit.

This manual describes the basic techniques. Servicing must be carried out strictly in
accordance with instructions so as to avoid the risk of accidents and to maintain the
power generator system to its original state.

All maintenance procedures written in this manual should be undertaken by personne

trained in the commissioning, servicing and maintenance of electrical and mechanica
components. In accordance with all relevant safety regulations to IEC and those of
other technical authorities, and with other overriding instructions.

Inspection and maintenance should be carefully carried out and safety must be given
the first priority. Safety precautions are highlighted with " " symbol and technical
precautions with " " symbol in this manual. This safety information is intended
only to supplement safety codes, insurance requirements, local laws and regulation

Some pictures illustrated in this manual may be different from the actual power
generator system as technical improvement is continuously reflected on it.

This operation and maintenance manual may contain attachment and optiona
equipment that are not available in your area. Please consult your local Komatsu
distributor for those items you may required.

Materials and specifications in this manual are subjected to change without notice.

-- 1 --
 BREAK IN THE NEW MACHINE
Each machine is carefully adjusted and tested before shipment. However, a new machine requires
careful operation during first 100 hours to break in the various parts.
If a machine is subjected to unreasonably hard use at the initial operation stage, the potential of
performance will prematurely deteriorated and the service life will be reduced.
A new machine must be operated with care, particularly with regard to the following items.

After start up, let the engine runs without Be sure to perform periodical maintenance
load for 5 minutes to allow proper engine and check all relevant items as indicated in
warm-up prior to actual operation. this manual.
If the machine is delivered without any When replacing oil filter elements (cartridge),
cooling water in the radiator, flush the check their interiors for dirt and dust. If
cooling system with sufficient clean heavily contaminated, check for possible
water to clean the system, then fill the causes before starting operation.
radiator with clean cooling water. Hour of operation are indicated by the Hour
Run meter.

CONTENTS
FOR OPERATION
SAFETY HINTS 3
TYPES OF GENERATOR SET 4
CONFIGURATION OF CONTROL PANEL 5
AC/DC GENERATOR CONTROL PANEL 6
DSE 5220 GEN CONTROL MODULE
GRAPHICAL LCD DISPLAY LIST
DC ENGINE CONTROL PANEL 10
DSE 521 ENGINE CONTROL MODULE
OPTIONAL COMPONENTS 13
OUTPUT TERMINALS 14
LOAD CONNECTION 15
CHECK BEFORE STARTING 16
SINGLE OPERATION 18
MANUAL PARALLELING OPERATION (OPTIONAL) 20
OPERATING PRECAUTIONS 21
TRANSPORTATION

FOR MAINTENANCE
PERIODIC MAINTENANCE 22
MAINTENANCE PRECAUTIONS
GENERAL PRECAUTIONS
MAINTENANCE TABLE FOR GENERATOR SET 25
MAINTENANCE FOR SYNCHRONIZING PANEL (OPTIONAL) 41

APPENDIX
FUEL, COOLANT AND LUBRICANTS 43
BRAND OF LUBRICANTS, GREASE AND COOLANT 44

-- 2 --
 SAFETY HINTS

Before Operation
1. Wear a hamlet and safety shoes ! 6. Beware of harmful exhaust gas !
You may need a safety goggles, mask To operate engine indoor, a proper ventilation
and ear plugs too. is required.

2. Wear close-fitting working clothes ! 7. Learn about the machine !

Loose clothing can get caught in the Read the Operation and Maintenance Manual
machinery. Do not wear oil stained and be familiar with the function and
clothing, it can catch fire easily. operation of the Generator Set.

3. Do not operate the Generator Set 8. Connected the load before starting !
when fatigued or after drinking ! Before starting the generator set, make sure
Poor physical condition cause bad all the load are connected.
judgement when emergency arose.
9. Be aware of the surroundings !
4. Observe workshop rules ! When starting the generator set, signal to
Always follow the safety rules, warnings other personnel to ensure safety.
and operating instructions.
10. Fix the generator on a level ground !
5. Be prepared for emergency ! Set the machine on a firm and level ground.
Know in advance whom to inform and what
to do in case of fire and other accidents. 11. Beware of flammable materials !
Know how to use and the location of fire A burning cigarette or match is prohibited.
extinguishers and first-aid kits.

During Operation
1. Beware of electric shock ! 4. Immediately check the generator
Do not touch either the terminals or wire set if any abnormality is noticed !
connections during operation. If any abnormality such as noise; vibration;
overheat; bad smell or abnormal gauge
2. Follow the pre-arranged signal ! reading is noticed, immediately switch off
When operating with partner, pre-determine the breaker and stop the generator set.
some common sign signals and operate
as according to them. 5. Keep the alternator free from water !
If water, steam or oil sticks to the alternator,
3. Keep unauthorized personnel out ! it may cause an electrical leakage or poor
Do not allow any unauthorized personnel to power generation. If the alternator is wet, ask
come near or operating the generator set. a specialist to measure insulation resistance
before operation.

After Operation
1. Stop the engine properly !
Switch off the breaker before stopping the
generator set.
Locked and removed the key to prevent
tampering.

-- 3 --
 TYPES OF GENERATOR SET
1. Open Type

NO MAIN COMPONENTS
1 Engine
Side View 2 Alternator
2. Basic Type 3 Radiator
4 Control Panel
5 Silencer
6 Air Cleaner
7 Skid Base
8 Rubber Isolator
9 MCCB Box (behind)
10 Bellow
11* Exhaust Piping
12 Canopy (Weatherproof)
Side View 13 Canopy (Soundproof)
14 Terminal Box
3. Bonnet Type
< NOTE >
No. 11* specification depends on
site installation unless mounted type
of silencer is required.

Side View

4. Bonnet & Soundproof Type

Side View Rear View

-- 4 --
 CONFIGURATION OF CONTROL PANEL
1. AC/DC Generator Control Panel (Open Type)

NO MAIN COMPONENTS
1 DSE 5220 Gen Control Module
2 Emergency Stop Button
3 Panel Lock Key Switch
4 Buzzer Cancel Button
5 Buzzer

Front View Side View

2. DC Engine Control Panel (Basic Type)

NO MAIN COMPONENTS
1 DSE 521 Eng Control Module
2 Water Temperature Gauge
3 Oil Pressure Gauge
4 Charging Ammeter
5 Hour Run Meter
6 Tachometer
7 Manual Start Button
8 Manual Stop Button
9 Emergency Stop Button

Front View

-- 5 --
 AC/DC GENERATOR CONTROL PANEL

NO MAIN COMPONENTS
1 DSE 5220 Gen Control Module
2 Emergency Stop Button
3 Panel Lock Key Switch
4 Buzzer Cancel Button
5 Buzzer

Front View Side View

The control module provides indication of operational status and fault conditions, automatically shutdown
the gen-set and indicating failures by means of an LCD display, and appropriate flashing LED on
the front panel. This module can be used to monitor a mains power supply and automatically
start a standby gen-set if mains failure occurred.

DC Measurements :
Digital display of Engine RPM, Engine Oil Pressure, Engine Water Temp, Battery Voltage and
Engine Hours Run measurements.
Optional digital display of Fuel Level measurement if supplied with Skid Base Fuel Tank.

AC Measurements :
Digital display of Gen Voltage (L1-N, L2-N, L3-N), Gen Voltage (L1-L2, L2-L3, L3-L1),
Gen Current (L1, L2, L3), Gen Frequency Hz, Gen kVA, Gen kW and Gen PF measurements.
Optional digital display of Mains Voltage (L1-N, L2-N, L3-N), Mains Voltage (L1-L2, L2-L3, L3-L1),
and Mains Frequency Hz measurements if connected to Mains power.

Built-In Functions :
1. Panel Lock Key Switch
To lock the operation of all push buttons except Emergency Stop button so that unauthorized
personnel not able to make adjustment. It is useful for AMF operation when gen-set is on standby.
2. Visual and Audible Alarm
A clear icon based language free display provides access to full gen-set instrumentation, which
combined with a buzzer for any alarm.
3. Event Logging of Shutdown Alarms
Capable of storing 15 shutdown events along with date and time for reference.

