OPERATION & MAINTENANCE

MANUAL

Komatsu Diesel Generator :

EGS45-6 EGS360(BS)-6 EGS850(BS)-6C

EGS65-6 EGS380(BS)-6 EGS1000(BS)-7C
EGS120-8 EGS500(BS)-6 EGS1050(BS)-7C
EGS160-8 EGS630(BS)-6 EGS1200(BS)-6C
EGS240(BS)-6 EGS650(BS)-6 EGS1300-7
EGS300(BS)-6 EGS760(BS)-6C

Blank：Open Type (Example: EGS120-6)

BS： Bonnet & Soundproof Type (Example: EGS630BS-6)
BSC： Container Type (Example: EGS850BS-6C)

EGS Series product models:

EGS xxxx xx - x C

C: Container type

6, 7 or 8: Series No.

BS: Bonnet & Soundproof type

Generator capacity

Engine Generator Set

 CONTENTS
FOREWORD .............................................................................................................................................. - 1 -

1. BREAK IN THE NEW MACHINE ......................................................................................................... - 2 -

2. SAFETY HINTS ..................................................................................................................................... - 3 -

2.1 BEFORE OPERATION ................................................................................................................................- 3 -

2.2 DURING OPERATION ................................................................................................................................- 3 -
2.3 AFTER OPERATION ...................................................................................................................................- 4 -

3. SAFETY & WARNING INSTRUCTIONS ............................................................................................. - 5 -

3.1 SAFETY & WARNING CATEGORY ..............................................................................................................- 5 -

3.2 SAFETY & WARNING LABELS ....................................................................................................................- 5 -

4. TYPES OF GENERATOR SETS .......................................................................................................... - 8 -

4.1 OPEN TYPE ...............................................................................................................................................- 8 -

4.2 BONNET & SOUNDPROOF TYPE ...............................................................................................................- 8 -
4.3 CONTAINER TYPE .....................................................................................................................................- 8 -

5. DSE7320 CONTROL PANEL ............................................................................................................. - 10 -

5.1 DSE7320 AMF CONTROL MODULE ........................................................................................................- 10 -

5.2 WARNINGS, SHUTDOWN AND ELECTRICAL TRIP ALARMS LIST .............................................................- 12 -
5.2.1 WARNINGS ................................................................................................................................... - 12 -
5.2.2 SHUTDOWN ALARMS .................................................................................................................. - 13 -
5.2.3 ELECTRICAL TRIP ALARMS ........................................................................................................... - 14 -
5.3 DSE7320 GENSET CONTROL PANEL........................................................................................................- 15 -
5.3.1 GENSET CONTROL PANEL (OPEN TYPE) ....................................................................................... - 15 -
5.3.2 GENSET CONTROL PANEL (BS TYPE) ............................................................................................ - 15 -
5.4 DSE7320 GENSET OPERATING SYSTEM ..................................................................................................- 16 -
5.4.1 ENGINE INSTRUMENTS ................................................................................................................ - 16 -
5.4.2 GENERATOR INSTRUMENTS ......................................................................................................... - 16 -
5.4.3 MAINS INSTRUMENTS ................................................................................................................. - 17 -
5.4.4 ALARMS AND EVENT LOG ............................................................................................................ - 17 -
5.4.5 OTHERS FUNCTIONS .................................................................................................................... - 17 -
5.4.6 SAFETY PROTECTIONS .................................................................................................................. - 18 -
5.4.7 DISPLAY LANGUAGES ................................................................................................................... - 18 -

6. OPTIONAL COMPONENTS ............................................................................................................... - 20 -

7. OUTPUT TERMINALS ........................................................................................................................ - 22 -

7.1 3-PHASE 4-WIRES OUTPUT TERMINALS ................................................................................................- 22 -

7.2 LOAD CONNECTION ...............................................................................................................................- 23 -
7.2.1 CONNECTION OF SINGLE-PHASE LOAD……………………………………………………………………………………- 23 -
7.2.2 CONNECTION OF TWO-PHASE LOAD ........................................................................................... - 24 -
7.2.3 CONNECTION OF 3-PHASE LOAD ................................................................................................. - 24 -
7.3 METHODS OF CONNECTING LOAD CABLE TERMINALS ..........................................................................- 24 -
 7.4 PRECAUTIONS FOR CONNECTING LOAD ................................................................................................- 25 -

8. THE OPERATION OF GENERATING SET ....................................................................................... - 26 -

8.1 CHECK BEFORE STARTING …………………………………………………………………………………………………………………- 26 -

8.2 SINGLE OPERATION ...............................................................................................................................- 27 -
8.3 MANUAL PARALLELING OPERATION(OPTIONAL) ...................................................................................- 29 -
8.4 OPERATING PRECAUTIONS ....................................................................................................................- 30 -

