Parts Book (Edition 3) Utk Unit EGS

FOREWORD
GENERAL
1. This Parts Book is applicable to the Standard Model of EGS-6 & 7 Series
Generator Sets, which assembled by Komatsu Power Generation Systems
(Shanghai) Ltd (KPGS).
2. Only the major essential components which have high replacement rate are
mentioned in this Parts Book.
3. For those components that are not mentioned in this Parts Book.
3.1 Please refer to the Material List in the file for the following components.
a. All optional components in the AC/DC Generator Control Panel and DC
Engine Control Panel.
b. All electrical components in the Synchronizing Panels or ATS Panel.
3.2 Please refer to the Engine Parts Book for the following components
a. All engine related parts.
b. All radiator related parts.
3.3 Please refer to the Alternator's Installation, Service & Maintenance
Manual for the following components.
a. All alternator related parts.
APPLICATION
1. Some components on the generator or engine control panel might be different in
respect of Generator model.
Please refer to the respective page in this book, in which your Generator model is
mentioned.
2. The following information must be provided when you order or have enquiry about
components or spare parts.
2.1 Generator Model and Serial No
2.2 Engine Model and Serial No
2.3 Installation Date and Failure Date
2.4 Operating Hours
2.5 Details of Failure
3. If you are able to provide the component Name and Parts No that printed on the
respective item during your enquiry, this will substantially shorten our response
time.
* Materials and specifications are subjected to change without prior notice.
-1-
CONTENTS
FOREWORD -------------------------------------------------- 1
CONTENTS -------------------------------------------------- 2
1.0 TYPE OF EGS SERIES GENERATOR SET -------------------------------------------------- 3
1.1 Open Type
1.2 Bonnet Soundproof Type
1.3 For Paralleling Operation
1.4 ATS Panel Between Mains And Genset
2.0 FEATURE OF AC/DC GENERATOR CONTROL PANEL ----------------------------------- 6
2.1 Standard Components of DSE5220
2.2 Standard Components List of DSE5220
2.3 Optional Components List
2.4 Other Standard Components List
3.0 FEATURE OF DC ENGINE CONTROL PANEL--------------------------------------------------10
3.1 Standard Components
3.2 Standard Components List
4.0 TYPE OF ELECTRONIC GOVERNOR SYSTEM -----------------------------------12
4.1 Electric Actuator
4.2 Magnetic Pick Up
4.3 Components List
5.0 MODEL OF CIRCUIT BREAKER --------------------------------------------------14
5.1 50Hz System
5.2 60Hz System
6.0 MODEL OF RUBBER ISOLATOR --------------------------------------------------16
7.0 MODEL OF SILENCER --------------------------------------------------17
8.0 MODEL OF ALTERNATOR --------------------------------------------------20
8.1 Stamford Alternator
8.1.1 50Hz System
8.1.2 60Hz System
8.2 Parts List of Stamford Alternator
8.2.1 Typical UCI 224 & 274 Single Bearing Alternator
8.2.2 Typical HCI 4, 5 Single Bearing Alternator
8.2.3 Typical HCI 6 Single Bearing Alternator
8.3 Leroy Somer Alternator
8.3.1 50Hz System
8.3.2 60Hz System
8.4 Parts List of Leroy Somer Alternator
8.4.1 Typical LSA 42.3 Single Bearing Alternator
8.4.2 Typical LSA 43.2 & 44.2 Single Bearing Alternator
9.0 MODEL OF RADIATOR --------------------------------------------------38
9.1 Toyo/Chevon Radiator
9.2 50Hz System
9.3 60Hz System
-2-
1.0 TYPE OF EGS SERIES GENERATOR SET
Definition of " AC/DC Generator Control Panel " and " DC Engine Control Panel ".
a. AC/DC Generator Control Panel

The control panel equips with a compact and intelligent generator control module,
which capable to provide all safety protections and its window able to display both AC
and DC digital measurements.
b. DC Engine Control Panel

The control panel equips with an engine control module and analogue engine gauges,
which capable to provide all safety protections related to engine.
1.1 Open Type
1.2 Bonnet Soundproof Type
-3-
1.3 For Paralleling Operation
Multiple units of generator set can be paralleling together to achieve an optimum power
and operation. It is an optional item to parallel to the Mains / Utility power.
The below is an illustration of Komatsu's Fully Automatic Synchronizing Panel.
Gen No. 1 Gen No. 2
Power Cables and

Control Cables
for Gen No. 1 Power Cables
and Control Cables
for Gen No. 2
To Load
Fully Automatic Synchronizing Panel
-4-
1.4 ATS Panel Between Mains And Genset
ATS is available between mains and genset for customer. It can automatically achieve
changeover between mains power supply and generator set power supply.
a. The below is an illustration of Komatsu's ATS Panel.