Safety Protections :
1. Low Oil Pressure Shutdown 6. Under / Over Voltage
2. High Water Temp Shutdown 7. Under / Over Frequency
3. Fail to Start 8. Over Current
4. Fail to Charge 9. Under / Over Battery Voltage
5. Under / Over Speed

Optional Items :
1. RS485 'Modbus' output allows full system integration into building management and control schemes.
2. RS232 Modem link to PC via either PSTN line or GSM network. The module can also signal
Engineers via their cell phones using the GSM SMS messaging system to advise of system alarm.

-- 6 --
 DSE 5220 GEN CONTROL MODULE

Green LED indicates signal to close Mains CB Green LED indicates signal to close Gen CB
1
when Mains is stable. when Gen reached rated Hz & Volt in mains failure.
Area for displaying engine 7
related fault icons, LOP;
Area for displaying Gen AC
HWT and others.
8
related fault icons, Under /Over
Hz; Under /Over Volt and others.
Area for displaying mains
Green LED indicates Gen is
related fault icons, Under
running.
/Over Hz & Under /Over
Volt. Green LED indicates
mains is stable. 2 3 4 5 6

NO ITEM DESCRIPTION
1 LCD DISPLAY This window displays the following instrumentation.
WINDOW Generator Volts L1-N, L2-N, L3-N Engine Speed RPM
Generator Volts L1-L2, L2-L3, L3-L1 Engine Oil Pressure (Bar, PSI and KPa)
Generator Amperes L1, L2, L3 Engine Water Temperature (°C and °F)
Generator Frequency Hz Battery Voltage
Generator kVA Hours Run
Generator kW Mains Volts L1-N, L2-N, L3-N
Generator Power Factor Mains Volts L1-L2, L2-L3, L3-L1
Mains Frequency Hz

Hid-'til-lit' icons are used to show the presence of alarm conditions detected by the module.
Refer to the attached GRAPHICAL LCD DISPLAY for details.

2 STOP / RESET This set the module into it's Stop / Reset mode. This will clear any alarm condition for
BUTTON which triggering criteria has been removed. In Manual operating mode, this will stop the
generator set.

3 MANUAL MODE This set the module into it's Manual mode. The engine can be started and stopped by an
BUTTON manual Start and Stop buttons.

4 TEST This set the module into it's Test mode. This mode is used to test the function and timing
BUTTON of the generator start and load sequence after the Start button has been pushed. This operation
is applicable to a built-in ATS panel only.

5 AUTO MODE This set the module into it's Automatic / Standby mode. For a built-in ATS system, this
BUTTON allows the generator to be automatically started up and carried load when mains failure occurred.
The generator starts up procedure is as follow.

(A) If the engine does not start up at 1st cranking, this process will repeat for 2 times.
(B) If the engine still can not start up after the third attempts, the "Fail to Start" icon on
the module will light up.
(C) If the mains returned, the load will be transferred back to the Mains and the engine will
automatically stop after the cooldown running. Then, standby for another mains failure.

6 START This push-button is used to manually start the engine. The module must first be placed in the
BUTTON Manual mode of operation.

7 SCROLL This scroll button enables you to select the type of display. This display can be either Engine
BUTTON or Generator measurement.

8 EVENT LOG This button enables you to read the shutdown events along with date and time.
BUTTON

-- 7 --
 GRAPHICAL LCD DISPLAY LIST
NO ITEM DESCRIPTION DISPLAY ICONS
1 Fail To Start The engine failed to start up after 3 attempts.
Total time taken 37 seconds. The buzzer will be
activated.

2 Low Oil The oil pressure dropped below the preset value
Pressure (0.5 or 1.0 bar) during gen-set operation. The engine
will be shut down immediately and the MCCB tripped
open. The buzzer will be activated.

3 High Water The water temperature exceeded the preset

Temperature value (101 °C) during gen-set operation. The engine
will be shut down immediately and the MCCB tripped
open. The buzzer will be activated.

4 Low Speed The rotating speed dropped below the preset

value (- 15%) during gen-set operation. The engine
will be shut down immediately and the MCCB tripped
open. The buzzer will be activated.

5 Over Speed The rotating speed exceeded the preset

value (+ 15%) during gen-set operation. The engine
will be shut down immediately and the MCCB tripped
open. The buzzer will be activated.

6 Emergency The engine will be shut down immediately when the

Stop emergency stop button is pushed. The MCCB
tripped open and the buzzer will be activated.

7 Fail To Charge There is no output from the charging alternator

during gen-set operation. The engine will not be
shut down for this warning alarm. The buzzer will
be activated.

8 Gen High The AC voltage exceeded the preset value (+ 10%)

Voltage during gen-set operation. The engine will be shut
down immediately and the MCCB tripped open.
The buzzer will be activated.

9 Gen Low The AC voltage dropped below the preset value

Voltage (- 10%) during gen-set operation. The engine will be
shut down immediately and the MCCB tripped open.
The buzzer will be activated.

10 Gen High The frequency exceeded the preset value (+ 15%)

Frequency during gen-set operation. The engine will be shut
down immediately and the MCCB tripped open.
The buzzer will be activated.

* The above given preset values are all factory default.

-- 8 --
 NO ITEMS DESCRIPTION DISPLAY ICONS
11 Gen Low The frequency dropped below the preset value
Frequency (- 15%) during gen-set operation. The engine will be
shut down immediately and the MCCB tripped open.
The buzzer will be activated.

12 Gen Over The loading current exceeded the preset value

Load /Current (100% of prime current) during gen-set operation. The
engine will be shut down as according to the IDMTL
graph then the MCCB tripped open. The buzzer will be
activated.

13 Mains High If the Mains voltage exceeded the preset value

Voltage (+ 10%) over a preset time during standby operation.
The engine will start up immediately then take over
the load. The buzzer will not activate.

14 Mains Low If the Mains voltage dropped below the preset value
Voltage (- 10%) over a preset time during standby operation.
The engine will start up immediately then take over
the load. The buzzer will not activate.

15 Mains High If the Mains frequency exceeded the preset value

Frequency (+ 15%) over a preset time during standby operation.
The engine will start up immediately then take over
the load. The buzzer will not activate.

16 Mains Low If the Mains frequency dropped below the preset value
Frequency (- 15%) over a preset time during standby operation.
The engine will start up immediately then take over
the load. The buzzer will not activate.

17 Battery High The battery voltage exceeded the preset value (30V)
Voltage during gen-set operation. The engine will not be
shut down for this warning alarm. The buzzer will
be activated.

18 Battery Low The battery voltage dropped below the preset value
Voltage (20V) during gen-set operation. The engine will not be
shut down for this warning alarm. The buzzer will
be activated.

19 Shutdown Besides all the above mentioned fault alarms, this

Alarm icon is used for other shutdown fault. Example: loss
of speed sensing and others.

20 Low Fuel The diesel fuel level dropped below the preset value
Level (20%) during gen-set operation. The engine will not be
(Optional Item) shut down for this warning alarm. The buzzer will
be activated.

* The above given preset values are all factory default.

-- 9 --
 DC ENGINE CONTROL PANEL
NO MAIN COMPONENTS
1 DSE 521 Eng Control Module
2 Water Temperature Gauge
3 Oil Pressure Gauge
4 Charging Ammeter
5 Hour Run Meter
6 Tachometer
7 Manual Start Button
8 Manual Stop Button
Front View 9 Emergency Stop Button

The control module minimizes the required control components and wiring inside the panel, so as to
simplify its maintenance. The iconic symbols and LED can identify the engine status more directly
and can be easily recognized.
The analogue gauges provide measurement of Water Temperature, Oil Pressure, Charging Ampere
and Engine Operating Hours.

DSE 521 ENGINE CONTROL MODULE

LED 11 : Emergency Stop LED 7 : Low Oil Pressure
Emergency Stop
LED 10 : Under Speed LED 6 : High Water Temperature
Under speed

LED 9 : Loss of Sensing Loss of Sensing

LED 5 : Fail to Start
LED 8 : Spare LED 4 : Over Speed
LED 3 : Common Alarm
Key Switch LED 2 : Fail to Charge
LED 1 : Remote Start Present
LED 0 : Power On

1. Position of Key Switch

1. Auto Mode :" " position

2. Manual Mode :" " position

3. Off / Reset :" " position

2. Function of Key Switch

1. : This set the module into its automatic operation mode. It allows the engine
to start up by a remote start signal. This signal can be either from an AMF
system or a Synchronizing Panel system.

a. If the engine failed to start up at the first attempt, this process will repeat
two (2) times.