9. TRANSPORTATION ............................................................................................................................ - 31 -

10. PERIODIC MAINTENANCE ............................................................................................................. - 32 -

10.1 MAINTENANCE PRECAUTIONS ............................................................................................................- 32 -

10.2 GENERAL PRECAUTIONS......................................................................................................................- 33 -
10.3 MAINTENANCE TABLE FOR GENERATOR SET .......................................................................................- 34 -
10.4 DETAILED DESCRIPTION OF MAINTENANCE ITEMS .............................................................................- 36 -
10.5 MAINTENANCE FOR SYNCHRONIZING PANEL (OPTIONAL) ..................................................................- 48 -

11. APPENDIX ......................................................................................................................................... - 50 -

11.1 FUEL, COOLANT AND LUBRICANTS ......................................................................................................- 50 -

11.2 BRAND OF LUBRICANTS, GREASE AND COOLANT ................................................................................- 51 -

12. CIRCUIT DRAWING………………………………………………………………………………….. – 52

12.1 EGS, CIRCUIT DG…………………………………………………………………………………………………………………..………….-52-

12.2 EGS, TERMINAL WIRING DIAGRAM..……………………..…………………………………………………………………………-53-
CURRENT TRANSFORMER INSTALL INSTRUCTION…………………………………….……………………………………………….. -54-
ASSEMBLY OUTLINE DRAWING…………………………………………………………………………………………………………………...-55
 QUICK REFERENCE
COMPONENT MODEL SERIES NO.

Generator Set

Engine

Alternator

Distributor name and phone number :

REGULAR MAINTENANCE
ITEM DATE HOURS

Delivery

Regular maintenance

Regular maintenance

Regular maintenance

Regular maintenance

CONSUMABLE PARTS
Parts number Parts name Quantity
 FOREWORD
This manual is about specific procedures for lubrication, maintenance, checking and adjustment of
power generator system. It will help the operator or anyone else achieve optimal performance of the
machine through effective, economical and safe maintenance.

 Please read this manual carefully before carrying out any maintenance on the machine. Please
continue studying this manual until proper maintaining procedures have been completely
reinforced into personal habit.

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

 All maintenance procedures detailed in this manual should be undertaken by personnel trained in
the commissioning, servicing and maintenance of electrical and mechanical components.
Always follow all relevant safety regulations to IEC and those of other technical authorities, as
well as 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 regulations.

 Some pictures illustrated in this manual may be different from the actual power generator system
due to continuous technical improvement

 This operation and maintenance manual may contain attachment and optional 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-
 1. BREAK IN THE NEW MACHINE
Each machine shall be 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 be prematurely deteriorated and the service life will be shortened.
A new machine must be operated with care, particularly with regard to the following items.

 After start up, let the engine runs without load for 5 minutes to allow proper engine warm-up prior
to actual operation.

 Be sure to perform regular maintenance and check all relevant items as indicated in this manual.

 If the machine is delivered without any cooling water in the radiator, flush and clean the cooling
system with sufficient clean water, then fill the radiator with clean cooling water.

★ When replacing oil filter elements (cartridge), check their interiors for dirt and dust. If they are
severely contaminated, check for possible causes before starting operation.
★ Hours of operation are indicated by the Hour Run meter or controller.

-2-
 2. SAFETY HINTS

2.1 Before Operation

 Wear a hamlet and safety shoes !

You may need a safety goggles, mask and ear plugs too.
 Wear close-fitting working clothes !
Loose clothing can get caught in the machine. Do not wear oil stained clothing for it can
catch fire easily.
 Do not operate the Generator Set when fatigued or after drinking !
Poor physical conditions can cause bad judgements when an emergency arises.
 Observe workshop rules !
Always follow the safety rules, warnings and operating instructions.
 Be prepared for emergency !
Know in advance whom to inform and what to do in case of fire and other accidents. Know
the locations and usage of fire extinguishers and first-aid kits.
 Beware of harmful exhaust gas !
If the engine is operated indoor, proper ventilation is required.
 Learn about the machine !
Read the Operation and Maintenance Manual and be familiar with the function and operation
of the Generator Set.
 Connect the load before starting !
Before starting the generator set, make sure all the load are connected.
 Be aware of the surroundings !
When starting the generator set, signal to other personnel to ensure safety.
 Fix the generator on a level ground !
Set the machine on a firm and level ground.
 Beware of flammable materials !
A burning cigarette or match is prohibited.

2.2 During Operation

 Beware of electric shock !

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

 Stop the engine properly !

Switch off the breaker before stopping the generator set. Lock and remove the key to prevent
tampering.

-4-
 3. SAFETY & WARNING INSTRUCTIONS
Always read through and comply with the following safety instructions!

3.1 Safety & Warning Category

Warning symbol

Notice: general danger symbol

Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.