3
4
11 6
10
8
7
b. ATS switch's capacity List
No. ATS Type Capacity(A)

1 ATyS M 3s 63
2 ATyS M 3s 100
3 ATyS M 3s 160
1 4 ATyS 3s 250
Mains power supply 5 ATyS 3s 400
6 ATyS 3s 630
7 ATyS 3s 800
Genset power supply 8 ATyS 3s 1250
9 ATyS 3s 1600
To customer's load
Front View For ATS Panel
c. ATS Components List
NO. PART NO DESCRIPTION QTY BRAND NAME

1 ATyS (63 ~ 1600A) ATS main switch 1 SOCOMEC
2 DPS Double power supply accessory 1 SOCOMEC
3 AD17-30ZH 0103 3-phase power indicator(AC220V) 3 TAYEE
4 AD17-30ZH 0102 Position indicator (AC220V) 1 TAYEE
5 C65N/6A Miniature Circuit Breaker 1P 9 Schneider
6 LW39-16A-4OC-1111JX/2 ATS switcher 1 APT
7 LW39A-16YH5/4 Voltage switcher 1 APT
8 LW39A-16LH3/4 Current switcher 1 APT
9 RU2S-2P /10A Control Relay (AC220V) 6 IDEC
10 CP-C96V Voltmeter-AC (0~450V) 1 COMPLEE
11 CP-C96A Ammeter-AC 1 COMPLEE
12 CT ***/5A 3 PUDONG
13 UK 5N Terminals 30 Phoenix
-5-
2.0 FEATURE OF AC/DC GENERATOR CONTROL PANEL
12 1 13
Front View Side View
11 6 7 8 9
6A 6A 6A 6A 6A 6A 10A RR ST SDR
GAC
ESD5500E
10
Terminal Block
Internal View
-6-
1 DSE5220 Generator Control Module 1 DEEP SEA
2 AVW401 Emergency Stop, NC, Red 1 IDEC
3 ASW2K01 Panel Lock Key Switch 1 IDEC
4 ABW110B Buzzer Cancel Push-Button 1 IDEC
5 AD16-22M/K 24V Buzzer 1 APT
6 C65N-6A Miniature Circuit Breaker 1P 3 Schneider
9 RH2B-U 24V DC Control Relay 3 IDEC
10 UK 5N/3N Terminals 49 Phoenix
Speed Controller
11 ESD5500E (A standard supply for 1 GAC
EGS760-6 & EGS850-6 only)

Speed Controller
12 ESD5500E (Except for EGS760-6 & 1 GAC
EGS850-6)
13 3590S-2-502L 5 kohms 1 Bourns
14 3590S-2-501L 500 kohms 1 Bourns

1 AB303 Door Knob 1 HENGZHU
2 HY802 Oil Pressure Sensor 1 HAIYING
3 11Y-06-11381 Water Temperature Sensor 1 KOMATSU
4 600-815-1942 Oil Pressure Switch 1 KOMATSU
5 6950-92-1290 Water Temperature Switch 1 KOMATSU
6 ***/5A Current Transformer 3 PUDONG
-7-
1
Front View Side View
10 5 6 7 8
6A 6A 6A 6A 6A 6A 10A RR ST SDR
GAC
ESD5500E
9
Terminal Block
Internal View
-8-
NO. PARTS NO DESCRIPTION QTY BRAND NAME
1 DSE7320 Generator Control Module 1 DEEP SEA
2 AVW401 Emergency Stop, NC, Red 1 IDEC
3 ASW2K01 Panel Lock Key Switch 1 IDEC
4 AD16-22M/K 24V Buzzer 1 APT
5 iC65N-C6A /1P Miniature Circuit Breaker 3 Schneider
RH2B-U/2P/10A Control Relay for 24VDC Genset 3 IDEC
8
LY2NJ/2P/10A Control Relay for 12VDC Genset 3 OMRON
UK 3N Terminals 35 Phoenix
9
UK 5N Terminals 14 Phoenix
Speed Controller
10 ESD5500E (A standard supply for EGS760-6 & 1 GAC
EGS850-6 only)

Speed Controller
1 ESD5500E 1 GAC
(Except for EGS760-6 & EGS850-6)
2 3590S-2-502L 5kΩ for speed trimmer 1 Bourns
3 3590S-2-501L 500Ω for LSA voltage trimmer 1 Bourns
4 DSE9130 Battery charger for 12VDC Genset 1 DEEP SEA
5 DSE9255 Battery charger for 24VDC Genset 1 DEEP SEA
6 LW39-16B-40B Select switch for Battery charger 1 APT
7 CP72A/10A Ammeter for Battery charger 1 Complee
8 XB2BVB4LC DC24V red lamp for level switch 1 Schneider
9 XB2BVB3LC DC24V green lamp for level switch 1 Schneider
10 XB2BVB5LC DC24V yellow lamp for level switch 2 Schneider
11 ZB2-BE101C Select switch for level switch 1 Schneider
12 XB2BW33B1C Pushbutton with 24VDC green lamp 1 Schneider
13 XB2BW34B1C Pushbutton with 24VDC red lamp 1 Schneider

1 AB303 Door Knob 1 HENGZHU
2 HY802 Oil Pressure Sensor 1 HAIYING
3 11Y-06-11381 Water Temperature Sensor 1 KOMATSU
4 600-815-1942 Oil Pressure Switch 1 KOMATSU
5 69509-2-1290 Water Temperature Switch 1 KOMATSU
6 ***/5A Current Transformer 3 PUDONG
-9-
3.0 FEATURE OF DC ENGINE CONTROL PANEL
3.1 Standard Components on DC Eng Control Panel
Front View Internal View
- 10 -
3.2 Standard Components List for DC Eng Control Panel
1 DSE521 Engine Control Module 1 DEEP SEA
2 110190 Hour Run Meter, 24V DC 1 DATCON
3 600-815-5481 Coolant Temperature Gauge, 120°C 1 KOMATSU
4 600-815-5461 Oil Pressure Gauge, 10kg/cm2 1 KOMATSU
5 08651-23000 Charging Ammeter, + 30A 1 KOMATSU
6 108392 Tachometer 1 DATCON
ABS110 1 IDEC
7 Manual Start Push-button (Green), NO
XB7EA31 1 TELEM
ABS101 1 IDEC
8 Manual Stop Push-button (Red), NC
XB7EA42 1 TELEM
AVS301N-R 1 IDEC
9 Emergency Stop Latch-button, NC
ZB2-B2102 1 TELEM
C60N-10A 1 MERLIN GERIN
10 Miniature Circuit Breaker 1P, 24V DC
11 Miniature Circuit Breaker 1P, 230V AC
RH2B-U 1 IDEC
12 24V DC Relay
RR2PU 1 IZUMI
RR2P 1 IDEC
13 230V AC Relay
RR2PU 1 IZUMI
14 BA111 Terminal Block 1 IDEC
Speed Controller
15 ESD5500 (a standard supply for EGS760-3 & 1 GAC
EGS850-3 only)
3.3 Optional Components List for DC Engine Control Panel