-- 10 --
 b. If the engine still failed to start up after three (3) attempts, the "Fail to Start"
LED will light up.
c. If the remote start signal disappeared, the engine will stop automatically
after the cooldown running.

2. : This set the module into its manual operation mode. It allows the engine to
start or stop by using the auxiliary manual Start and Stop push-buttons.

3. : This set the module into its stop position or reset mode. It will clear any
alarm condition for which the triggering criteria has been removed.

3. LED Indications
1. Heavy Alarm (Shutdown Fault)

FAULTS DESCRIPTION
Fail The engine can not be started after 3 attempts.
to The total time taken is 37sec for the whole cranking process.
Start When this happened, the LED will light up.
Low The engine oil pressure falls below the preset pressure.
2
Oil The preset value of sensing switch is either 0.5 or 1.0kg/cm .
Pressure When this happened, the LED will light up and the engine will shut down.
High The engine coolant temperature exceeds the preset temperature.
Coolant The preset value of sensing switch is 101°C.
Temperature When this happened, the LED will light up and the engine will shut down.
Over The engine speed exceeds the preset speed.
Speed The pre-set value in the controller is 115% of rated speed.
When this happened, the LED will light up and the engine will shut down.
Emergency Once the push button is pressed, the engine will immediately shut down.
Stop When this happened, the LED will light up.
Under The engine speed drops below the preset speed.
Speed The preset value in the controller is 85% of rated speed.
When this happened, the LED will light up and the engine will shut down.
Loss The controller failed to detect any MPU signal for more than 5sec.
of When this happened, the LED will light up and the engine will shut down.
Sensing

2. Light Alarm (Warning Fault)

Charge When the LED lit up, this indicates that the charging alternator is not
Fail charging the battery.
Common The LED will always light up whenever an alarm condition has been
Alarm detected, such as all the above faults, Fail to Stop and others.
The LED flashing is for Shutdown fault and steady is for Warning fault.

-- 11 --
3. Indication

FAULTS DESCRIPTION
Power When the LED lit up, this indicates that DC power is supplying to the
on module.
Remote When the LED lit up, this indicates that a remote start signal is
Start presented. This signal is from either the ATS Panel or the Synchronizing
Present Panel.

EVENTS LED INDICATION

0 1 2 3 4 5 6 7 8 9 10 11
Power On ON
Remote Start Present ON
Fail to Charge ON ON
Common Alarm ON
Over Speed ON ON
Fail to Start ON ON
High Water Temperature ON ON
Low Oil Pressure ON ON
Loss of Sensing ON ON
Under Speed ON ON
Emergency Stop ON ON

-- 12 --
 OPTIONAL COMPONENTS
1. Voltage Trimmer

This trimmer is for fine tuning of generator set voltage.

This trimmer is connected to the Auto Voltage Regulator (AVR)
of an alternator.

2. Speed Trimmer

This trimmer is for fine adjustment of engine speed.

This trimmer is connected to the Electronic Speed Controller.

3. Speed Switch

This switch is for fine adjustment of engine speed.

This switch is connected to the DC Electrical Motor for adjusting
the lever of Mechanical Governor.

4. Earth Fault Protection Relay

This relay protects the generator set from any earth leaking.
This relay measures the current flowing through the 3-phase and
neutral, then comparing these readings to its preset value. It will
trip open the circuit breaker and activate an alarm if measurement
exceeded the setting.

5. Engine Oil Temperature Gauge

This gauge indicates the temperature of engine lubricant oil.

The oil temperature should be below 113°C under normal operation.

-- 13 --
 OUTPUT TERMINALS
1. 3-Phase Output Terminals

Open Type B or BS Type Terminal R, Y and B are terminals

for the 3-phase output.

Terminal N is the neutral.

All power cables must be connected

firmly to the output terminals before
generator set operation.

Generator Set Open Type Generator Set B and BS Type

The N terminal is not the ground, so never connect the ground wire to it.
If the ground wire is connected to the N terminal, there is a possibility of electrical shock.

-- 14 --
 LOAD CONNECTION
1. Connection of 3-Phase Load
When connecting a 3-phase loads, such as a 3-phase induction
motor, connect as shown in the diagram.
The amount of loads that can be connected depends on the
rated current of the generator set.
When connecting the cables from R, Y and B terminals to a
3-phase induction motor, the motor may rotate in the wrong
direction.
In this case, swap any 2 (two) cables at R, Y and B terminals.
When connecting the power cables, stop the generator set
and switch off the circuit breaker.

2. Connection of Single-Phase Load

When connecting a single-phase loads, such as a single-phase induction motor or a welding
machine, connect as shown in the diagram.

1. For R-N, Y-N or B-N Connection 2. For R-Y, Y-B or B-R Connection

When connecting a single-phase loads, ensure that the load is equally distributed
among the three phases.
When connecting the power cables, stop the generator set and switch off the circuit
breaker.

3. Method of Connecting Load Cable Terminals

When connecting the power cables to the terminals, secure it tightly and
firmly.

4. Precautions for Connecting Load

1. Always install a breaker between the terminals and the load so that the load can be turned
on (connected) or off (disconnected).
2. When connecting the power cables, always stop the generator set and switch off all the
breakers inside both the control panel and terminal box.

-- 15 --
 CHECK BEFORE STARTING
Daily inspection is essential to maintenance the diesel engine generator set in reliable operating
condition.

1. Check Leakage of Water or Oil

Inspect around generator set for evidence of oil and water leakage. If found, locate the cause
of leaking and repair immediately before operation. Contact KOMATSU distributor service if help
is required.

2. Check Tightness of Bolts and Nuts

Confirm tightness of bolts and nuts. Pay special attention to the mounting bolts of air cleaner,
silencer, engine stand and alternator stand.

3. Check and Refill Coolant

1
Remove Radiator Cap (1) at the top rear of the generator set and
check whether the cooling water level reaches the marking line.
Otherwise, top up the cooling water.

If the volume of coolant water added is more than usual,

check for possible water leakage.

Do not remove the radiator cap while the cooling water is hot. Hot water may spout out.
When removing radiator cap, lift the lever to relieve inner pressure first.

4. Check Oil Level in Engine Oil Pan

1. Use Dipstick (1) to check oil level.
1 2. The oil level should be within marking L and H.
2
If necessary, oil can be added at Oil Filler (2).

The type of lubricant used depends on the ambient

temperature. Select as according to the type listed in Fuel,
Coolant and Lubricants Table.
When checking the oil level, park the generator set on a level ground.
Carry out oil level check before engine starting, or, 15 minutes or more after the engine is
stopped. If oil remains at various portions of the engine, an accurate oil level can not be
measured.

5. Check Dust Indicator

When the air cleaner element is clogged, the red piston of Dust
Indicator (1) will be displayed.
Refer to the section "When Required" for method of cleaning.
After cleaning, push the button for resetting the dust indicator.

-- 16 --
6. Check Electrical Wiring
1. Check for any sign of disconnection or short circuit in the electrical wiring.
2. Check for loose terminals proceed to tighten if necessary.
3. Check the following items carefully.
Battery
Starting Motor
Alternator
If there is any sign of short circuit in the electrical wiring, always investigate the cause and
rectify it.
Please contact KOMATSU distributor for investigation or rectification if necessary.

7. Check Air Intake

1. Check and ensure not blockage to the fresh air intake to the generator room.
2. Check and ensure not blockage to the fresh air intake to the alternator.

-- 17 --
 SINGLE OPERATION
1. Before Starting of Generator Set
Install the generator set on a level foundation, then check the position of the circuit breaker.

Open Type B and BS Type

* The MCCB is
mounted inside
the canopy.

Turn OFF

Busbar Terminal Box Busbar Terminal Box

1. Whether initial inspection has been carried out before operation?

(Refer to section "Check Before Starting" for details)
2. Whether the handle of the MCCB circuit breaker is at the OFF position?
3. Whether the power cables are firmly connected to the busbar inside the terminal box?