Electric shock

Danger symbol of electric shock.

If electrical safety is not observed, electric shock, fire
and/or serious personal injury or death may occur.

3.2 Safety & Warning Labels

Electric shock warning

Do not touch output terminals or internal wiring, while

the unit is operating.
Turn off power before servicing.
Only qualified personel should install, use and service
this equipment.

Fire warning

Never fill the fuel tank while the engine is running or in

the dark. Fuel spillage on a hot engine can cause a
fire or explosion.
DO NOT smoke around or near the machine.
NEVER operate the generator in an explosive
atmosphere or near combustible materials. An
explosion or fire could result in severe bodily harm or
even death.

-5-
 High temperature warning

Please stay away from hot parts.

Do not touch until the machine has sufficient cooling.
Before you open the cap of radiator, the generator set
needs to be stopped and cooled down completely.

Battery warning

In case the battery liquid (dilute sulfuric acid) comes in

contact with clothing or skin, rinse skin or clothing
immediately with plenty of water. If it splashes in your
eyes, rinse eyes immediately with plenty of water, and
then contact the nearest doctor or hospital.
DO NOT expose the battery to open flames, sparks,
cigarettes etc. The battery contains combustible gases
and liquids. If these gases and liquids come in contact
with a flame or spark, an explosion could occur.
When the unit is running, please do not disconnect the
battery cable.

Exhaust gas warning

Exhaust gases from diesel engines are extremely

poisonous. Whenever an engine is installed indoors, the
exhaust fumes must be vented to the outside.
Please don't inhale exhaust; otherwise, it will harm your
health.

Hands and head warning

Caution: don't hurt your hands. Please don't close to

the rotating parts with your hands.
Pay attention to the top, and mind your head.

-6-
Protective earthing warning

This is a “protective grounding” logo that requires

reliable grounding.

Hoisting warning

When hoisting equipment, you should lift the

equipment from lifting logo.

To prevent disassembly

Do not remove the cable of starting motor when the

unit is running; otherwise, it will cause a short circuit
or other safety accidents.

-7-
 4. TYPES OF GENERATOR SETS

4.1 Open Type

The components of open type are shown in table 4-1.

4.2 Bonnet & Soundproof Type

The components of bonnet & soundproof type are shown in table 4-2.

4.3 Container Type

The components of container type are shown in table 4-3.

-8-
 4-1: Components Table
No. MAIN COMPONENTS No. MAIN COMPONENTS
1* Exhaust Piping 8 Alternator
2 Radiator 9 MCCB Box
3 Silencer 10 Rubber Isolator
4 Bellows 11 Skid Base
5 Engine 12 Canopy (Soundproof)
6 Air Cleaner
7 Control Panel

-9-
 5. DSE7320 CONTROL PANEL

5.1 DSE7320 AMF Control Module

The DSE7320 is a control module for single gen-set applications and it is an AMF ( Auto Mains Failure)
control module.

NO. ITEMS DESCRIPTION

It is a main status and instrumentation display.

Instrumentation display as follows:
Generator Instruments
Volts, Hz, Amps, kW, kVA, Pf, kWh, kVAr,
kVArh, KVAh
LCD Display Engine Instruments
1
Window RPM, Oil Pressure, Coolant Temperature,
Hours Run, Charging Voltage, Battery Volts.
Mains/Utility Instruments
Volts, Frequency

In addition, it can display alarms, event log and status information.

This button places the module into Stop/Reset mode. This will
clear any alarm conditions for which the triggering criteria have
been removed. If the engine is running and the module is in Stop
mode, the fuel supply de-energises and the engine comes to a
2 standstill.
NOTE:
Under normal operation, pressing this button can reset all alarms.
Stop/Reset Mode
If the alarm can not be reset, please disconnect the module DC
power supply, and then power up to reset the alarm.

- 10 -
 This mode allows manual control of the generator functions. Once
3 in Manual mode the module will respond to the start button, start
the engine, and run off load.

Manual Mode

This button places the module into Test mode. This allows an on
load test of the generator.
4
Once in Test mode the module will respond to the start button,
start the engine, and run on load.
Test Mode

This button places the module into Automatic mode. This mode
allows the module to control the functions of the generator
5 automatically. The module will monitor the remote start input and
mains supply status and once a start request is made, the set will
be automatically started and placed on load.
Automatic Mode

This button silences the audible alarm if it is making sounds and

6
illuminates all of the LEDs as a lamp test feature.

Mute / Lamp Test

This button is only active in STOP/RESET or MANUAL mode.

7 Pressing this button in manual or test mode will start the engine
and run off load (manual) or on load (test).

Start Button

8 Close Mains LED The LED is on when the mains is required to be on load.

Allows the operator to transfer the load to the mains.