1 MOD534-1K Voltage Trimmer, 1 kohms 1 SPECTROL
2 MOD534-5K Speed Trimmer, 5 kohms 1 SPECTROL
3 ESD5500 Speed Controller 1 GAC
- 11 -
4.0 TYPE OF ELECTRONIC GOVERNOR SYSTEM
4.1 Electric Actuator
In EGS series, only EGS760-6 and EGS850-6 equipped with electronic governor as a
standard scope of supply. It is an optional item for all other models.
MODEL Open BS
EGS760-6 & EGS850-6 Equipped Equipped
other models Optional Optional
A complete set of Electronic Governor system consists of a (1) Speed Controller,

(2) Actuator, (3) Linkage and (4) Magnetic Pick Up.
4.2 Magnetic Pick Up

In EGS series, all generator models are equipped with a magnetic pick up for control
module's speed sensing. For an electronic governor system, an extra piece will be
mounted on the flywheel housing for speed controller's speed sensing.
Refer to the below Figure 1 for more details.
Figure 1. Electronic Governor System
Fuel Injection Fuel Level

Pump Linkage
Electric Electronic Speed
Actuator Controller mounted inside
the Control Panel
Magnetic Pick Up
mounted on
Flywheel Housing
- 12 -
4.3 Components List
PART NO DESCRIPTION QTY BRAND NAME
ESD5500E Speed Controller 1 GAC
ADD225GSC Electric Actuator 1 GAC
MSP6720 Magnetic Pick Up 1 GAC
LNK5500 Linkage 1 GAC
- 13 -
5.0 MODEL OF CIRCUIT BREAKER
Molded Case Circuit Breakers (MCCB) are from ABB or TER except the Air Circuit
Breaker(ACB), ACB is from Merlin Gerin. Refer to the Figure 2 for actual location of
circuit breaker.
NOTE：ABB：MADE IN ABB；TER：MADE IN TERASAKI.
5.1 50Hz System

400V CLASS 200V CLASS
MODEL
ABB TERASAKI ABB TERASAKI
EGS45-6 S1N125 R63 TP XS100 NB 75A TP S1N125 R125 TP XS225 NS 150A TP
EGS120-6 S3N250 R200 TP XS225 NS 200A TP S5N400 R320 TP XS400 NE 400A TP
EGS160-7 S3N250 R250 TP XS400 NE 225A TP S5N400 R400 TP XS400 NE 400A TP
EGS300-6 S5N630 R630 TP XS600 NE 500A TP S7S1250R1000TP XS1000 NE900A TP
EGS650-6 S7S1250R1000TP XS1000 NE1000A TP — —
5.2 60Hz System

400V CLASS 200V CLASS
MODEL
ABB TERASAKI ABB TERASAKI
EGS120-6 S3N250 R250 TP XS225 NS 225A TP S5N400 R400 TP XS400 NE 400A TP
EGS500-6 S7S1250R1000TP XS1000 NE1000A TP S7S1600R1600TP XS1600 NE1600A TP
AR220S 3P FH 2000A
E2N R2000 3P
EGS1300-7 AC230V MOT,SHT With — —
FHR/PR121-LI
AX(4c) AGR-22BS-PS
- 14 -
Figure 2. Molded Case Circuit Breaker (MCCB)
In EGS series, only Open, and BS Types are equipped with MCCB as a standard
scope of supply.
- 15 -
6.0 MODEL OF RUBBER ISOLATOR
Total Quantity = Engine Side + Alternator Side
TOTAL QTY TOTAL QTY

MODEL TYPE OF ISOLATOR WITH WITH
STAMFORD LEROY SOMER
EGS45-6 30010001 4 4
EGS65-6 30010001 4 4
EGS120-6 30010002 4 4
EGS160-7 30010002 4 4
EGS240-6 30010002 6 6
EGS300-6 30010002 6 6
EGS360-6 30010002 6 6
EGS380-6 30010002 6 6
EGS500-6 30010002 8 8
EGS630-6 30010002 8 8
EGS650-6 30010002 10 10
EGS760-6 30010002 10 10
EGS850-6 30010002 10 10
EGS1000-7 30010002 12 12
EGS1050-7 30010002 12 12
EGS1200-6 30010002 12 12
EGS1300-7 30010002 12 12
M16 Hole
2 x M12
Unit :
mm
- 16 -
7.0 MODEL OF SILENCER
The below silencers are suitable for the open type of generator set only.
MODEL INDUSTRIAL TYPE RESIDENTIAL TYPE

