Additional Parts Book EGS Series - 678 - Receipt On Sept 2014 PDF

Edition : 4
WI-JS-010
20140516
KOMATSU DIESEL GENERATOR SETS

PARTS BOOK
EGS-6, 7 & 8 Series:
EGS45 (BS) - 6 EGS630 (BS) - 6

EGS65 (BS) - 6 EGS650 (BS) - 6
EGS120 (BS) - 8 EGS760 (BS) - 6
EGS160 (BS) - 8 EGS850 (BS) - 6 (C)
EGS240 (BS) - 6 EGS1000 (BS) - 7
EGS300 (BS) - 6 EGS1050 (BS) - 7
EGS360 (BS) - 6 EGS1200 (BS) - 6 (C)
EGS380 (BS) - 6 EGS1300 (BS) - 7
EGS500 (BS) - 6
Blank : Open Type

BS : Bonnet & Soundproof Type
C : Container Type
Serial No : 65001 and up

FOREWORD
GENERAL
1. This Parts Book is applicable to the Standard Model of EGS-6, 7 & 8 Series
Generator Sets which were manufactured by Komatsu Power Generation
Systems (Shanghai) Ltd (KPGS).
2. This Parts Book describes not only standard items but also optional items.
3. Only the major essential components which have high replacement rate are
mentioned in this Parts Book.
4. For those components/parts that are not mentioned in this Parts Book:
3.1 Please refer to the Parts List sheet separately in the manual file for
the electrical parts of Synchronizing Panels.
3.2 Please refer to Engine Parts Book for the following components/parts:
a. All diesel engine related parts.
b. All Toyo (T.RAD) radiator related parts.
3.3 Please refer to the Alternator's Installation, Service & Maintenance

Manual for all alternator related parts.
APPLICATION
1. Some components/parts are different by each Generator Set model.

Please refer to the respective page in this book on which your Generator set
model is mentioned.
2. When ordering a spare part, please specify the part number, part name and
quantity required, and also specify the following information:
2.1 Generator Set Model and Serial No.
2.2 Engine Model and Serial No.
2.3 Installation Date (and Failure Date).
2.4 Service meter reading hours.
3. If you provide the Part Name and Part No. printed on the respective item
upon your enquiry, it 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 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 ELECTRONIC GOVERNOR SYSTEM ------------------------------- 10
3.1 Electric Actuator
3.2 Magnetic Pick Up
3.3 Components List
4.0 MODEL OF CIRCUIT BREAKER ---------------------------------------------- 12
4.1 50Hz System
4.2 60Hz System
4.3 Mororized MCCB for 50Hz System
5.0 RUBBER ISOLATOR ---------------------------------------------- 14
6.0 SILENCER ---------------------------------------------- 15
7.0 MODEL OF ALTERNATOR ---------------------------------------------- 19
7.1 Stamford Alternator
7.1.1 50Hz System
7.1.2 60Hz System
7.2 Parts List of Stamford Alternator
7.2.1 Typical UCI 224 & 274 Single Bearing Alternator
7.2.2 Typical HCI 4, 5 Single Bearing Alternator
7.2.3 Typical HCI 6 Single Bearing Alternator
7.3 Leroy Somer Alternator
7.3.1 50Hz System
7.3.2 60Hz System
7.4 Parts List of Leroy Somer Alternator
7.4.1 Typical LSA 42.3 Single Bearing Alternator
7.4.2 Typical LSA 43.2 & 44.2 Single Bearing Alternator
8.0 MODEL OF RADIATOR ---------------------------------------------- 37
8.1 Toyo/Chevon Radiator
8.2 50Hz System
8.3 60Hz System
-2-
1.0 TYPE OF EGS SERIES GENERATOR SET
1.1 Open Type
1.2 Bonnet Soundproof Type
-3-
1.3 For Paralleling Operation
Multiple units of generator set can synchronize to achieve optimum power
and operations.
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
1.4 ATS Panel Between Mains And Generator sets

ATS is installed between mains and generator sets. It is to automatically
changeover between mains power supply and generator set power supply.
-4-
a. The below is an illustration of Komatsu's ATS Panel.
3
V A
5 9
10 11 4 Internal View
7 8 6
2 12
b. ATS Switch List

