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WI-JS-010
20140516
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.
APPLICATION
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.
-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
2.5 Standard Components of DSE7320
2.6 Standard Components List of DSE7320
2.7 Other Standard Components List
2.8 Optional 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
4.4 Mororized MCCB for 60Hz 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
7.4.3 Typical LSA 46.2 Single Bearing Alternator
7.4.4 Typical LSA 47.2 Single Bearing Alternator
7.4.5 Typical LSA 49.1 Single Bearing Alternator
8.0 MODEL OF RADIATOR ---------------------------------------------- 37
8.1 Toyo/Chevon Radiator
8.2 50Hz System
8.3 60Hz System
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1.0 TYPE OF EGS SERIES GENERATOR SET
-3-
1.3 For Paralleling Operation
Multiple units of generator set can synchronize to achieve optimum power
and operations.
To Load
-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
-5-
2.0 AC/DC GENERATOR CONTROL PANEL
2.1 Standard Components of DSE5220
12 1 13
14 3
11 6 7 8 9
6A 6A 6A 6A 6A 6A 10A RR ST SDR
GAC
ESD5500E
10
Terminal Block
Internal View
-6-
2.2 Standard Components List of DSE5220
NO. PART NO. DESCRIPTION MODEL QTY SUPPLIER
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
7 20180001 MCB C65(C6) 3 Schneider
8 20180002 MCB C65(C10) 1 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
20460002 Terminals UK 5N 14 Phoenix
* :Only used in EGS45(BS)-6 and EGS65(BS)-6.
-7-
2.5 Standard Components of DSE7320
11 3
10 5 6 7 8
6A 6A 6A 6A 6A 6A 10A RR ST SDR
GAC
ESD5500E
9
Terminal Block
Internal View
-8-
2.6 Standard Components List of DSE7320
NO. PART NO. DESCRIPTION MODEL QTY SUPPLIER
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
6 20180015 MCB iC65N-C6A /1P 3 Schneider
7 20180020 MCB iC65N-C10A /1P 1 Schneider
20400005 Control Relay RH2B-U(DC24V 10A 2P) 3 IDEC
8
20400001 Control Relay LY2N-J DC12V 2P 10A * 3 OMRON
20460003 Terminals UK 3N 35 Phoenix
9
20460002 Terminals UK 5N 14 Phoenix
-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
- 10 -
3.3 Components List
NO. PART NO. DESCRIPTION MODEL QTY SUPPLIER
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.
- 12 -
4.4 Mororized MCCB for 60Hz System
400V CLASS 200V CLASS
EGS Model
Schneider —
EGS650BS-6 NS1250A N/3P/2.0/F/MX/2OF —
EGS760BS-6 NS1250A N/3P/2.0/F/MX/2OF —
EGS1000BS-7 NS1600A N/3P/2.0/F/MX/2OF —
- 13 -
5.0 RUBBER ISOLATOR
Total Quantity = Engine Side + Alternator Side
- 14 -
6.0 SILENCER
The below silencers are for open type of generator set only.
- 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.
- 19 -
7.2 Parts List of Stamford Alternator
7.2.1 Typical UCI 224 & 274 Single Bearing 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
Refer to Figure 8
NO. DESCRIPTION
1 Varistor Assembly
2 Diode Forward (1 SET of 3 )
3 Diode Reverse (1 SET of 3 )
Refer to Figure 9
- 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
- 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.