9
(only in Manual mode)

Transfer to mains

Mains
10 The LED is on when the mains is within limits and able to take load.
Available LED

- 11 -
 Close
11 The LED is on when the generator is required to be on load.
Generator LED

Allows the operator to transfer the load to the generator.

12
(only in Manual mode)

Transfer To
Generator

Generator The LED is on when the generator is within limits and able to take
13
Available LED load.

Used for navigating the instrumentation, event log and

configuration screens.
14
Use the navigation buttons of the module to traverse the menu and
make value changes to the parameters.
Menu navigation
These four LEDs are Panel Lock, Oil Pressure Switch, Coolant
15 Four LEDs
Temp Switch and Air Filter Dust (only suitable for HPI).

5.2 Warnings, Shutdown and Electrical Trip Alarms List

When an alarm is present, the audible alarm will make sounds and the common alarm LED (if
configured) will illuminate. The audible alarm can be silenced by pressing the Mute button. The LCD
display will change from the ‘Information page’ to the “Alarm page”.

5.2.1 Warnings

Warnings are non-critical alarm conditions and do not affect the operation of the generator system.
They serve to draw the operators attention to an undesirable condition.

NO. LCD DISPLAY DESCRIPTION

The auxiliary charge alternator voltage is low as measured

1 Charge Alt Failure
from the D+ terminal.

Battery The DC supply has fallen below the low volts setting level
2
Under Voltage (22Vdc) for the duration of the low battery volts timer.

- 12 -
 Battery The DC supply has risen above the high volts setting level
3
Over Voltage (30Vdc) for the duration of the high battery volts timer.

The module has detected a condition that the engine is

4 Fail To Stop
running when it has been instructed to stop.

5.2.2 Shutdown Alarms

Shutdowns are latching alarms to stop the Generator. Clear the alarm and remove the fault before
pressing Stop/Reset to reset the module.

NO. LCD DISPLAY DESCRIPTION

The engine does not work after the preset number of start
1 Fail To Start
attempts.

The emergency stop button has been depressed. This is a

failsafe input and will immediately stop the set should the
signal be removed. Removal of the battery positive supply
from the emergency stop input will also remove DC supply
2 Emergency Stop from the fuel and start outputs of the controller.

NOTE:
The Emergency Stop Positive signal must be present
otherwise the unit will shut down.

Oil pressure switch is closed when engine is running, and

Oil Pressure
3 then the engine will immediately stop and a shutdown alarm
Low Switch
will occur.

Coolant temperature switch is closed when engine is running,

Coolant Temp
4 and then the engine will immediately stop and a shutdown
High Switch
alarm will occur.

Active if the engine speed exceeds the over speed shutdown

5 Engine Over Speed
setting (+15%).

- 13 -
 Active when the engine speed falls below the under speed
6 Engine Under Speed
shutdown setting (-15%).

The generator output frequency has risen above the

7 Gen Over Frequency
shutdown setting level (+15%).

The generator output frequency has fallen below the

8 Gen Under Frequency
shutdown setting level (-15%).

The generator output voltage has risen above the shutdown

9 Gen Over Voltage
setting level (+15%).

The generator output voltage has fallen below the shutdown

10 Gen Under Voltage
setting level (-15%).

5.2.3 Electrical Trip Alarms

On initiation of the electrical trip condition the module will de-energise the ”Close Generator” output to
remove the load from the generator. Once this has occurred the module will start the Cooling timer
and allow the engine to cool off-load before shutting down the engine. The alarm must be accepted
and cleared, and the fault must be removed to reset the module.

NO. LCD DISPLAY DESCRIPTION

The measured Total kW is above the setting of the kW

1 kW Overload
overload Electrical Trip alarm

If a high current condition has continued for an excess period,

2 Generator High Current
the alarm will escalate to a electrical trip condition.

If the current has continued for an excess period for more

3 Short Circuit than two times, the alarm will escalate to a electrical trip
condition.

- 14 -
5.3 DSE7320 Genset Control Panel

5.3.1 Genset Control Panel (Open Type)

NO. MAIN COMPONENTS

1 DSE 7320 Gen Control Module
2 Emergency Stop Button
3 Panel Lock Key Switch
4 Buzzer

5.3.2 Genset Control Panel (BS Type)

Standard Parts:
NO. MAIN COMPONENTS
1 DSE 7320 Gen Control Module
2 Emergency Stop Button
3 Panel Lock Key Switch
4 Buzzer

- 15 -
 Option Parts:
NO. COMPONENTS
5 Potentiometer For Voltage Control
6 Potentiometer For Speed Control
7 Control Switch For Solenoid Valve
8 Lamps Indication For Level Switch
9 Charger Ammeter
10 Charger Selector Switch
11 Pushbutton For Breaker ON / OFF
12 Heater Switch For Alternator

5.4 DSE7320 Genset Operating System

The operating system for diesel generator set can start, run and stop control operation in manual or
automatical mode. The system can display the set parameters, running state, event log and alarm
information.