EGS45-6 80290001 —
EGS65-6 80290002 —
EGS120-6 80290003 —
EGS160-7 80290003 —
EGS240-6 80290003 80290006
EGS300-6 80290003 80290006
EGS360-6 80290003 80290006
EGS380-6 80290003 80290006
EGS500-6 80290004 80290007
EGS630-6 80290004 80290007
EGS650-6 80290005 80290008
EGS760-6 80290005 80290008
EGS850-6 80290006 80290008
EGS1000-7 80290007 80290008
EGS1050-7 80290008 80290008
EGS1200-6 80290009 80290008
EGS1300-7 80290009 80290008
Refer to Figure 3 and Figure 4 for the size of silencer.
- 17 -
Figure 3. Size of Industrial Silencer
- 18 -
Figure 4. Size of Residential Silencer
- 19 -
8.0 MODEL OF ALTERNATOR
8.1 Stamford Alternator
The model and serial no of alternator should be provided to Komatsu distributor when
enquiry for a new alternator and / or some relevant parts.
8.1.1 50Hz System

MODEL ENGINE ALTERNATOR SAE COUPLING
EGS45-6 4D95LE-2 UCI224C1 #4 / #10
EGS65-6 S4D95LE-2 UCI224D1 #4 / #10
EGS120-6 S6D102E-1 UCI 274C1 #2 / #11.5
EGS160-7 SAA6D102E-2 UCI 274E1 #1 / #14
EGS240-6 S6D125-1 UCI 274H1 #1 / #14
EGS300-6 SA6D125-2 HCI 434D1 #1 / #14
EGS380-6 SAA6D125-P400 HCI 434FS1 #0 / #18
EGS630-6 SAA6D140-P580 HCI 534D1 #0 / #18
EGS650-6 SA6D170-A-1 HCI 534E1 #0 / #18
EGS850-6 SAA6D170-P800 HCI 634G1 #0 / #18
EGS1000-7 SAA6D170E-P910 HCI 634H1 #0 / #18
EGS1050-7 SAA6D170E-P970 HCI 634H1 #0 / #18
EGS1200-6 SAA12V140-P1150 HCI 634J1 #0 / #18
8.1.2 60Hz System

EGS45-6 4D95LE-2 UCI224C1 #4 / #10
EGS65-6 S4D95LE-2 UCI224D1 #4 / #10
EGS120-6 S6D102E-1 UCI 274C1 #2 / #11.5
EGS160-7 SAA6D102E-2 UCI 274E1 #1 / #14
EGS240-6 S6D125-1 UCI 274H1 #1 / #14
EGS300-6 SA6D125-2 HCI 434D1 #1 / #14
EGS360-6 SAA6D125-P380 HCI 434ES1 #0 / #18
EGS500-6 SAA6D140-P460 HCI 534C1 #0 / #18
EGS650-6 SA6D170-A-1 HCI 534E1 #0 / #18
EGS760-6 SAA6D170-P740 HCI 534F1 #0 / #18
EGS1000-7 SAA6D170E-P910 HCI 634H1 #0 / #18
EGS1300-7 SAA12V140-P1160 HCI 634J1 #0 / #18
- 20 -
8.2 Parts List of Stamford Alternator
8.2.1 Typical UCI 224 & 274 Single Bearing Alternator
NO. DESCRIPTION NO. DESCRIPTION

1 Stator 21 AVR
2 Rotor 22 Side Panel
3 Exciter Rotor 23 AVR Mounting Bracket
4 Exciter Stator 24 Main Rectifier Assembly - Forward
5 N.D.E Bracket 25 Main Rectifier Assembly - Reverse
6 Cover N.D.E 26 Varistor
7 Bearing 'O' Ring N.D.E 27 Diode - Forward Polarity
8 Bearing N.D.E 28 Diode - Reverse Polarity
9 Bearing Circlip N.D.E 29 Lifting Lug - D.E
- 21 -
10 D.E Bracket / Engine Adaptor 30 Lifting Lug - N.D.E

11 D.E Screen 31 Frame to Endbracket Adaptor Ring
12 Coupling Disc 32 Main Terminal Panel
13 Coupling Bolt 33 Terminal Link
14 Foot 34 Edging Strip
15 Frame Cover Bottom 35 Fan
16 Frame Cover Top 36 Foot Mounting Spacer
17 Air Inlet Cover 37 Cap Screw
18 Terminal Box Lid 38 AVR Access Cover
19 Endpanel D.E 39 AVR Anti-Vibration Mounting Assembly
20 Endpanel N.D.E 40 Auxiliary Terminal Assembly
Refer to Figure 5 and Figure 6 for the structure of alternator.

Figure 5. Typical UCI 224 & 274 Single Bearing Alternator
- 22 -
Figure 6. Rotating Rectifier Assembly
- 23 -
8.2.2 Typical HCI 4, 5 Single Bearing Alternator
NO. DESCRIPTION
1 N.D.E Bracket (Non Drive End)
2 N.D.E Cover
3 D. E. Adaptor SAE-0 (Drive End)
4 Main Frame Only (Non Service Part)C,D,E
4 Main Frame Only (Non Service Part) F
5 Wound Main Stator Assembly (No sensors)
6 Wound Rotor Assembly Complete
7 Fan
8 Shaft (Non Service Part)
9 Wound Exciter Stator 65mm
10 Wound Exciter Rotor 65mm
11 Rotating Rectifier Assembly
12 Terminal Box Side Panel
13 Terminal Box Lid
14 A. V. R. MX341-2
15 Main Terminal Arrangement
16 Drive End Screen
17 Coupling Disc SAE 18
18 Coupling Disc Washer
19 Coupling Bolt M20 x 60 Long
20 Terminal Box Endpanel N.D.E.
21 Terminal Box Endpanel D.E.
22 Coupling Spacer
23 Foot Hole Reducing Bush
Refer to Figure 7 for the structure of alternator.
Figure 7: the structure of alternator
- 24 -
NO. DESCRIPTION NO. DESCRIPTION
1 N.D.E. Bracket 7 Exciter Stator
2 Perm Magnet Stator Assy 8 Bearing O Ring
3 Perm Magnet Rotor Assy 9 Circlip
4 Perm Magnet Endcover 10 Waved washer
5 P M Rotor Fixing Bolt 11 Circlip
6 Bearing
Note: Items 2 to 5 supplied as Permanent Magnet Kit.