13 1
No. PART NO. MODEL SUPPLIER
20220009 ATyS M 3s 125A/4P Socomec
20220008 ATyS M 3s 160A/4P Socomec
20220010 ATyS 3s 250A/4P Socomec
1 20220001 ATyS 3s 630A/4P Socomec
Front View
c. ATS Components List

NO. PART NO. DESCRIPTION MODEL QTY SUPPLIER
1 Refer to "b" Main switch ATyS (125 ~ 1600A) 1 Socomec
2 20240021 DPS DPS 1 Socomec
3 20260005 3-phase indicator AD17-30ZH 0103 3 TAYEE
4 20260006 Position indicator AD17-30ZH 0102 1 TAYEE
5 20180015 MCB iC65N C6A/1P 9 Schneider
20270009 ATS switcher LW39-16A-4OC-1111JX/2 1 APT
6
20270015 ATS switcher LW39-16B-4OB-111 X/2 * 1 APT
20270007 Voltage switcher LW39A-16YH5/4 1 APT
7
20270016 Voltage switcher LW39-16B-YH5/4 * 1 APT
20270008 Current switcher LW39A-16LH3/4 1 APT
8
20270017 Current switcher LW39-16B-LH3/4 * 1 APT
9 20400006 Control Relay RU2S(AC220V 10A 2P) 6 IDEC
20370016 Voltmeter-AC CP-C96V/0~450V 1 Complee
10
20370017 Voltmeter-AC CP-C72V/0~450V * 1 Complee
20370018 Ammeter-AC CP-C96A/2000/5A 1 Complee
20370011 Ammeter-AC CP-96A / 1200/5A 1 Complee
11
12 20460002 Terminals UK 5N 30 Phoenix
20230024 CT BH 2000/5A 3 Hangzhou
20230023 CT BH 1200/5A 3 Hangzhou
20230022 CT BH 1000/5A 3 Hangzhou
20230021 CT BH 600/5A 3 Hangzhou
13
* ： only used in ATS panel with capacity of 250A or below.
-5-
2.0 AC/DC GENERATOR CONTROL PANEL
12 1 13
14 3
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 20240001 Control Module DSE5220 1 DEEP SEA
2 20290002 Emergency Stop AVW401 1 IDEC
3 20290003 Panel Lock ASW2K01 1 IDEC
4 20290004 Buzzer Cancel ABW110B 1 IDEC
20300002 Buzzer AD16-22M/K(24V) 1 APT
5
20300001 Buzzer AD16-22M/K(12V) * 1 APT
6 20180001 MCB C65(C6) 3 Schneider
20400005 Control Relay RH2B-U(DC24V 10A 2P) 3 IDEC
9
20400001 Control Relay LY2N-J DC12V 2P 10A * 3 OMRON
20460003 Terminals UK 3N 35 Phoenix
10
* ：Only used in EGS45(BS)-6 and EGS65(BS)-6.

11 20310001 Speed Controller ESD5500E 1 GAC
12 20380008 Speed Trimmer 3590S-2-502L(5KΩ) 1 Bourns
20380008 Voltage Trimmer 3590S-2-502L(5KΩ) 1 Bourns
13
20380009 Voltage Trimmer 3590S-2-501L(0.5KΩ) * 1 Bourns
* ：Only used in LEROYSOMER alternator.

14 10430001 Door Knob AB303 1 Hengzhu
-7-
11 3
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-
1 20240008 Control Module DSE7320 1 DEEP SEA
2 20290002 Emergency Stop AVW401 1 IDEC
3 20290003 Panel Lock ASW2K01 1 IDEC
20300002 Buzzer AD16-22M/K(24V) 1 APT
4
20300001 Buzzer AD16-22M/K(12V) * 1 APT
5 20180015 MCB iC65N-C6A /1P 3 Schneider
20400005 Control Relay RH2B-U(DC24V 10A 2P) 3 IDEC
8
20400001 Control Relay LY2N-J DC12V 2P 10A * 3 OMRON
9
ESD5500E (A standard supply for EGS760-

10 20310001 Speed Controller 1 GAC
6 & EGS850-6 only)
* ：Only used in EGS45(BS)-6 and EGS65(BS)-6.