In addition, the built-in AMF function can meet automatic load transfer of double power supply. When
the mains (utility) power failure occurs, control system can automatically start genset, and then
transfer the load to the generator set. When the mains (utility) power is restored, genset will cool down,
stop and finally transfer the load to the mains supply.

The system can display the following basic information (see section 5.3.1~5.3.4).

5.4.1 Engine Instruments

 Speed (RPM)
 Oil Pressure (bar)
In normal operation, the pressure is in the range of 2 ~ 7bar.
 Coolant Temp. (℃)
In normal operation, the coolant temperature is in the range of 75 to 100℃.
 Battery Volts (V)
In normal operation, the battery voltage is in the range of 24 ~ 28.5V.
 Charging Volts (V)
 Run Time (h)

5.4.2 Generator Instruments

 Volts, L1-N，L2-N, L3-N (V)

 Volts, L1-L2，L2-L3，L3-L1 (V)
 Frequency (Hz)
 Current, L1,L2,L3(A)
 Load, L1,L2,L3 (KW)
 Total Load (KW)
 Total %, , L1,L2,L3
 Load Total %
- 16 -
 Load, L1,L2,L3 (KVA)
 Total Load (KVA)
 Power Factor, L1,L2,L3
 Power Factor Average
 Load, L1,L2,L3 (KVAr)
 Total Load (KVAr)
 Load (KWh / KVAh / KVArh)

5.4.3 Mains Instruments

 Volts, L1-N，L2-N, L3-N (V)

 Volts, L1-L2，L2-L3，L3-L1 (V)
 Frequency (Hz)

5.4.4 Alarms and Event Log

 Alarm
Alarms include warnings, shutdowns, electrical trips.

 Event log
The 7320 module log is capable of storing the last 250 log entries. This function assists the user to find
the faults and maintain a generator set.
To view the event log, repeatedly press the next page button until the LCD screen displays the
event log.

5.4.5 Others Functions

 Panel lock key

It is used to provide security to the service or operation. If the Panel lock key is active, the module
will not respond to operation of the mode select or start buttons, but the emergency stop button
and navigation buttons can still be in normal used.

 Audible alarm
When an alarm is present, both the DSE7320 module and buzzer will sound. The audible alarm
can be silenced by pressing the Mute button.

 Communication ports
The control system includes USB, RS232 and RS485 ports.

USB Port for connection to PC running DSE configuration suite only Max distance 6m (20 feet).

RS232 is for short distance communication and is typically used to connect the DSE7320
controller to a telephone or GSM modem for more remote communications.

The RS485 port supports the Modbus RTU protocol. RS485 is used for point to point cable
connection of more than one device and allows for connection to PCs, PLCs and Building
Management Systems.
- 17 -
5.4.6 Safety Protections

The basic protections are as follows.

 Low Oil Pressure Shutdown
 High Coolant Temp. Shutdown
 Fail to start
 Emergency stop
 Under / over speed
 Under / over voltage
 Under / over frequency
 Over Current
 Fail to charging
 Under / over battery voltage

5.4.7 Display Languages

Text based LCD display supports multiple languages.

The display language of DSE7320 is configured by the language editor in the software.The language
Editor is included to allow the user to tailor the text of the DSE7320 controller to suit their own
requirements.
Configurable language files have the following kinds:
 Chinese
 Dutch
 Spanish
 English (USA)
 French
 German
 Italian
 Polish
 Portuguese
 Swedish
 Thai
 Turkish

NOTE:
We recommend customers to use the international common language: English.

- 18 -
Remarks:
.
 DSE7320 includes over current , overload and short circuit function for MCCB trip.
Overcurrent or short circuit can trip MCCB and then cool down for the protection of alternator.
Overload can also trip MCCB and then cool down for the protection of engine.

For example: when the generator sets is in overload, coolant temperature, oil temperature and
exhaust temperature will rise rapidly. If the engine does not cool down, high temperature will
cause damage to the parts of engine.

 DSE7320 includes PLC new function.

It is convenient that we can keep no change of wiring diagram. We can flexibly change the
software to realize the special requirements.
Komatsu uses PLC function for "common shutdown" and "common electrical trip". We have
tested the function of PLC and it exposes no problem.

- 19 -
 6. OPTIONAL COMPONENTS
Optional items are shown in table 6-1 below
6-1：Optional parts list

NO. PARTS NAME ICONS FUNCTION

This trimmer is for fine tuning of

generator set voltage. This trimmer
1 Voltage Trimmer
is connected to the Auto Voltage
Regulator (AVR) of an alternator.