Items 6, 8, & 10 supplied as Replacement Bearing Kit.
Refer to Figure 8
Figure 8: the structure of N.D.E Bracket
NO. DESCRIPTION
1 Varistor Assembly
2 Diode Forward (1 SET of 3 )
3 Diode Reverse (1 SET of 3 )
Note: Items 1 to 3 supplied as Rectifier

Service Kit.
Refer to Figure 9
Figure 9: the structure of Rotating Rectifier Assembly
- 25 -
8.2.3 Typical HCI 6 Single Bearing Alternator (Refer to Figure 10)
Not supplied as
NO. Replacement parts NO. Replacement parts
individual parts
1 NDE Bracket 23 Rotor Includes:
2 NDE bearing cap (HC6) 2 Bearing cap
3 PMG stator 8 Bearing kit
4 PMG rotor 14 Bearing cartridge
5 PMG Cover 18 Shaft hub
6 Rear air inlet cover (if fitted) 21 Shaft
7 Bolts for discs 22 Fan
9 Main Exciter Stator 24 Rectifier assembly
14 NDE brg cartridge (HC6) 25 Exciter rotor
15 NDE cover 27 Main Frame Includes:
16 Coupling Disc 26 Wound Stator
17 DE Adapter 24 Rotating rectifier Kit contains
31 Terminal box side panel 28 3 forward diodes
32 Terminal box lid 29 2 varistors
33 Terminal box endpanel 30 3 reverse diodes
34 Terminal box side panel Kit NDE bearing Kit contains:
35 Terminal box endpanel DE 8 Bearing
36 Isolating transformer 10 2× bearing ‘O’ rings
37 AVR & fixing arrangement 11 Circlip
38 AVR access covers 12 Waved washer
39 NDE cover 13 Grease Flinger
40 Main terminals
Figure 10: the structure of alternator
- 26 -
8.3 Leroy Somer Alternator
The model and serial no of alternator should be provided to Komatsu distributor when
enquiry for a new alternator and / or some relevant parts.
8.3.1 50Hz System

EGS45-6 4D95LE-2 LSA 42.3 S5 #4 / #10
EGS65-6 S4D95LE-2 LSA 42.3 L9 #4 / #10
EGS120-6 S6D102E-1 LSA 44.2 VS45 #2 / #11.5
EGS160-7 SAA6D102E-2 LSA 44.2 S75 #1 / #14
EGS240-6 S6D125-1 LSA 46.2 M5 #1 / #14
EGS300-6 SA6D125-2 LSA 46.2 L9 #1 / #14
EGS380-6 SAA6D125-P400 LSA 47.2 VS2 #0 / #18
EGS630-6 SAA6D140-P580 LSA 47.2 M7 #0 / #18
EGS650-6 SA6D170-A-1 LSA 47.2 M8 #0 / #18
EGS850-6 SAA6D170-P800 LSA 49.1 M6 #0 / #18
EGS1000-7 SAA6D170E-P910 LSA 49.1 L9 #0 / #18
EGS1050-7 SAA6D170E-P970 LSA 49.1 L10 #0 / #18
EGS1200-6 SAA12V140-P1150 LSA 49.1 L11 #0 / #18
8.3.2 60Hz System

EGS45-6 4D95LE-2 LSA 42.3 S5 #4 / #10
EGS65-6 S4D95LE-2 LSA 42.3 L9 #4 / #10
EGS120-6 S6D102E-1 LSA 44.2 VS45 #2 / #11.5
EGS160-7 SAA6D102E-2 LSA 44.2 S75 #1 / #14
EGS240-6 S6D125-1 LSA 46.2 M5 #1 / #14
EGS300-6 SA6D125-2 LSA 46.2 L9 #1 / #14
EGS360-6 SAA6D125-P380 LSA 46.2 VL12 #0 / #18
EGS500-6 SAA6D140-P460 LSA 47.2 S4 #0 / #18
EGS650-6 SA6D170-A-1 LSA 47.2 M8 #0 / #18
EGS760-6 SAA6D170-P740 LSA 49.1 S4 #0 / #18
EGS1000-7 SAA6D170E-P910 LSA 49.1 L9 #0 / #18
EGS1300-7 SAA12V140-P1160 LSA 49.1 L11 #0 / #18
- 27 -
8.4 Parts List of Leroy Somer Alternator
NO DESCRIPTION QTY NO DESCRIPTION QTY