- 26 -
7.4 Parts List of Leroy Somer Alternator
7.4.1 Typical LSA 42.3 Single Bearing Alternator
- 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
6 07281-00709 CLAMP 3 KOMATSU
7 6738-61-1211 HOSE 1 KOMATSU
8 07281-00809 CLAMP 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
INDEX PART NO. DESCRIPTION Q'TY SUPPLIERS
1 10015018 RADIATOR 1 CHEVON
2 10650013 CAP 1 CHEVON
3 10015020 CHARGED AIR COOLER 1 CHEVON
4 07289-00070 CLAMP 4 KOMATSU
5 6738-11-4790 HOSE 2 KOMATSU
6 07281-00709 CLAMP 3 KOMATSU
7 6738-61-1241 HOSE 1 KOMATSU
8 07281-00809 CLAMP 1 KOMATSU
9 6738-61-1250 HOSE 1 KOMATSU
10 10780002 SIGHT GLASS 1 CHEVON
11 10650013 CLAMP 8 CHEVON
12 30140019 HOSE 2 CHEVON
13 10480060 PIPE 1 CHEVON
- 39 -
EGS 160-8
RADIATOR AND PIPING
TYPE: SXL106.4.106A
INDEX PART NO. DESCRIPTION Q'TY SUPPLIERS
1 10015001 RADIATOR 1 CHEVON
2 6152-62-1520 HOSE 1 KOMATSU
3 07281-00809 CLAMP 6 KOMATSU
4 07261-20911 HOSE 1 KOMATSU
5 07281-00197 CLAMP 2 KOMATSU
6 6152-61-1531 HOSE 1 KOMATSU
7 07281-00909 CLAMP 2 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
- 40 -
EGS 240/300-6
RADIATOR AND PIPING TYPE: SK116.5
INDEX PART NO. DESCRIPTION Q'TY SUPPLIERS
1 10015002 RADIATOR 1 CHEVON
2 6152-12-4410 HOSE 2 KOMATSU
3 07289-00080 CLAMP 8 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
8 07281-00809 CLAMP 4 KOMATSU
9 07261-20911 HOSE 1 KOMATSU
10 07281-00197 CLAMP 2 KOMATSU
11 6152-62-1541 HOSE 1 KOMATSU
12 07281-00809 CLAMP 2 KOMATSU
13 07281-00909
07281 00909 CLAMP 2 KOMATSU
14 10700002 CAP 1 CHEVON
- 41 -
EGS 500-6
RADIATOR AND PIPING TYPE: SK94A
INDEX PART NO. DESCRIPTION Q'TY SUPPLIERS
1 10015004 RADIATOR 1 CHEVON
2 6212-11-4420 HOSE 2 KOMATSU
3 07289-00120 CLAMP 2 KOMATSU
4 07289-00105 CLAMP 2 KOMATSU
5 6162-14-4750 CLAMP 2 KOMATSU
6 07299-00105 CLAMP 2 KOMATSU
7 6212-61-9680 HOSE 1 KOMATSU
8 07281-00909 CLAMP 4 KOMATSU
9 6212-61-9690 HOSE 1 KOMATSU
10 07281-00167 CLAMP 2 KOMATSU
11 10480028 PIPE 1 CHEVON
12 30140025 HOSE 2 CHEVON
13 10650011 CLAMP 4 CHEVON
14 10700002 CAP 1 CHEVON
- 43 -
EGS 630-6
RADIATOR AND PIPING TYPE: SL137.4
INDEX PART NO. DESCRIPTION Q'TY SUPPLIERS
1 100150009 RADIATOR 1 CHEVON
2 07281-01029 CLAMP 4 KOMASTU
3 6995-62-1692 HOSE 1 KOMASTU
4 10650021 CLAMP 2 CHEVON
5 30140022 HOSE 1 CHEVON
6 10650017 CLAMP 1 CHEVON
7 10480040 PIPE 1 CHEVON
8 10230010 PLATE 1 CHEVON
9 10370010 WASHER 2 CHEVON
10 10390007 SPRING WASHER 2 CHEVON
11 10350009 NUT 2 CHEVON
12 10650004 CLAMP 2 CHEVON
13 07261-20910
07261 20910 HOSE 1 KOMASTU
14 10780002 SIGHT GLASS 1 CHEVON
- 44 -
EGS 650-6
RADIATOR AND PIPING TYPE: SK260
INDEX PART NO. DESCRIPTION Q'TY SUPPLIERS
1 100150005 RADIATOR 1 CHEVON
2 6162-14-4810 HOSE 1 KOMASTU
3 10650020 CLAMP 4 CHEVON
4 6162-14-4820 HOSE 1 KOMASTU
5 10650012 CLAMP 1 CHEVON
6 10320026 BOLT 4 CHEVON
7 10390007 SPRING WASHER 6 CHEVON
8 10370010 WASHER 6 CHEVON
9 10230009 PLATE 1 CHEVON
10 10370015 WASHER 2 CHEVON
11 10390010 SPRING WASHER 2 CHEVON
12 10350013 NUT 2 CHEVON
13 10230010 PLATE 1 CHEVON
14 10350009 NUT 2 CHEVON
- 45 -
EGS 1200-6
RADIATOR AND PIPING TYPE: SK426.8
INDEX PART NO. DESCRIPTION Q'TY SUPPLIERS
1 10015007 RADIATOR 1 CHEVON
2 6215-11-4190 HOSE 4 KOMATSU
3 07299-00105 CLAMP 8 KOMATSU
4 07261-20915 HOSE 2 KOMATSU
5 07281-00197 CLAMP 4 KOMATSU
6 6215-61-9660 HOSE 2 KOMATSU
7 07281-00909 CLAMP 8 KOMATSU
8 07289-00105 CLAMP 8 KOMATSU
9 6215-61-9820 HOSE 1 KOMATSU
10 07281-01159 CLAMP 4 KOMATSU
11 6215-61-9650 CONNECTOR 1 KOMATSU
12 10700002 CAP 1 CHEVON
13 10780002 SIGHT GLASS 1 CHEVON
14 10650013 CLAMP 8 CHEVON
- 48 -
EGS 1300-7