11 10430001 Door Knob AB303 1 Hengzhu

ESD5500E (Except for EGS760-6 &
1 20310001 Speed Controller 1 GAC
EGS850-6)
2 20380008 Speed Trimmer 3590S-2-502L(5KΩ) 1 Bourns
3 20380009 Voltage Trimmer 3590S-2-501L(0.5KΩ) * 1 Bourns
20340005 Battery charger DSE9255(24V) 1 DEEP SEA
4
20340006 Battery charger DSE9130(12V) 1 DEEP SEA
5 20270003 Select switch LW39-16B-40B-034X/2 1 APT
6 20370002 Ammeter CP72A/10A 1 Complee
7 20260002 Red Lamp XB2BVB4LC 1 Schneider
8 20260004 Green Lamp XB2BVB3LC 1 Schneider
9 20260003 Yellow Lamp XB2BVB5LC 2 Schneider
10 20270006 Select switch ZB2-BE101C 1 Schneider
11 20290005 Pushbutton XB2BW33B1C 1 Schneider
12 20290006 Pushbutton XB2BW34B1C 1 Schneider
13 20280001 Level Switch 230 type 1) 1 Zhinuo
16 20320002 Solenoid Valve 22E2-25(24V) 1 HYDOR
17 10630006 Three-way valve 1/2' /stainless 1 PEIZ
18 10760002 Level Gauge L=190{EGS45/65(BS)-6} 1 EASWY
19 10760003 Level Gauge L=220(EGS630BS-6) 1 EASWY
20 10760004 Level Gauge L=250(EGS240~1200-6/EGS650~850BS-6) 1 EASWY
21 10760005 Level Gauge L=280(EGS240/300/360/380BS-6) 1 EASWY
22 10760006 Level Gauge L=340(EGS1200BS-6) 1 EASWY
* ：Only used in LEROY SOMER alternator.
1) ：for all model except for "2)" and "3)".
2) ：for EGS240BS-6,EGS300BS-6, EGS380BS-6 and EGS1200BS-6.
3) ：for EGS1050BS-7.
-9-
3.0 ELECTRONIC GOVERNOR SYSTEM
3.1 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.
3.2 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
- 10 -
3.3 Components List
1 20310001 Speed Controller ESD5500E 1 GAC
2 20310005 Electric Actuator ADD225GSC 1 GAC
3 20330001 Magnetic Pick Up MSP6720 1 GAC
4 10470002 Linkage LNK5500 1 GAC
- 11 -
4.0 MODEL OF CIRCUIT BREAKER
Molded Case Circuit Breakers (MCCB) are from ABB, TERASAKI or Schneider as below.
Refer to Figure 2 for actual location of circuit breaker.
4.1 50Hz System

400V CLASS 200V CLASS
EGS Model
ABB TERASAKI ABB TERASAKI
EGS45(BS)-6 S1N125 R63 TP XS100 NB 75A TP S1N125 R125 TP XS225 NS 150A TP
EGS120(BS)-8 S3N250 R200 TP XS225 NS 200A TP S5N400 R320 TP XS400 NE 400A TP
EGS160(BS)-8 S3N250 R250 TP XS400 NE 225A TP S5N400 R400 TP XS400 NE 400A TP
EGS300(BS)-6 S5N630 R630 TP XS600 NE 500A TP S7S1250R1000TP XS1000 NE900A TP
EGS650-6 S7S1250R1000TP XS1000 NE1000A TP — —
4.2 60Hz System

EGS Model
ABB TERASAKI ABB TERASAKI
EGS120(BS)-8 S3N250 R250 TP XS225 NS 225A TP S5N400 R400 TP XS400 NE 400A TP
EGS500(BS)-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

EGS Model
Schneider —
EGS650BS-6 NS1000A N/3P/2.0/F/MX/2OF —
EGS850BS-6(C) NS1250A N/3P/2.0/F/MX/2OF —
EGS1200BS-6(C) NS1600A N/3P/2.0/F/MX/2OF —
- 12 -
EGS Model
Schneider —
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.
- 13 -
5.0 RUBBER ISOLATOR
Total Quantity = Engine Side + Alternator Side
TOTAL QTY TOTAL QTY

EGS Model PART NO. WITH WITH
STAMFORD LEROY SOMER
EGS45(BS)-6 30010001 4 4
EGS65(BS)-6 30010001 4 4
EGS120(BS)-8 30010002 4 4
EGS160(BS)-8 30010002 4 4
EGS240(BS)-6 30010002 6 6(Open) / 8(BS)
EGS300(BS)-6 30010002 6 6(Open) / 8(BS)
EGS360(BS)-6 30010002 6 6(Open) / 8(BS)
EGS380(BS)-6 30010002 6 6(Open) / 8(BS)
EGS500(BS)-6 30010002 8 6
EGS630(BS)-6 30010002 8 6
EGS650(BS)-6 30010002 10 10
EGS760(BS)-6 30010002 10 10
EGS850(BS)-6(C) 30010002 10 10
EGS1000(BS)-7 30010002 12 12
EGS1050(BS)-7 30010002 12 12
EGS1200(BS)-6(C) 30010002 12 12
EGS1300(BS)-7 30010002 12 12
- 14 -
6.0 SILENCER
The below silencers are for open type of generator set only.
EGS Model PART NO.