This trimmer is for fine adjustment of

Speed engine speed. This trimmer is
2
Trimmer connected to the Electronic Speed
Controller.

This switch is for fine adjustment of

engine speed. This switch is connected
3 Speed Switch
to the DC Electrical Motor for lever
adjustment of Mechanical Governor.

4 Battery Charger Only for battery charging

N L

- 20 -
NO. PARTS NAME ICONS FUNCTION

Electronic Automatically adjust the

5 Speed engine speed, and keep a
Controller. constant speed.

Auxiliary startup parts in

low temperature. Low
6 Air Heater
Temperature environment
for air heating.

Auxiliary startup parts in

low temperature. Low
7 Jacket Heater
temperature environment
for water heating.

Used in easy
condensation sites, damp
Anti
places or places where
Condensation
8 temperature difference is
Heaters
bigger. To prevent the
destruction of generator
insulation.

- 21 -
 7. OUTPUT TERMINALS

7.1 3-Phase 4-Wires Output Terminals

Figure 8-1, 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.

A B C N
(R)(Y)(B) (N)

Figure 7-1 MCCB Box

Figure 7-2 Open Type Figure 7-3 BS Type

Figure 7-2 is MCCB position of open type; Figure 7-3 is MCCB position of 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.

- 22 -
7.2 Load Connection

Before starting, please carefully confirm the load voltage, and load cable should be connected to the
output of the circuit breaker. Refer to figure 7-4.
Note:
 Cable joint must be bolted tight to prevent overheating which may lead to cable damage or fire!
 When connecting the load, the generator set must be in stop state, and the circuit breaker should
be placed in “OFF” position.

A B C N

LOAD
(R) (Y) (B) (N)
A B C N

Figure 7-4 Load Connection

7.2.1 Connection of Single-Phase Load

When connecting a single-phase load, such as a electric lamp, a single-phase induction motor or a
welding machine, refer to figure 7-5 for the connection.

A B C N

Figure 7-5 Connection of Single-Phase Load

★ When connecting a single-phase load, ensure that the load is equally distributed among the
three phases.

- 23 -
7.2.2 Connection of Two-Phase Load

Connection as shown in figure 7-6; for example, according to A-B, B-C, C-A (or R-Y, Y-B, B-R) way to
connection.

A B C N

Figure 7-6 Connection of Two-Phase Load

7.2.3 Connection of 3-Phase Load

When connecting a 3-phase load, such as a 3-phase induction motor, refer to figure 7-7 for the
connection.

A B C N

Figure 7-7 Connection of 3-Phase Load

★ The amount of loads that can be connected depends on the rated current of the generator
set.
★ When connecting the cables from A(R), B(Y) and C(B) terminals to a 3-phase induction
motor, the motor may rotate in a wrong direction. In this case, swap any 2 (two) cables at
A(R), B(Y) and C(B) terminals.

7.3 Methods of Connecting Load Cable Terminals

When connecting the power cables to the terminals, secure it tightly and firmly.
Refer to figure 7-8.

- 24 -
 Figure 7-8 Connection Methods

7.4 Precautions for Connecting Loads

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

- 25 -
 8. THE OPERATION OF GENERATING SET

8.1 Check Before Starting

Daily inspection is essential to maintain the diesel engine generator set in a reliable operating
condition.
a) Check Leakage of Water or Oil
Inspect around generator set for evidence of oil and water leakage. If any leakage is found,
locate the cause of leaking and repair immediately before operation. Contact KOMATSU
distributor service if help is required.
b) 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.
c) Check and Refill Coolant

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.
d) Check Oil Level in Engine Oil Pan


 Use Dipstick ① to check oil level.
 The oil level should be within marking L and H.
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.

- 26 -
 ★ When checking the oil level, park the generator set on a level ground.
★ Carry out oil level check before the engine starts up, or, 15 minutes or more after the engine
stops. If oil remains at various portions of the engine, an accurate oil level can not be
measured.
e) 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 cleaning methods. After cleaning, push the button
to reset the dust indicator.
f) Check Electrical Wiring
 Check for any sign of disconnection or short circuit in the electrical wiring.
 Check for loose terminals and proceed to tighten if necessary.
 Check the following items carefully.
- Battery
- Starting Motor
- Alternator
 Please contact KOMATSU distributor for investigation or rectification if necessary.

If there is any sign of short circuit in the electrical wiring, always investigate the cause and
rectify it.
g) Check Air Intake
 Check and ensure no blockage to the fresh air intake to the generator room.
 Check and ensure no blockage to the fresh air intake to the alternator.

8.2 Single Operation

a) Before Starting Generator Set

Install the generator set on a level foundation, then check the position of the circuit breaker.