2. To Start the Generator Set

Before starting the generator set, ensure that the surrounding area is clear and suitable for
operation.

1. Turn on MCB (1) and (2).

MCB (1) : Battery DC Supply
MCB (2) : R, Y and B-phase Generator
Set AC Supply
MR, MY and MB are the 3 phases AC
supply from Mains.
2. Turn the Key Switch (beside the box) to
"OFF" position.

Internal View of Generator Control Panel

3. Push the "Start" button (on the module) to crank-start the engine.
If the engine does not start after 3 attempts, try again by pushing the "Start" button after
2 minutes.

-- 18 --
3. After Starting of Generator Set
If the engine is cold, carry out the following procedures before applying load.

1. Run the engine at mid-range speed without load for 5 minutes.

2. After engine warmed up, check all engine measurements are normal at rated speed.
Continue to warm up the engine with light load until the water temperature reached its
operating range, 70~90°C.

3. Check and ensure that there is no abnormal noise, vibration or black exhaust gas.
Avoid abrupt accelerating the engine until the warm-up period completed.
Do not run the engine at low idling or high idling for more than 20 minutes.
If running the engine at idling speed is required, apply a load or run at mid-range speed
from time to time.

4. Check Frequency and Voltage

The below should be the setting of generator set at no load.

RATED SPEED FREQUENCY ENGINE SPEED

50 Hz 52.5 Hz 1575 rpm
60 Hz 63.0 Hz 1890 rpm

The Voltage and Speed Trimmers are not within the scope of standard supply.
Therefore, adjustment can be made at the Auto Voltage Regulator (AVR) and Fuel Lever
respectively.

5. Switch On the MCCB

After the rated Voltage and Frequency have

been reached, switch ON the MCCB circuit
breaker to take load.

Turn ON

6. To Stop the Generator Set

1. Turn OFF the breaker at the load side.
2. Turn OFF the MCCB circuit breaker at the generator set side.
3. Push the "STOP" button (on the module) to stop the engine after cooling down.
4. Turn OFF all the MCB inside the Control Panel.

-- 19 --
 MANUAL PARALLELING OPERATION (OPTIONAL

Several optional components are required in the control panel for this manual paralleling
operation.
Please consult KOMATSU distributor when this operation is required.

1. Switch OFF the individual circuit breaker, MCCB at the generator set side.
2. As shown in the above diagram, connect the 3-phase power cables to the common
busbar respectively. Try to use same size and same length of power cables.

1. Paralleling Procedure
1. Make sure that all the MCCB and Breaker (A) at the load side are turned OFF.
2. After warm-up operation, increase the speed of any unit of generator set by using Speed
Trimmer, to 52Hz or 62Hz, and set the voltage to the rating.
3. Turn ON the MCCB of this unit of generator set.
4. Repeat Step 2 with second unit of generator set. Its speed and voltage must be similar to
the first unit.
5. Turn the Speed Trimmer very slowly to such direction when the Synchronizing Lamps on
the second unit goes from Bright to Dim very slowly.
6. Turn ON the MCCB on the second unit at the moment when the Synchronizing Lamps
goes "Bright and Dim" extremely slow and stays off for approximately 5 seconds.
7. If the AC Ammeter indicates negative current value during no load paralleling operation,
slightly adjust individual Voltage Trimmer to reduce negative current value to zero.
8. Switch ON the Breaker (A) when paralleling operation completed.

2. Stop of Paralleling Operation

1. Switch OFF Breaker (A), then follow with the MCCB at each generator set.
2. Allow each generator set to cool down for at least 3 minutes before shut down.

3. Cautions

1. To avoid failure or unstable operation, other EGS models or brands of generator set
should never be subjected to this paralleling operation.
2. When not in use, turn the Single / Paralleling selector switch to Single position.

-- 20 --
 OPERATING PRECAUTIONS
When Operating Outdoors When Operating Indoors
When operating on roads or outdoors, Leave an area of at least 1m from the
be careful of the wind direction and the generator set to allow operation and
direction of exhaust gas to prevent from periodic maintenance to be carried out.
blowing towards human crowd or Use the exhaust piping to direct the
residential area. exhaust gas to the outside ambient.
Install the generator set on a firm and
hard concrete foundation.

TRANSPORTATION
When transporting a generator set, follow the local traffic laws and regulations.
When using a truck or a forklift truck, please observe the following safety points.

1. Block the hauling truck and secure tires with a wooden blocks to prevent movement.
2. Use a crane to load the generator set in the specific position on the truck.
Secure the generator set with a chains or wire ropes, then choke the skid base with wood to
prevent it from sliding during transportation.
Extremely careful to prevent it from shifting side to side.
When deciding the transportation route, take into account the road width, the truck height and
weight.
Before transporting the generator set, you might want to consult your KOMATSU distributor.
When loading a generator set on to a truck, park the truck on a flat, solid surface and allow
sufficient distance between the truck and the road shoulder.

-- 21 --
 PERIODIC MAINTENANCE
A proper lubrication and maintenance serves to preserve trouble-free operation and prolong
machine life. The time and money spent for scheduling a periodic maintenance will be fully reward
by saving on smooth operation and operating cost.
All service hour figures given in this manual are based on the reading of Running Hour Meter.
However, in practice, it is recommended to rearrange all of these figures into unit of days, weeks
and months to make the maintenance schedule more easy to follow.
Under rough job site or operating condition, it is necessary to shorten the maintenance interval as
stated in this manual.

MAINTENANCE PRECAUTIONS
Even a simple maintenance procedure can cause injury if not carry out carefully.
Observe the following safety rules closely and develop a safe working habit.

1. Wear a hamlet and safety shoes ! 7. When servicing a generator with the
You may need a safety goggles, mask engine running, work in pair !
and ear plugs too. If the generator must be serviced while the
engine is running, one person should watch
2. Wear close-fitting working clothes ! the meters and gauges of the generator
Loose clothing can get caught in the while the other person carries out the
machinery. Do not wear oil stained clothing, maintenance.
it can catch fire easily.
8. Stop the engine while refueling !
3. Beware of harmful exhaust gas ! Before cleaning or refueling the generator,
To operate engine indoor, a proper always stop the engine. When adding oil or
ventilation is required. fuel, do not let the oil or fuel overflow.

4. Beware of flammable materials ! 9. Keep the alternator free from water

A burning cigarette or match is prohibited. and oil !
If water, steam or oil sticks to the alternator,
5. Be prepared for emergency ! it can cause an electrical leakage or poor
Know in advance whom to inform and what generation of power. If the alternator is wet,
to do in case of fire and other accidents. ask a specialist to measure insulation
Know how to use and the location of fire resistance value.
extinguishers and first-aid kits.
10. Never use an open flame for lighting !
6. When working with a partner, keep Never try to check the level of oil, coolant,
him informed of what you are doing ! fuel or battery electrolyte by using an open
When working on a generator, always follow flame for illumination.
your supervisor's instruction.

-- 22 --
11. Beware of rotating parts ! 16. Keep unauthorized personnel out !
Never check the fan belt tension while the Do not allow any unauthorized personnel to
engine is running. Ensure the engine is come near or operating the generator set.
stopped completely before checking any
moving or rotating parts. 17. Be alert for abnormalities while the
generator is in operation !
12. Fix the generator on a level ground ! If abnormal noise, vibration, heat, smell or
Set the machine on a firm and level ground. unusual reading from an instrument is
noticed, stop the engine immediately and look
13. Put up notice ! for the cause of the trouble. Arrange for
During maintenance, put up a "UNDER repairing if necessary.
MAINTENANCE" tag on the Engine Control
Panel and the Synchronizing Panel. 18. Handle tools properly !
Ensure to use correct tools for the job.
14. Keep the engine clean !
Keep dead leaves, waste paper and spilt 19. Disconnect the battery ground cable !
oil away from the engine. These may Before servicing the electrical system, make
cause fire, so wipe off all spilt oil. Repair sure to disconnect the negative (-ve) cable
any fuel or oil leakage immediately. from the terminal.