INDUSTRIAL TYPE RESIDENTIAL TYPE
EGS45-6 80290001 —
EGS65-6 80290002 —
EGS120-8 80290003 —
EGS160-8 80290003 —
EGS240-6 80290003 80290006+80290009
EGS300-6 80290003 80290006+80290009
EGS360-6 80290003 80290006+80290009
EGS380-6 80290003 80290006+80290009
EGS500-6 80290004 80290007+80290010
EGS630-6 80290004 80290007+80290010
EGS650-6 80290005 80290008+80290010
EGS760-6 80290005 80290008+80290010
EGS850-6 80290005 80290008+80290010
EGS1000-7 80290005 80290008+80290010
EGS1050-7 80290005 80290008+80290010
EGS1200-6 80290005 80290008+80290010
EGS1300-7 80290005 80290008+80290010
Refer to Figure 3, Figuer 4 and Figure 5 for the size of silencer.
- 15 -
Figure 3. Size of Industrial Silencer
- 16 -
Figure 4. Size of Residential Silencer
- 17 -
Figure 5. Size of Residential Second Silencer
- 18 -
7.0 MODEL OF ALTERNATOR
7.1 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.
7.1.1 50Hz System

EGS Model ENGINE ALTERNATOR SAE COUPLING
EGS45(BS)-6 4D95LE-2 UCI224C1 #4 / #10
EGS65(BS)-6 S4D95LE-2 UCI224D1 #4 / #10
EGS120(BS)-8 S6D102E-1 UCI 274C1 #2 / #11.5
EGS160(BS)-8 SAA6D102E-2 UCI 274E1 #1 / #14
EGS240(BS)-6 S6D125-1 UCI 274H1 #1 / #14
EGS300(BS)-6 SA6D125-2 HCI 434D1 #1 / #14
EGS380(BS)-6 SAA6D125-P400 HCI 434FS1 #0 / #18
EGS630(BS)-6 SAA6D140-P580 HCI 534D1 #0 / #18
EGS650(BS)-6 SA6D170-A-1 HCI 534E1 #0 / #18
EGS850(BS)-6(C) SAA6D170-P800 HCI 634G1 #0 / #18
EGS1000(BS)-7 SAA6D170E-P910 HCI 634H1 #0 / #18
EGS1200(BS)-6(C) SAA12V140-P1150 HCI 634J1 #0 / #18
7.1.2 60Hz System

EGS45(BS)-6 4D95LE-2 UCI224C1 #4 / #10
EGS65(BS)-6 S4D95LE-2 UCI224D1 #4 / #10
EGS120(BS)-8 S6D102E-1 UCI 274C1 #2 / #11.5
EGS160(BS)-8 SAA6D102E-2 UCI 274E1 #1 / #14
EGS240(BS)-6 S6D125-1 UCI 274H1 #1 / #14
EGS300(BS)-6 SA6D125-2 HCI 434D1 #1 / #14
EGS360(BS)-6 SAA6D125-P380 HCI 434ES1 #0 / #18
EGS500(BS)-6 SAA6D140-P460 HCI 534C1 #0 / #18
EGS650(BS)-6 SA6D170-A-1 HCI 534E1 #0 / #18
EGS760(BS)-6 SAA6D170-P740 HCI 534F1 #0 / #18
EGS1300(BS)-7 SAA12V140-P1160 HCI 634J1 #0 / #18
- 19 -
7.2 Parts List of Stamford Alternator
7.2.1 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 DE
N.D.E 28 Diode - Reverse Polarity
9 Bearing Circlip N.D.E 29 Lifting Lug - D.E
- 20 -
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
- 21 -
Figure 6. Rotating Rectifier Assembly
- 22 -
7.2.2 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
- 23 -
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
- 24 -
7.2.3 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
a teterminals
as
Figure 10: the structure of alternator
- 25 -
7.3 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.
7.3.1 50Hz System