1 Stator Assembly 1 70 NDE bearing 1
4 Rotor Assembly 1 79 Preloading wavy washer 1
15 Fan 1 90 Wound exciter field 1
28 Earth Terminal 1 91 Field fixing screw 4
30 D.E Flange 1 100 Exciter armature 1
33 Air Outlet Grille 1 120 Terminal plate support 1
36 N.D.E. bracket 1 124 Terminal plate 1
37 Tie Rod 4 198 Regulator (AVR) 1
40 Plastic cover 1 199 Interference suppression module --
41 Terminal box lid 2 322 Coupling disc 1
- 28 -
49 Terminal box screw -- 323 Fixing screw 6

53 Plug 1 324 Clamping washer 1
59 Terminal box lid 1 343 Direct diode assembly 2
60 N.D.E Bearing 1 349 O ring seal 1
62 Fixing screw 2 410 DE shield 1
68 Inner bearing cap 1 411 Fixing screw 8

Figure 11. Typical LSA 42.3 Single Bearing Alternator
- 29 -
8.4.2 Typical LSA 43.2 & 44.2 Single Bearing Alternator

1 Stator Assembly 1 120 Terminal Block Support (AREP) 1
4 Rotor Assembly 1 124 Terminal Block 1
15 Fan 1 198 Voltage Regulator (AVR) 1
16 Fixing Screw (44.2 only) 6 207 AVR Damper Seal 1
28 Earth Terminal 1 217 Terminal Block 1
30 D.E Shield 1 290 PMG Housing 1
33 Air Outlet Griller 1 291 Adaptation Shaft 1
36 Shield On Exciter End 1 292 Magnetic Rotor 1
37 Tie Rod 4 293 Stator 1
41 Cover Front Panel 1 294 Fixing Screw 2
- 30 -
47 Cover Rear Panel 1 295 Tie Rod 1

48 Cover Top Panel 1 296 Cable Gland Washer + Nut 1
49 Fixing Screw 34 297 End Plate 1
51 Air Intake Griller 1 320 Hub (43.2 L8 & 44.2 only) 1
59 Inspection Door 3 322 Coupling Disc 1
70 N.D.E Bearing 1 323 Fixing Screws ---
79 Preloading Wavy Washer 1 324 Clamping Washer ( 43.2 S1 to L6) 1
90 Exciter Field 1 325 Spacer Shim ( 43.2 L8 & 44.2 only ) ---
91 Exciter Field Fixing Screw 4 343 Diode Bridge Assembly 1
100 Exciter Armature 1 347 Surge Suppressor 1
107 Diode Crescent Support 1 349 "O" Ring 1

Figure 12. Typical LSA 43.2 & 44.2 Single Bearing Alternator
- 31 -
1 Stator Assembly 1 122 Plate Support 1
4 Rotor Assembly 1 124 Terminal Plate 1
15 Fan 1 177 AVR Support Bracket 2
21 Lifting Ring 1 198 Voltage Regulator (AVR) 1
28 Earth Terminal 1 290 PMG Housing 1
30 D.E Flange 1 291 Adaptation Shaft 1
31 Fixing Screws 6 292 Magnetic Rotor 1
33 Protective Grille 1 293 Stator 1
34 Fixing Screws 2 294 Fixing Screw 2
36 Exciter End Shield 1 295 Tie Rod 1
37 Fixing Screws 5 296 Cable Gland Washer + Nut 1
41 Cover Front Panel 1 297 End Plate 1
48 Cover Top Panel 1 320 Coupling Sleeve 1
- 32 -
49 Cover Screws --- 321 Sleeve Key 1

51 Air Intake Grille 1 322 Coupling Disc 3
53 Plug 1 323 Fixing Screw 6
70 N.D.E Bearing 1 325 Spacer Shim ---
71 Cover 1 343 Diode Bridge Assembly 1
72 Fixing Screws 2 347 Protection Varistor (+ PCB) 1
78 Inner Bearing Retainer 1 349 'O' Ring 1
79 Preloading Wavy Washer 1 364 AVR Support 1
90 Exciter Field 1 365 Cover Rear Panel 1
91 Fixing Screws 4 367 Side Panel 2
100 Exciter Armature 1 371 Damper 4
120 Terminal Plate Support 1 466 AVR Inspection Door 2

- 33 -
1 Stator Assembly 1 124 Terminal Block 1
4 Rotor Assembly 1 128 Starting Range 3
15 Fan 1 130 Neutral Link 1
21 Lifting Ring 1 131 Terminal Block Terminal Screws 9
28 Earth Terminal 1 198 Voltage Regulator (AVR) 1
30 D.E Flange 1 290 PMG Housing 1
31 Fixing Screws 6 291 Adaptation Shaft 1
33 Protective Grille 1 292 Magnetic Rotor 1
34 Fixing Screws 2 293 Stator 1
36 Exciter End Shield 1 294 Fixing Screws 2
37 Fixing Screws 5 295 Tie Rod 1
41 Cover Front Panel 1 296 Cable Gland Washer + Nut 1
48 Cover Top Panel 1 297 End Plate 1
- 34 -
49 Cover Screws --- 322 Coupling Disc 3

51 Air Intake Grille 1 323 Fixing Screws 8
53 Plug 1 325 Spacer Shim ---
70 N.D.E Bearing 1 343 Diode Bridge Assembly 1
71 Cover 1 347 Protection Varistor (+ PCB) 1
72 Fixing Screws 2 349 "O" Ring 1
78 Inner Bearing Retainer 1 365 Cover Rear Panel 1
79 Preloading Wavy Washer 1 366 Side Panel 1
90 Exciter Field 1 367 Side Panel With Inspection Door 1
91 Fixing Screws 4 466 AVR Inspection Door 1
100 Exciter Armature 1