The MCCB is
mounted
inside the
canopy.
Turn OFF

Open Type（Busbar Terminal Box） BS Type （Busbar Terminal Box）

 Whether initial inspection has been carried out before operation?

(Refer to section "Check Before Starting" for details)
- 27 -
  Whether the handle of the MCCB circuit breaker is at the OFF position?
 Whether the power cables are firmly connected to the busbar inside the terminal box?
b) To Start the Generator Set
Before starting the generator set, ensure that the surrounding area is clear and suitable for
operation.

MCB1

MCB2

MCB3

MCB4

MCB5

MCB6

MCB7
RR ST SDR

Terminal block

Internal View of Generator Control Panel

 Turn on all MCB (1~7), descriptions of MCB are as follows.

MCB1～3：3-phase AC supply from Mains.
MCB4～6：R, Y and B-phase Generator Set AC Supply.
MCB7：Battery DC Supply.
 Turn the Key Switch to "OFF" position.
 Push the "Start" button (on the DSE 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.
c) After Starting Generator Set
If the engine is cold, carry out the following procedures before applying load.
 Run the engine at mid-range speed without load for 5 minutes.
 After the engine has warmed up, check if all engine measurements are normal at rated
speed.
 Check and ensure that there is no abnormal noise, vibration or black exhaust gas.
★ Continue to warm up the engine with light load until the water temperature reaches its
operating range, 70~90°C.
★ Avoid abruptly accelerating the engine until the warm-up period has 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.
d) Check Frequency and Voltage
The below should be the setting of generator set at no load.
RATED SPEED FREQUENCY ENGINE SPEED
50Hz/1500RPM 52.5 Hz 1575RPM
60Hz/1800RPM 63 Hz 1890RPM

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.
For electronic control units, no-load condition, the standard of frequency or speed, please meet
the following form parameters to adjust or calibration.

- 28 -
 RATED SPEED FREQUENCY ENGINE SPEED
50Hz/1500RPM 50 Hz 1500RPM
60Hz/1800RPM 60 Hz 1800RPM

e) Switch On the MCCB

After the rated Voltage and Frequency have been reached, switch ON the MCCB circuit breaker
to take load.

↑Turn ON

↓Turn OFF

f) To Stop the Generator Set

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

8.3 Manual Paralleling Operation(Optional)

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

并联操作系统属于可选配置。

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

- 29 -
  Make sure that all the MCCB and Breaker (A) at the load side are turned OFF.
 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.
 Turn ON the MCCB of this unit of generator set.
 Repeat Step 2 with second unit of generator set. Its speed and voltage must be similar to the
first unit.
 Turn the Speed Trimmer very slowly to such direction when the Synchronizing Lamps on the
second unit goes from Bright to Dim very slowly.
 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.
 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.
 Switch ON the Breaker (A) when paralleling operation is completed.
b) Stop of Paralleling Operation
 Switch OFF Breaker (A), then follow with the MCCB at each generator set.
 Allow each generator set to cool down for at least 3 minutes before shut it down.
c) Cautions
 To avoid failure or unstable operation, other EGS models or brands of generator set should
never be subjected to this paralleling operation.
 Turn the Single / Paralleling selector switch to Single position when it is not in use.

8.4 Operating Precautions

a) When Operating Outdoors

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

- 30 -
 9. 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.
 Block the hauling truck and secure tires with a wooden blocks to prevent movement.
 Use a crane to load the generator set in the specific position on the truck. Secure the generator
set with chains or wire ropes, then choke the skid base with wood to prevent it from sliding during
transportation. Be extremely careful to prevent it from shifting side to side.
★ When deciding the transportation route, take into account the road width, 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.

- 31 -
 10. 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 rewarded by
savings on smooth operation and operating cost.
All service hour figures given in this manual are based on the readings 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.

10.1 Maintenance Precautions

Even a simple maintenance procedure can cause injury if not carried out carefully. Observe the
following safety rules closely and develop a safe working habit.
 Wear a hamlet and safety shoes !
You may need a safety goggles, mask and ear plugs too.
 Wear close-fitting working clothes !
Loose clothing can get caught in the machine. Do not wear oil stained clothing, for it can
catch fire easily.
 Beware of harmful exhaust gas !
To operate engine indoor, a proper ventilation is required.
 Beware of flammable materials !
A burning cigarette or match is prohibited.
 Be prepared for emergency !
Know in advance whom to inform and what to do in case of fire and other accidents. Know
location and usage of fire extinguishers and first-aid kits.
 When working with a partner, keep him informed of what you are doing !
When working on a generator, always follow your supervisor's instructions.
 When servicing a generator with the engine running, work in pair !
If the generator must be serviced while the engine is running, one person should watch the
meters and gauges of the generator while the other person carries out the maintenance.
 Stop the engine while refueling !
Before cleaning or refueling the generator, always stop the engine. When adding oil or fuel,
do not let the oil or fuel overflow.
 Keep the alternator free from water and oil !
If water, steam or oil sticks to the alternator, it can cause an electrical leakage or poor
generation of power. If the alternator is wet, ask a specialist to measure insulation resistance
value.
 Never use an open flame for lighting !
Never try to check the level of oil, coolant, fuel or battery electrolyte by using an open flame
for illumination.
 Beware of rotating parts !
Never check the fan belt tension while the engine is running. Ensure that the engine is
stopped completely before checking any moving or rotating parts.