15. Do not use non-repaired generator ! 20. Consult us !

Before running the generator, check it Special instruments may be required when
carefully and repair if necessary. measuring the insulation resistance of the
Ensure that the machine is free from alternator and its link. In such case, consult
defects. the nearest Komatsu distributor.

-- 23 --
 GENERAL PRECAUTIONS
Clean the lubricating oil filters, grease the When changing the oil or replacing the filters,
nipples and oil the moving parts to prevent inspect the discharged oil and oil filter to see
any foreign particles from entering engine. whether there is a large amount of metal
powder or foreign particles.
Use genuine KOMATSU parts specified in
the parts book when replacing parts. When any parts that use an O-ring or gasket
seal is removed, clean the seal mounting
Use genuine KOMATSU lubricants. surface before replacing a new seal.
Select the required viscosity for the
specific ambient temperature. When oil or cooling water is drained,
attached a caution tag to the Engine Control
Always use a clean oil and grease in Panel to prevent any accidental starting by
cleaning container to prevent entrance other operators.
of foreign particles.
Wash parts in a non-combustible detergent
When adding fuel, prevent water from the or light oil. If light oil is used, keep fire away
drum head or bottom from mixing with the from the operating area.
fuel.
When washing the machine, prevent water
Check and replace oil at a dustless from splashing onto any electrical parts.
location to prevent entrance of dust.
Use ordinary automobile washing fluid.
Generally the oil and cooling water in Be careful not to let dirt or dust get in.
the generator is hot after stopping.
Do not discharge the oil or water, or While inspecting with the machine cover
replace the filter until the temperature opened and your head down, things may
has dropped. On the other hand, if the accidentally dropped into the machine.
oil is cold, do not discharge the oil Ensure the pocket is empty. Do not drop
until it has been warmed up to 20°C any wrench or nut into the machine.
to 40°C.
During welding, be careful of the following :
After cleaning or replacing the oil, filter 1. Turn off the power supply (MCB).
element and strainer, bleed air from the 2. Do not continuously apply more than
circuit. 200V.
3. Connect the ground cable at 1m from
If a strainer is provided at the oil filter, do the location to be welded.
not remove the strainer when adding the 4. Take care not to install any seals
oil. between the grounded point and the
location to be welded.
Make sure the lubricating oil is neither
excessive nor insufficient. Check if the oil
level is proper at the time of inspection
and replenish if necessary.

-- 24 --
 MAINTENANCE TABLE FOR GENERATOR SET
PERIOD NO ITEMS SERVICE PAGE
First 1 Mounting Bolts Check and Tighten 26
20 Hours 2 Cooling Circuit of Alternator Check
First 1 Fuel Filter Change Cartridge 26
250 Hours 2 Engine Oil Pan and Filter Change Oil and Cartridge
3 Engine Valve Clearance Check and Adjust
Every 1 Fuel Tank Drain Water and Sediment 26
50 Hours
Every 1 Battery Electrolyte Check 27
250 Hours 2 Fan Belt Check and Adjust Tension
3 Alternator Belt Check and Adjust Tension
4 Insulation Resistance Check
5 Engine Oil Pan and Filter Change Oil and Cartridge
(Except SAA6D125, SAA6D140 and SAA12V140 engines)
Every 1 Fuel Filter Change Cartridge 29
500 Hours 2 Engine Oil Pan and Filter Change Oil and Cartridge
(SAA6D125, SAA6D140 and SAA12V140 engines only)
3 Radiator Fins Check
Every 1 Mounting Bolts of Turbocharger Check and Re-tighten 31
1,000 Hours 2 Corrosion Resistor Replace Cartridge
3 Actuator Linkage Apply Grease
Every 1 Rotor Play of Turbocharger Check 32
2,000 Hours 2 Turbocharger Check and Clean
3 Engine Breather Clean
4 Alternator and Starting Motor Check
5 Engine Valve Clearance Check and Adjust
Every 1 Water Pump Clean 34
4,000 Hours 2 Engine Vibration Damper Clean
When 1 Cooling System Clean and Change 35
Necessary 2 Air Cleaner Element Check, Clean or Change
3 Cooling Circuit of Alternator Check and Clean
4 Alternator Body Clean
5 Bearings of Alternator Apply Grease or Change
6 Alternator Winding Clean
7 Engine Control Panel Check and Clean

-- 25 --
 First 20 Hours Service
Checking for the first 20 hours of operation.
1. Mounting Bolts
Check that all mounting and fixing bolts on engine and alternator are still tight.
Check that all fixing screws of electrical wiring on terminal block are still tight.
Check that all fixing screws of power cable on busbar are still tight.

2. Cooling Circuit of Alternator

Check and ensure that circulation of air is not reduced by partial blocking of the air intake and
outlet grilles : mud, fiber, grease, etc.

First 250 Hours Service

For new engine and its first 250 hours service, carry out the following maintenance.
1. Fuel Filter
For the details of replacing method, see the section on "Every 500 Hours Service".

2. Engine Oil Pan and Filter

For the details of replacing method, see the section on "Every 500 Hours Service".

3. Engine Valve Clearance

Request KOMATSU distributor to check this engine valve clearance because special tools
need to be used.

Every 50 Hours Service

For new engine and its first 250 hours service, carry out the following maintenance.
1. Fuel Tank (Skid Base)

Remove the Drain Plug (1) located at the side of skid base, to drain
water and sediment accumulated at the bottom of the fuel tank.

-- 26 --
 Every 250 Hours Service
Maintenance for every 250 hours of operation.
1. Battery Electrolyte
Remove the Cap (1), check the level of battery electrolyte.
If it is lower than the specified level (10-20 mm above the
pole plate), top up with distilled water.
Should any of the acid being spilt, have it replenished by the
nearest battery shop with acid of the correct gravity.
When inspecting electrolyte level, clean the hole of
battery cap.
Never use a metal funnel for supplying of electrolyte.
Handle the battery electrolyte with care.

When the electrolyte dripped on the body or skin by

accident, clean off with clean water immediately.
To avoid any gas explosion, do not bring fire or spark
near to the battery.

2. Fan Belt

1. The belt tension should normally deflected by about

10 mm when pressed with the finger (approx. 6 kg) at a
point midway between the Tension Pulley and the Fan
Pulley.
2. To adjust the belt tension, loosen Nut (1) and turn the
Tension Pulley Adjustment Bolt (2).
3. After adjustment, tighten Nut (1). Then, loosen the
Tension Pulley Adjustment Bolt (2) slightly to give play.

Tightening torque of Nut (1) : 22 + 2 kgm.

Check each pulley and its V-groove for damage. Check
the V-belt for wear and tear.
Particularly, check whether the bottom of V-belt is in
good contact with the V-groove.
Replace the V-belt either if it has been over stretched,
leaving no allowance for adjustment, or, there is a cut or
crack on the belt.
Fan Pulley
About 10mm

Tension
Pulley

Crankshaft Pulley

-- 27 --
3. Alternator Belt

1. The belt tension should normally deflected by about

10 mm when pressed with the finger (approx. 6 kg) at a
point midway between the Tension Pulley and the Fan
Pulley.
2. To adjust the belt tension, loosen Bolt (1) and Nut (2).
Then, shift the angle of Alternator (3) slightly.
3. After adjustment, tighten Bolt (1) and Nut (2) firmly.

Check each pulley and its V-groove for damage. Check

the V-belt for wear and tear.
Particularly, check whether the bottom of V-belt is in
good contact with the V-groove.
Replace the V-belt either if it has been over stretched,
leaving no allowance for adjustment, or, there is a cut or
crack on the belt.
When adjusting the V-belt, do not push the Alternator (3)
directly with a bar or the like, but use a wood pad to
Alternator Pulley
prevent damage to the core,

10mm

Drive Shaft Pulley

4. Insulation Resistance
Disconnect those wires from the output terminals of engine alternator. To determine the
insulation resistance of alternator by measuring the resistance between the terminal bolt and
its body.

If the resistance value is less than 3 megaohm, there will be a danger of electrical shock
or fire, so contact Komatsu distributor for repair.

5. Engine Oil Pan and Filter

For the procedures of changing oil and cartridge, please refer to the Every 500 Hours service
section.