EGS45(BS)-6 4D95LE-2 LSA 42.3 S5 #4 / #10
EGS65(BS)-6 S4D95LE-2 LSA 42.3 L9 #4 / #10
EGS120(BS)-8 S6D102E-1 LSA 44.2 VS45 #2 / #11.5
EGS160(BS)-8 SAA6D102E-2 LSA 44.2 S75 #1 / #14
EGS240(BS)-6 S6D125-1 LSA 46.2 M5 #1 / #14
EGS300(BS)-6 SA6D125-2 LSA 46.2 L9 #1 / #14
EGS380(BS)-6 SAA6D125-P400 LSA 47.2 VS2 #0 / #18
EGS630(BS)-6 SAA6D140-P580 LSA 47.2 M7 #0 / #18
EGS650(BS)-6 SA6D170-A-1 LSA 47.2 M8 #0 / #18
EGS850(BS)-6(C) SAA6D170-P800 LSA 49.1 M6 #0 / #18
EGS1000(BS)-7 SAA6D170E-P910 LSA 49.1 L9 #0 / #18
EGS1200(BS)-6(C) SAA12V140-P1150 LSA 49.1 L11 #0 / #18
7.3.2 60Hz System

MODEL ENGINE ALTERNATOR SAE COUPLING
EGS45(BS)-6 4D95LE-2 LSA 42.3 S4 #4 / #10
EGS65(BS)-6 S4D95LE-2 LSA 42.3 M8 #4 / #10
EGS120(BS)-8 S6D102E-1 LSA 44.2 VS45 #2 / #11.5
EGS160(BS)-8 SAA6D102E-2 LSA 44.2 S75 #1 / #14
EGS240(BS)-6 S6D125-1 LSA 46.2 M5 #1 / #14
EGS300(BS)-6 SA6D125-2 LSA 46.2 L9 #1 / #14
EGS360(BS)-6 SAA6D125-P380 LSA 46.2 VL12 #0 / #18
EGS500(BS)-6 SAA6D140-P460 LSA 47.2 S4 #0 / #18
EGS650(BS)-6 SA6D170-A-1 LSA 47.2 M8 #0 / #18
EGS760(BS)-6 SAA6D170-P740 LSA 49.1 S4 #0 / #18
EGS1300(BS)-7 SAA12V140-P1160 LSA 49.1 L11 #0 / #18
- 26 -
7.4 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
49 Terminal box screw -- 323 Fixing screw 6
- 27 -
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
- 28 -
7.4.2 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
47 Cover Rear Panel 1 295 Tie Rod 1
- 29 -
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
- 30 -
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
- 31 -
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

- 32 -
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
- 33 -
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

- 34 -
1 Stator Assembly 1 268D.E Cross-member 1
4 Rotor Assembly 1 269N.D.E Cross-member 1
15 Turbine 1 270Connection Plate 3
18 Balancing Disc 1 277Copper Bar Support 3/4
21 Lifting Ring 1 278Neutral 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
- 35 -
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
- 36 -
8.0 MODEL OF RADIATOR
8.1 Toyo (T.RAD) / 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.
1) Toyo (T.RAD) radiator related parts: Refer to Engine Parts Book.

2) Chevon radiator related parts: Refer to page 38 to 48.
8.2 50Hz System

Toyo (T.RAD) Chevon EGS Genset
EGS Model
RADIATOR RADIATOR S/No.
EGS45(BS)-6 Z471-002-0000 N.A. N.A.
EGS65(BS)-6 Z471-002-0000 N.A. N.A.
EGS120(BS)-8 6735-61-9030 SAA6D102E-2-AT55 85001~
EGS160(BS)-8 6151-61-9350 SAA6D102E-2T55 85001~
EGS240(BS)-6 6152-61-9720 SXL106.4.106A 65034～
EGS300(BS)-6 6152-61-9720 SXL106.4.106A 65079～
EGS380(BS)-6 6152-62-9101 SK116.5 65116～
EGS630(BS)-6 6212-61-9570 SK94A 65188～
EGS650(BS)-6 6162-63-9171 SL137.4 N.A.
EGS850(BS)-6(C) 6162-63-9200 SK260 65056～
EGS1000(BS)-7 6240-61-9204 SK300 75005~
EGS1050(BS)-7 6240-61-9204 SK300 75001～
EGS1200(BS)-6(C) 6215-61-9953 SK368 65121～
8.3 60Hz System