- 35 -
1 Stator Assembly 1 268 D.E Cross-member 1
4 Rotor Assembly 1 269 N.D.E Cross-member 1
15 Turbine 1 270 Connection Plate 3
18 Balancing Disc 1 277 Copper Bar Support 3/4
21 Lifting Ring 1 278 Neutral Link 1
22 Key 1 279 6/8
28 Earth Terminal 1 280 Plastic Bar Support 3/4
30 Drive End Shield 1 281 Cover Crosspiece 2
31 Fixing Screws 6 282 Cover Spacer 2
33 Protective Guard 1 283 Plastic or Copper Support 4/6
34 Fixing Screws 2 284 Circlip 1
36 Exciter End Shield 1 290 PMG Housing 1
37 Fixing Screws 4 291 Adaptation Shaft 1
41 Cover Front Panel 1 292 Magnetic Rotor 1
- 36 -
48 Cover Top Panel 1 293 Stator 1

49 Cover Screws --- 294 Fixing Screw 2
51 Air Intake Grille 1 295 Tie Rod 1
53 Plug 1 296 Cable Gland Washer + Nut 1
59 Cover Inspection Door 1 297 End Plate 1
70 N.D.E Bearing 1 320 Coupling Sleeve 1
71 Outer Bearing Retainer 1 321 Sleeve Key 1
78 Inner Bearing Retainer 1 322 Coupling Disc 3
79 Preloading Wavy Washer 1 323 Fixing Screws 8
90 Exciter Field 1 325 Spacer Shim ---
91 Fixing Screws 4 343 Diode Bridge Assembly 1
100 Exciter Armature 1 347 Surge Suppressor (+PCB) 1
107 Crescent Support 1 349 "O" Ring Seal 1
172 Isolator --- 364 AVR Support 1
177 AVR Support Stirrup 2 365 Cover Rear Panel 1
198 AVR 1 367 Left Side Panel 1
254 Right Air Intake Grille 1 368 Right Side Panel 1
255 Left Air Intake Grille 1 371 Damper 4
- 37 -
9.0 MODEL OF RADIATOR
9.1 Toyo/Chevon Radiator
The model and serial no of radiator should be provided to Komatsu distributor when
enquiry for a new radiator and / or some relevant parts.
9.2 50Hz System
MODEL TOYO CHEVON GEN SET NO

RADIATOR RADIATOR
EGS45-6 Z471-002-0000
EGS65-6 Z471-002-0000
EGS120-6 6735-61-9030
EGS160-7 6151-61-9350
EGS240-6 6152-61-9720 SXL106.4.106A 65034～
EGS300-6 6152-61-9720 SXL106.4.106A 65079～
EGS380-6 6152-62-9101 SK116.5 65116～
EGS630-6 6212-61-9570 SK94A 65188～
EGS650-6 6162-63-9171 SL137.4
EGS850-6 6162-63-9200 SK260 65056～
EGS1050-7 6240-61-9204 SK300 75001～
EGS1200-6 6215-61-9953 SK368 65121～
9.3 60Hz System
MODEL TOYO CHEVON GEN SET NO

RADIATOR RADIATOR
EGS45-6 Z471-002-0000
EGS65-6 Z471-002-0000
EGS120-6 6735-61-9030
EGS160-7 6151-6-19350
EGS240-6 6152-61-9720 SXL106.4.106A 65032～
EGS300-6 6152-61-9720 SXL106.4.106A 65092～
EGS360-6 6152-62-9101 SK116.5 65009～
EGS500-6 6212-61-9500 SK84 65007～
EGS650-6 6162-63-9171 SL137.4
EGS760-6 6162-63-9200 SK260 65009～
EGS1000-7 6240-61-9204 SK300 75001～
EGS1300-7 SK368 75001～
- 38 -
RADIATOR AND PIPING TYPE: SXL106.4.106A
INDEX PART NO. DESCRIPTION Q'TY SUPPLIERS
1 10015001 RADIATOR 1 CHEVON
2 6152-61-1520 HOSE 1 KOMATSU
3 07281-00809 CLAMP 6 KOMATSU
4 07261-20911 HOSE 1 KOMATSU
6 6152-61-1531 HOSE 1 KOMATSU
8 10700002 CAP 1 CHEVON
9 10780002 SIGHT GLASS 1 CHEVON
10 10650013 CLAMP 8 CHEVON
11 30140019 HOSE 2 CHEVON
12 10480033 PIPE 1 CHEVON
- 39 -
EGS 240-6
RADIATOR AND PIPING
TYPE: SXL106.4.106A
2 6152-62-1520 HOSE 1 KOMATSU
4 07261-20911 HOSE 1 KOMATSU
6 6152-61-1531 HOSE 1 KOMATSU
8 10700002 CAP 1 CHEVON
- 40 -
EGS 300-6
RADIATOR AND PIPING TYPE: SK116.5
2 6152-12-4410 HOSE 2 KOMATSU
4 6152-12-4380 TUBE 1 KOMATSU
5 6152-12-4420 HOSE 1 KOMATSU
6 6152-12-4490 CLAMP 4 KOMATSU
7 6152-62-1530 HOSE 1 KOMATSU
9 07261-20911 HOSE 1 KOMATSU
11 6152-62-1541 HOSE 1 KOMATSU
14 10700002 CAP 1 CHEVON
- 41 -