-- 28 --
 Every 500 Hours Service
Maintenance for every 250 hours service should be carried out at the same time.
1. Fuel Filter
1. Remove the Cartridge (1) of Fuel Filter by using the Filter
Wrench, turning it counterclockwise.
2. Clean the filter holder, coat the thread surface of the new
Filter Cartridge with engine oil. Then, install it.
For installation, turned the cartridge until its top surface
came in contact with the seal of filter holder.
Then, tighten it with another 3/4 to 1 of a turn.
3. After finished replacing the Cartridge (1), loosen the Air
Vent Plug (2).

4. Loosen the Feed Pump Knob (3), move the pump up and
down to draw out fuel until all air bubbles escape through
the Plug (2).
5. Tighten back the Air Vent Plug (2).
6. Push the Feed Pump Knob (3) into the slot and tighten it.
After replacing the cartridge, start up the engine and
check the gap of filter seal for possible of fuel leakage.
Make sure to use genuine KOMATSU parts.

2. Engine Oil Pan and Filter

1. Open the Drain Valve (P) to drain oil from Oil Pan.
After all the oil has been drained, tighten the Valve (P).

2. Remove the Cartridge (1) of Engine Oil Filter by using

the Filter Wrench, turning it counterclockwise.

3. Clean the filter holder, coat the thread surface of the

new Filter Cartridge with engine oil. Then, install it.

For installation, turned the cartridge until its top surface

came in contact with the seal of filter holder.

Then, tighten it with another 3/4 to 1 of a turn.

-- 29 --
 4. After finished replacing the cartridge (1), top up the
engine oil through the Oil Filler (F).

5. Start up the engine at idling for a short time, then stop

the engine to check whether the oil level is sufficient.

The type of lubricant used should depend on the ambient

temperature. Select one as according to the table of
Fuel, Coolant and Lubricants.

Make sure to use a genuine KOMATSU cartridge.

Use the API category CD class of oil. If a CC class of oil

must be used, then change the oil and replace the filter
at half of the interval.

3. Radiator Fins
The mud, dust or leaves blocking the fins should be blown away by compressed air.
Steam or water must also be used instead of compressed air.
Check the rubber hose for crack or fragile. Replace the hose if necessary.
Check the Hose Clamps. Tighten them if necessary.

-- 30 --
 Every 1000 Hour Service
Maintenance for every 250 and 500 hours should be carried out at the same time.
1. Mounting Bolts of Turbocharger
Check the tightening torque for turbocharger mounting bolts.
Contact KOMATSU distributor for servicing if necessary.

NO PART NAMES TIGHTENING TORQUE REMARK

1 V-clamp for blower housing side 0.9 - 1.0 kgm
2 Turbine housing mounting bolt 6.5 - 7.5 kgm
3 Turbocharger mounting bolt 6.5 - 7.5 kgm
4 Turbocharger oil feed pipe (Inlet Line) 0.8 - 1.0 kgm PT1/4 Bolt
2.8 - 3.5 kgm M8 Bolt
5 Turbocharger oil feed pipe (Outlet Line) 6.5 - 7.5 kgm

2. Corrosion Resistor
1. Close the Valve (2) at the top of Corrosion Resistor (1).
2. Remove the Corrosion Resistor (1) by using the
Filter Wrench, turning it counterclockwise.
3. Clean the filter holder, coat the thread surface of the
new Cartridge with engine oil. Then, install it and open
2 the Valve (2).

For installation, turned the cartridge until its top

surface came in contact with the seal of filter holder.

1 Then, tighten it with another 3/4 to 1 of a turn.

Make sure to use genuine KOMATSU parts.

3. Actuator Linkage

Apply grease to the Ball Bearings of the Actuator Linkage.

-- 31 --
 Every 2000 Hour Service
Maintenance for every 250, 500 and 1000 hours should be carried out at the same time.
1. Rotor Play of Turbocharger
The Turbocharger can be checked by using the following instruction given, or to be inspected
by Komatsu distributor.
Remove the intake pipe, exhaust pipe and hose from the Turbocharger.

NO DIRECTION OF PLAY METHOD STANDARD VALUE

1 Axial Direction Move the Rotor and check for 0.08 - 0.18 mm
Rotor play in the axial direction.
2 Radial Direction Move the tip of the Blower Shaft 0.25 - 0.60 mm
in the radial direction by hand to
measure the radial play.

If the required play cannot be achieved, send the Turbocharger to KOMATSU distributor
for repairing.
If the Rotor is excessively soiled with dust or carbon, otherwise, any oil leakage caused by
Turbocharger, send to KOMATSU distributor for repair.

2. Turbocharger
Excessive carbon or oil sludge adhering to Turbocharger Blower Impeller may lead to the
deterioration of Turbocharger performance or possible damage.
Send the Turbocharger to KOMATSU distributor for cleaning.

1. Remove the Turbocharger's Oil Inlet Pipe and Drain Pipe. Then, remove the Intake Air
Pipe Connector and Blower Housing, so that the Blower Impeller can be seen.
2. Using light oil as cleaning agent, remove the carbon, sludge and other dirt from the Blower
Impeller. Do not use brush or other tool which may damaged the impeller.
3. Pour in light oil through the Turbocharger Oil Filler and rotate the Blower Impeller several
turns to wash out the sludge.
4. Rotate the Impeller by hand at least one turn to check is there any contact noise or
catching inside. If the Impeller does not turn smoothly, contact KOMATSU distributor for
repairing or replacement.
5. If there is no abnormality, dry off the light oil with compressed air after inspection. Then,
top up the engine oil.

-- 32 --
3. Engine Breather

1. Remove the Breather from the cylinder head.

2. Rinse the whole Breather in diesel oil or flushing oil, dry
with a compressed air.
Then, re-install back to the cylinder head.
3. Check the Breather Hose /Tube, if there is any oil
sediment clogged inside which cannot be clear, replace
with a new hose /tube.

Before removing the Breather, wipe off the dust from the
surrounding area.
Check the O-ring, replace it if it is scratched or damaged.
Coat the O-ring with engine oil or a thin layer of grease.
Then, install it.

4. Alternator and Starting Motor

The Brush may be worn or the Bearing may have run out of grease, contact KOMATSU
distributor for service and repair.

If the engine is start and stop frequently, carry out this inspection every 1000 hours.

5. Engine Valve Clearance

Request KOMATSU distributor to check this engine valve clearance because special tools
need to be used.

-- 33 --
 Every 4000 Hour Service
Maintenance for every 250, 500, 1000 and 2000 hours should be carried out at the same time.

1. Water Pump
Check that there is no play in the pulley and no water leakage or clogging from in the drain hole.
If any abnormality is found, contact KOMATSU distributor for repairing or replacement.

2. Engine Vibration Damper

Check the Damper for dents, face wear off or oil leakage. If any abnormality is found,
the damper must be repaired or replaced. Contact KOMATSU distributor for assistance.

-- 34 --
 When Necessary
1. Cooling System
Clean the cooling system, change the coolant and replace the Corrosion Resistor as
according to the below table.

Ensure that the generator is on a level ground when cleaning or changing the coolant.
Use a permanent type of antifreeze.
Due to some reason, if it is impossible to use a permanent type of antifreeze, then use
an Ethylene Glycol antifreeze.
Make sure the Inhibitor is replaced.
Use city water as the cooling water.
If need to use river water, well water or other type of water supply, then must contact
KOMATSU distributor for advise.

TYPE OF SOLUTION CLEANING SCHEDULE ACTION

Permanent type of antifreeze Every year (Autumn) or every
(All season type) 2000 hours whichever comes Replaced the
first Inhibitor at every
Non permanent type of Every 6 months (Spring and 1000 hours, when
antifreeze containing Autumn) cleaning the cooling
Ethylene Glycol (Drain antifreeze in spring, system or when
(Winter, one season type) add antifreeze in autumn) changing coolant.
Not using antifreeze Every 6 months or every
1000 hours whichever comes
first

When deciding the ratio between Mixing Ratio of Antifreeze and Water
antifreeze and water, one has to
check the lowest temperature in the Min. Atmosphere
past. Then, decide the mixing ratio Temperature ( °C ) -5 -10 -15 -20
as according to the given table.
Amount of Antifreeze 14 18 22 25
Actually, it is better to assume a (Liter)
temperature of about 10 °C lower Amount of Water 46 42 38 35
for the mixing ratio. (Liter)

Use a Density Gauge to measure

and control the mixing proportion.