Toyo (T.RAD) Chevon EGS Genset
EGS Model
RADIATOR RADIATOR S/No.
EGS45(BS)-6 Z471-002-0000 N.A. N.A.
EGS65(BS)-6 Z471-002-0000 N.A. N.A.
EGS120(BS)-8 6735-61-9030 SAA6D102E-2-AT55 N.A.
EGS160(BS)-8 6151-6-19350 SAA6D102E-2T55 N.A.
EGS240(BS)-6 6152-61-9720 SXL106.4.106A 65032～
EGS300(BS)-6 6152-61-9720 SXL106.4.106A 65092～
EGS360(BS)-6 6152-62-9101 SK116.5 65009～
EGS500(BS)-6 6212-61-9500 SK84 65007～
EGS650(BS)-6 6162-63-9171 SL137.4 65007~
EGS760(BS)-6 6162-63-9200 SK260 65009～
EGS1000(BS)-7 6240-61-9204 SK300 75005～
EGS1300(BS)-7 N.A. SK368 75001～
- 37 -
RADIATOR AND PIPING TYPE: SAA6D102E-2-AT55
INDEX PART NO. DESCRIPTION Q'TY SUPPLIERS
1 10015017 RADIATOR 1 CHEVON
2 10650013 CAP 1 CHEVON
3 10015019 CHARGED AIR COOLER 1 CHEVON
4 07289-00070 CLAMP 4 KOMATSU
5 6738-11-4790 HOSE 2 KOMATSU
7 6738-61-1211 HOSE 1 KOMATSU
9 6738-61-1220 HOSE 1 KOMATSU
10 10780002 SIGHT GLASS 1 CHEVON
11 10650013 CLAMP 8 CHEVON
12 30140019 HOSE 2 CHEVON
13 10480059 PIPE 1 CHEVON
- 38 -
EGS 120-8
RADIATOR AND PIPING TYPE: SAA6D102E-2T55
2 10650013 CAP 1 CHEVON
5 6738-11-4790 HOSE 2 KOMATSU
7 6738-61-1241 HOSE 1 KOMATSU
9 6738-61-1250 HOSE 1 KOMATSU
- 39 -
EGS 160-8
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 240/300-6
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
13 07281-00909
07281 00909 CLAMP 2 KOMATSU
14 10700002 CAP 1 CHEVON
- 41 -

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
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
13 07281-00197
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
13 07281-01159
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

Additional Parts Book EGS Series - 678 - Receipt On Sept 2014 PDF

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Additional Parts Book EGS Series - 678 - Receipt On Sept 2014 PDF

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Edition : 4

KOMATSU DIESEL GENERATOR SETS

EGS-6, 7 & 8 Series:

EGS45 (BS) - 6 EGS630 (BS) - 6

Blank : Open Type

Serial No : 65001 and up

3.3 Please refer to the Alternator's Installation, Service & Maintenance

1. Some components/parts are different by each Generator Set model.

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

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

1.4 ATS Panel Between Mains And Generator sets

b. ATS Switch List

c. ATS Components List

Front View Side View

2.3 Optional Components List

2.4 Other Standard Components List

Front View Side View

ESD5500E (A standard supply for EGS760-

* ：Only used in EGS45(BS)-6 and EGS65(BS)-6.

2.7 Other Standard Components List

2.8 Optional Components List

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

3.2 Magnetic Pick Up

Figure 1. Electronic Governor System

Fuel Injection Fuel Level

4.1 50Hz System

4.2 60Hz System

4.3 Mororized MCCB for 50Hz System

Figure 2. Molded Case Circuit Breaker (MCCB)

TOTAL QTY TOTAL QTY

EGS Model PART NO.

Refer to Figure 3, Figuer 4 and Figure 5 for the size of silencer.

7.1.1 50Hz System

7.1.2 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

7.3.1 50Hz System

7.3.2 60Hz System

NO DESCRIPTION QTY NO DESCRIPTION QTY

53 Plug 1 324 Clamping washer 1

Refer to Figure 11 for the structure of alternator.

NO DESCRIPTION QTY NO DESCRIPTION QTY

48 Cover Top Panel 1 296 Cable Gland Washer + Nut 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

1) Toyo (T.RAD) radiator related parts: Refer to Engine Parts Book.