19 10015011 CHARGED AIR COOLER 1 CHEVON
EGS 360-6/EGS 380-6

RADIATOR AND PIPING TYPE: SK84
2 6212-11-4880 HOSE 2 KOMATSU
11 10700002 CAP 1 CHEVON
- 42 -

EGS 500-6
RADIATOR AND PIPING TYPE: SK94A
2 6212-11-4420 HOSE 2 KOMATSU
5 6162-14-4750 CLAMP 2 KOMATSU
7 6212-61-9680 HOSE 1 KOMATSU
9 6212-61-9690 HOSE 1 KOMATSU
14 10700002 CAP 1 CHEVON
- 43 -

EGS 630-6
RADIATOR AND PIPING TYPE: SL137.4
2 07281-01029 CLAMP 4 KOMASTU
3 6995-62-1692 HOSE 1 KOMASTU
8 10230010 PLATE 1 CHEVON
9 10370010 WASHER 2 CHEVON
10 10390007 SPRING WASHER 2 CHEVON
11 10350009 NUT 2 CHEVON
13 07261-20910 HOSE 1 KOMASTU
- 44 -
15 10700002 CAP 1 CHEVON

EGS 650-6
2 6162-14-4810 HOSE 1 KOMASTU
4 6162-14-4820 HOSE 1 KOMASTU
6 10320026 BOLT 4 CHEVON
12 10350013 NUT 2 CHEVON
14 10350009 NUT 2 CHEVON
- 45 -

19 6995-62-1692 HOSE 1 KOMASTU
20 07281-01029 CLAMP 4 KOMASTU
21 07261-20910 HOSE 1 KOMASTU
25 10700002 CAP 1 CHEVON
EGS 760-6/EGS 850-6

2 6162-14-4810 HOSE 1 KOMATSU
8 6215-11-4190 HOSE 1 KOMATSU
10 6240-61-1850 HOSE 1 KOMATSU
12 07261-20913 HOSE 1 KOMATSU
14 10700002 CAP 1 CHEVON
- 46 -

EGS 1000-7/EGS 1050-7

2 6215-11-4190 HOSE 2 KOMATSU
4 07261-20915 HOSE 2 KOMATSU
6 6215-61-9660 HOSE 2 KOMATSU
8 6215-11-4190 HOSE 2 KOMATSU
12 6215-61-9820 HOSE 1 KOMATSU
14 6215-61-9650 CONNECTOR 1 KOMATSU
- 47 -
15 10700002 CAP 1 CHEVON

EGS 1200-6
RADIATOR AND PIPING TYPE: SK426.8
2 6215-11-4190 HOSE 4 KOMATSU
4 07261-20915 HOSE 2 KOMATSU
6 6215-61-9660 HOSE 2 KOMATSU
9 6215-61-9820 HOSE 1 KOMATSU
11 6215-61-9650 CONNECTOR 1 KOMATSU
12 10700002 CAP 1 CHEVON
- 48 -

EGS 1300-7

Parts Book (Edition 3) Utk Unit EGS

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FOREWORD

* Materials and specifications are subjected to change without prior notice.

a. AC/DC Generator Control Panel

b. DC Engine Control Panel

1.1 Open Type

1.2 Bonnet Soundproof Type

The below is an illustration of Komatsu's Fully Automatic Synchronizing Panel.

Gen No. 1 Gen No. 2

Power Cables and

Fully Automatic Synchronizing Panel

a. The below is an illustration of Komatsu's ATS Panel.

No. ATS Type Capacity(A)

Front View For ATS Panel

c. ATS Components List

NO. PART NO DESCRIPTION QTY BRAND NAME

Front View Side View

2.3 Optional Components List

2.4 Other Standard Components List

Front View Side View

2.7 Optional Components List

2.8 Other Standard Components List

Front View Internal View

3.3 Optional Components List for DC Engine Control Panel

A complete set of Electronic Governor system consists of a (1) Speed Controller,

4.2 Magnetic Pick Up

Figure 1. Electronic Governor System

Fuel Injection Fuel Level

5.1 50Hz System

5.2 60Hz System

TOTAL QTY TOTAL QTY

MODEL INDUSTRIAL TYPE RESIDENTIAL TYPE

Refer to Figure 3 and Figure 4 for the size of silencer.

8.1.1 50Hz System

8.1.2 60Hz System

NO. DESCRIPTION NO. DESCRIPTION

10 D.E Bracket / Engine Adaptor 30 Lifting Lug - N.D.E

Refer to Figure 5 and Figure 6 for the structure of alternator.

Refer to Figure 7 for the structure of alternator.

Figure 7: the structure of alternator

Note: Items 2 to 5 supplied as Permanent Magnet Kit.

Figure 8: the structure of N.D.E Bracket

Note: Items 1 to 3 supplied as Rectifier

Figure 9: the structure of Rotating Rectifier Assembly

Figure 10: the structure of alternator

8.3.1 50Hz System

8.3.2 60Hz System

NO DESCRIPTION QTY NO DESCRIPTION QTY

49 Terminal box screw -- 323 Fixing screw 6

Refer to Figure 11 for the structure of alternator.

NO DESCRIPTION QTY NO DESCRIPTION QTY

47 Cover Rear Panel 1 295 Tie Rod 1

Refer to Figure 12 for the structure of alternator.

49 Cover Screws --- 321 Sleeve Key 1

Refer to Figure 13 for the structure of alternator.

49 Cover Screws --- 322 Coupling Disc 3

Refer to Figure 14 for the structure of alternator.

48 Cover Top Panel 1 293 Stator 1

9.2 50Hz System

MODEL TOYO CHEVON GEN SET NO