-- 35 --
 Corrosion Resistor
1. Stop the engine and close Corrosion Resistor Valve (1).
2. Turn Radiator Cap (2) slowly until it comes off.

Do not open the Radiator Cap when the radiator

water is hot. Boiling water may spout out.
After the water cool down, raise the gap of the cap
1
to release the pressure. Then, remove the cap.

Water Filler 3. Open Drain Valve (3) at the bottom of the Radiator and
Plug (4) on the side of Cylinder Block to drain off the
cooling water.
2
4. Drain off all the water, close up Drain Valve (3) and
Plug (4). Then, top up with soft water (ex.: city water) up
to the marking on the Water Filler.
5. When the water reaches the marking on the Water Filler,
run the engine at low idling, open Drain Valve (3) and
Plug (4). Then, pass water through the cooling system
for 10 minutes.
When doing this, adjust the inflow and outflow of water
so that the radiator is always full.

Drain Valve 6. After flushing with water, stop the engine.

(Bottom of Radiator) Close Drain Valve (3) and Plug (4) after water was
drained.
7. After draining water, use a flushing agent to clean.
We recommend to use genuine KOMATSU flushing
agent Follow the instructions on the label of the flushing
agent to clean the cooling system.
8. After washing the cooling system, drain off all the water.
Then, close Drain Valve (3) and Plug (4).
Top up with soft water (ex.: city water) up to marking on
3 the Water Filler.
Drain Valve 9. When the water reaches the marking on the Water Filler,
(Cylinder Block) run the engine at low idling, open Drain Valve (3) and
Plug (4). Then, pass water through the cooling system
until clean water comes out from Drain Valve (3) and
Plug (4).
When doing this, adjust the inflow and outflow of water
4 so that the radiator is always full.
10. When the water becomes completely clean, stop the
engine, close Drain Valve (3) and Plug (4).

-- 36 --
 11. Replace the Corrosion Resistor Cartridge and open the
Corrosion Resistor Valve (1).
For details of replacement of the corrosion resistor, refer
to the Every 1000 Hours Service.
12. Supply water up to the marking on the Water Filler.
13. Run the engine for 5 minutes at low idling to eliminate
air trapped in the cooling system, then run the engine for
5 minutes at rated speed (leave Water Filler Cap (2) off
during this operation.)
14. Stop the engine, 3 minutes later, refill water again up to
the marking on Water Filler and tighten the Water Filler
Cap (2).

2. Air Cleaner Element

Checking
Whenever the Dust Indicator (1) shows red region,
clean the Air Cleaner Element.

Stop the engine when cleaning the element.

Cleaning or Replacing Outer Element

1. Loosen Bolt (2) and Clamp (3). Then, remove Cover (4).
Loose Wing Nut (5). Then, remove the Element.
2. Clean the interior body of the Air Cleaner and its Cover.
3. Clean and inspect the Element.
(Refer to the below "Cleaning Outer Element" for details)
4. Reinstall the Element after cleaning.
5. Reset the Dust Indicator, to return the indication back
to the green region.
The Outer Element needs to be replaced if it has been cleaned
for 6 times repeatedly or used for a year.
When this occurred, replace the Inner Element too.
Both Outer Element and Inner Element need to be replaced when
the Dust Indicator shows red region soon after installing the
cleaned Outer Element, even though it has been cleaned less
than 6 times.
Check and tighten the Inner Element Mounting Nut if necessary,
Replace Seal Washer (6) or Wing Nut (5) if they are broken.
When inspecting or cleaning the Air Cleaner, remove Evacuator
Valve (7) and clean with compressed air.
Remove a Seal from the Outer Element after each cleaning.
This is to monitor number of times the Element has been cleaned
by counting the number of removed Seal.

-- 37 --
 Replacing Inner Element
1. Remove the Outer Element.
2. Remove the nut and take out the Inner Element.
3. Using a clean cloth or tape, cover the air connector end.
4. Clean the interior body, then remove the cloth from the connector.
5. Install a new Element.
6. After replacing the Element, reset the Dust Indicator to its original position.

Never clean and reuse the Inner Element.

Do not clean or replace the air cleaner when the engine is running.

Cleaning Outer Element

2
Direct a dry compressed air (less than 7 kg/cm ) to Element
from inside along its folds. Then, direct it from outside along
its folds. Again from inside and check the element.
When working with compressed air, wear safety glasses
and other protection to maintain safety.
After cleaning and drying, using a lighting bulb to check
for small hole or thinner part in Element. If found, replace
the Element.
Do not use the Element which has been folded, and
either gasket or seal that is damaged.
When cleaning element, do not knock it or hit it against
something.

3. Cooling Circuit of Alternator

Check and ensure that circulation of air is not reduced by partial blocking of the air intake and
outlet grilles : mud, fiber, grease, etc.

4. Alternator Body
1. Cleaning of alternator using water spray or a high-pressure washer is strictly prohibited.
2. Use a brush and detergent (suitable for paint work) for degreasing.
3. Use air gun for dusting.

-- 38 --
5. Bearings of Alternator
Periodic checks for overheating or noise during the life of the bearings are recommended. If
excessive vibration develops after a period of time this may be due to bearings wear - the
bearing should then be examined for damage or lost of grease and replaced if necessary.
The bearings are permanently greased: approximate life of the grease (depending on use)
= 20,000 hours or 3 years.
Monitor the temperature rise in the bearings, which should not exceed 60 °C above the
ambient temperature. Should this value be exceeded, the alternator must be stopped and
checks carried out.

6. Alternator Winding
Cleaning of the Stator, Rotor, Exciter and Diode Bridge must be carried out periodically,
depend on site condition.
The insulating components and the impregnation system are not at risk of damage from
solvents. See the below list of authorized products.
Certain strictly defined pure volatile degreasing products can be used, such as :
1. Normal Petrol (without additives)
2. Toluene (slightly toxic) ; inflammable
3. Benzene (or benzine, toxic) ; inflammable
4. Ciclohexare (non toxic) ; inflammable
During cleaning, avoid letting the cleaning product run into the slots. Apply the product with a
brush, sponging frequently to avoid accumulation in the housing. Dry the winding with a dry
cloth.
Let any traces evaporate before reassembling the alternator.
After cleaning the alternator, it is essential to check the winding insulation. The condition of the
windings can be assessed by measurement of insulation resistance to earth.
The AVR should be disconnected during this test and the Resistance Temperature Detector
(RTD) leads grounded. A 500V "Megger" or similar instrument should be used.
The insulation resistance to earth of all windings should be in excess of 1 megaohm.
Under no circumstance should an alternator be operated if the insulation resistance is
less than 1 megaohms.
There are three possible methods for restoring these minimum values.
1. Dry out the alternator for 24 hours in a drying oven at a temperature of approximately
110 °C (without AVR).
2. Blow hot air into the air intake, having make sure the alternator is rotating with the exciter
field disconnected.

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 3. Run in short circuit mode (disconnect the AVR) :
Short circuit the three output power terminals using connections capable of supporting the
2
rated current (try not to exceed 6 A/mm ).
Insert a clamp ammeter to monitor the current passing through the short circuit
connections.
Connect a 24 Volt battery in series with a rheostat of approximately 10 ohms (50 W) to the
exciter field terminals, respecting the polarity.
Open fully all the alternator openings.
Run the alternator at its rated speed, and adjust the exciter field current using rheostat to
obtain the rated output current in the short circuit connections.

See the maker's Installation and Maintenance manual for more details.

7 Generator / Engine Control Panel

The generator must be disconnected from the common busbar while carrying out the following
maintenance.
1. Check the installation for abnormality of any kind, dirt and the effect of other environmental
influences.
2. Check all wiring terminals are properly and firmly tighten.
3. Check the function of switch equipment, and the controls, interlocks, protection,
annunciation and other devices by doing a simulation fault test.
4. Clear the dust from the surface of module or gauges with a soft dry cloth.

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 MAINTENANCE FOR SYNCHRONIZING PANEL (OPTIONAL)
1. General
Maintenance work may only be performed in a careful manner by trained personnel familiar
with characteristics of the synchronizing process and installation, in accordance with all
relevant safety regulations to IEC and those of other technical authorities, and with other
overriding instructions. It is recommended that KOMATSU distributor be called in to perform
servicing and repair work.
The inspection and servicing intervals of some of the components are determined by fixed
criteria such as switching frequency, length of service and number of short circuit breaking
operation. For other parts, on the other hand, the length of intervals depend, for example, on
the different modes of operation in individual cases, the degree of loading, and also
environment influences.
Inspection and servicing of Synchronizing Panels should be carried out approximately every
one to two years, depending on the operating conditions and local environment.

2. Inspection and Servicing on Panels

The inspection should include but not be limited to the following :
1. Disconnect the area where work is to be performed in accordance with the relevant safety
regulations, to IEC and other authorities, and secure it against reconnection.
2. Check the installation for abnormality of any kind, dirt and the effect of other environmental
influences.
3. Check all wiring terminals are properly and firmly tighten.
Check that bolt connections at the contact points in the breakers and busbar system are
tight, and the isolating contact system function correctly.
4. Check the function of switch equipment, and the controls, interlocks, protections,
annunciation and other devices by doing a simulation fault test.
5. Check the surface condition of the isolating contact system in the busbar. Ensure that
their surfaces are not heavily corroded or show signs of other damage or overheating
(discolor surface), otherwise, replace the contact parts.
6. Check all circuit breaker accessories and the auxiliary components.
7. Note external discharge that may occur on the surfaces of component at operating voltage.
This can, for example, be detected by characteristic noises, a clearly perceptible smell of
ozone, or visible glowing in the dark.
Should external discharge occur as a result of condensation, application of a thin silicon
film on the surface concerned is often effective as a temporary remedy. It is advisable to
request advise from KOMATSU distributor on permanent solutions to such unusual
problems.

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 8. Carefully clean the panel, and in particular the insulating material surfaces, when they are
found to be dirty (contamination may also be caused by mould formation, insects or
conductive materials in conjunction with frequent condensation). Remove the dry dust
deposits which do not adhere strongly using a soft dry cloth.
Remove more strongly adhering, sticky/grease dirt with a cloth soaked in a slightly alkaline
household cleaner. Wipe off with clear water and dry carefully. Use halogen-free cleaners
such as Rivolta BWR 210 or Rivolta Mix 60 Fronte (for insulating material components and
for major contamination). Observe the manufacturer's instructions on safety at work.
9. Completely remove all rust from damaged paint work area on steel sheet and other steel
parts by mechanical means, e.g. with wire brush.
Lightly grind the surrounding paint coat and carefully degrease the entire area. Then
immediately apply an anti-rust primer and, after an appropriate hardening period, apply the
top coat.

3. Inspection and Servicing on Circuit Breaker

Before carrying out any maintenance work it is essential to follow the procedures given below :
1. Open the Circuit Breaker and check that the closing springs are discharged.
2. Draw out the Circuit Breaker, work must only be carried out when they are withdrawn
from the enclosure.
3. The frequency and the sort of inspections and maintenance basically depend on the site
conditions. Various factors must be taken into account, e.g. frequency of operation,
interrupted current values and relative power factor as well as the installation ambient.
The below table gives the maintenance programme showing the relative time intervals
between maintenance works.

MAINTENANCE OPERATIONS TIME INTERVAL

INSTALLATION IN NORMAL AMBIENT
Carry out general inspection 12 months
Carry out visual inspection from the outside 12 months
and inspection of the parts.

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 FUEL, COOLANT AND LUBRICANTS
Proper selection of Fuel, Coolant and Lubricants

RESERVOIR TYPE OF AMBIENT TEMPERATURE

FLUID 14 32 50 68 86 °F
-10 0 10 20 30 °C

SAE 30

Engine Oil Pan Engine Oil SAE 10

SAE 10W - 30

SAE 15W - 40

Fuel Tank Diesel Fuel ASTM D975 No. 2

ASTM D975 No. 1

Cooling System Water Antifreeze

ASTM : American Society of Testing and Material

SAE : Society of Automotive Engineers
API : American Petroleum Institute

Note :

1. When sulfur content in fuel is less than 0.5 % , change oil in the oil pan at every periodic
maintenance hours described in this manual.

Change oil as according to the below table if sulfur content in fuel is above 0.5%.

SULFUR CONTENT INTERVAL OF CHANGING OIL IN OIL PAN

Less than 0.5% Regular Interval
0.5% to 1.0% Half of Regular Interval
2. When starting the engine in an atmospheric temperature of lower than 0 °C , make sure to
use engine oil of SAE10W, SAE10W-30 or SAE15W-40, even through an atmospheric
temperature goes up 10 °C or less in the day time.
3. Use API classification CD as engine oil. If API classification CC was used, reduce the engine
oil change interval to half.
4. There is no problem if single grade oil is mixed with multi-grade oil (SAE10W-30 or 15W-40),
but make sure to add single grade oil that matches the temperature in the table.
5. We recommend to use KOMATSU genuine oil which has been specifically formulated and
approved for use in engine and hydraulic work equipment applications.

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 BRAND OF LUBRICANTS, GREASE AND COOLANT
ENGINE OIL GREASE ANTIFREEZE COOLANT
(CD or CE) ( Lithium Base) (Ethylene Glycol Base)
NO MAKER SAE10W, 30, 40 NLGI No. 2 Permanent Type
(15W40 Oil marked * is CE)

EO10-CD AF-ACL
1 KOMATSU EO30-CD G2-L1 AF-PTL
EO10-30CD G2-L1-S AF-PT (Winter, One Season
EO15-40CD Type)
Diesel Sigma 5 GR MU/EP -----
2 AGIP Super Diesel Multigrade
* Sigma Turbo
3 AMOCO * Amoco 300 RYKON Premium Grease -----
4 ARCO * Arcofleet S3 Plus Litholine HEP 2 -----
Arco EP Moly D
5 BP Vanellus C3 Energrease LS-EP2 Antifreeze
6 CALTEX * PPM Delo 400 Marfak All Purpose 2 AF Engine Coolant
PPM Delo 450 Ultra-Duty Grease 2
* Turbomax MS3 Antifreeze
7 CASTROL * RX Super Spheerol EPL-2
CRD
8 CHEVARON * Delo 400 Ultra-Duty Grease 2 -----
9 CONOCO * Fleet Motor Oil Super-Star Grease -----
10 ELF Multi Performance 3C Tranself EP Glaself
Performance 3C Tranself EP type 2
Essolubel D3
* Essolubel XD-3
11 EXXON * Essolubel XD-3 Extra Beacon EP2 All Season Coolant
(ESSO) * Esso Heavy Duty
Exxon Heavy Duty
12 Gulf Super Duty Motor Oil Gulfcrown EP2 Antifreeze and Coolant
* Super Duty Plus Gulfcrown EP2 Special
Delvac 1300 Mobilux EP2 -----
13 MOBIL * Delvac Super Mobil Grease 77
10W-30, 15W-40 Mobil Grease Special
* Supreme Duty Multi Purpose
14 PENNZOIL Fleet Motor Oil White Grease 705 Antifreeze and
707L White-Bearing Grease Summer Coolant
15 PETROFINA FINA Kappa TD FINA Marson EPL2 FINA Tamidor
16 SHELL Rimula X Alvania EP Grease -----
Sunoco Ultra Sunoco Antifreeze and
17 SUN Prestige 2EP Summer Coolant
Sun Prestige 742
18 TEXACO * Ursa Super Plus Muftifak EP2 Code 2055 Startex
Ursa Premium Starplex 2 Antifreeze Coolant
19 TOTAL Rubia S Multis EP2 Antigel / Antifreeze
* Rubia X
20 UNION * Guardol Unoba EP -----
21 VEEDOL * Diesel Star ----- Antifreeze
MDC
22 Petroleum Super ----- -----
Diesel Engine Oil H3

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