 Fix the generator on a level ground !

- 32 -
 Set the machine on a firm and level ground.
 Put up notice !
During maintenance, put up a "UNDER MAINTENANCE" tag on the Engine Control Panel
and the Synchronizing Panel.
 Keep the engine clean !
Keep dead leaves, waste paper and spilt oil away from the engine. These may cause fire and
then wipe off all spilt oil. Repair any fuel or oil leakage immediately.
 Do not use non-repaired generator !
Before running the generator, check it carefully and repair if necessary. Ensure that the
machine is free from defects.
 Keep unauthorized personnel out !
Do not allow any unauthorized personnel to come near or operate the generator set.
 Be alert for abnormalities while the generator is in operation !
If abnormal noise, vibration, heat, smell or unusual reading from an instrument is noticed,
stop the engine immediately and look for the cause of the trouble. Arrange for repairing if
necessary.
 Handle tools properly !
Ensure to use correct tools for the job.
 Disconnect the battery ground cable !
Before servicing the electrical system, make sure to disconnect the negative (-ve) cable from
the terminal.
 Consult us !
Special instruments may be required when measuring the insulation resistance of the
alternator and its link. In such case, consult the nearest Komatsu distributor.
 Environmental requirements!
After the generator set maintenance, do not leave behind the waste oil and batteries, etc.,
Please deal with them in accordance with the local regulations with regard to environmental
protection. We can not casually throw them away !

10.2 General Precautions

 Clean the lubricating oil filters, grease the nipples and oil the moving parts to prevent any
foreign particles from entering engine.
 Use genuine KOMATSU parts specified in the parts book when replacing parts.
 Use genuine KOMATSU lubricants. Select the required viscosity for the specific ambient
temperature.
 Always use a clean oil and grease in cleaning container to prevent entrance of foreign
particles.
 When adding fuel, prevent water from the drum head or bottom from mixing with the fuel.
 Check and replace oil at a dustless location to prevent entrance of dust.
★ Generally the oil and cooling water in the generator is hot after the engine stops. Do not
discharge the oil or water, or replace the filter until the temperature has dropped. On the
other hand, if the oil is cold, do not discharge the oil until it has been warmed up to 20°C
to 40°C.
 After cleaning or replacing the oil, filter element and strainer, bleed air from the circuit.
 If a strainer is provided at the oil filter, do not remove the strainer when adding the oil.
 Make sure the lubricating oil is neither excessive nor insufficient. Check if the oil level is
- 33 -
 proper at the time of inspection and replenish if necessary.
 When changing the oil or replacing the filters, inspect the discharged oil and oil filter to see
whether there is a large amount of metal powders or foreign particles.
 When any parts that use an O-ring or gasket seal is removed, clean the seal mounting
surface before replacing a new seal.
 When oil or cooling water is drained, attach a caution tag to the Engine Control Panel to
prevent any accidental starting by other operators.
 Wash parts in a non-combustible detergent or light oil. If light oil is used, keep fire away from
the operating area.
 When washing the machine, prevent water from splashing onto any electrical parts.
★ Use ordinary automobile washing fluid. Be careful not to let dirt or dust get in.
 While inspecting with the machine cover opened and your head down, things may
accidentally drop into the machine. Ensure the pocket is empty. Do not drop any wrench or
nut into the machine.
 During welding, be careful of the following :
1) Turn off the power supply (MCB).
2) Do not continuously apply more than 200V.
3) Connect the ground cable at 1m from the location to be welded.
4) Take care not to install any seals between the grounded point and the location to be
welded.

10.3 Maintenance Table for Generator Set

Please refer to the maintenance table on the next page to maintain generator set.

- 34 -
 Maintenance Table
PERIOD NO. ITEMS SERVICE PAGE
First 1 Mounting Bolts Check and Tighten
36
20 Hours 2 Cooling Circuit of Alternator Check
1 Fuel Filter Change Cartridge
First
2 Engine Oil Pan and Filter Change Oil and Cartridge 36
250 Hours
3 Engine Valve Clearance Check and Adjust
Every
1 Fuel Tank Drain Water and Sediment 36
50 Hours
1 Battery Electrolyte Check
2 Fan Belt Check and Adjust Tension
3 Alternator Belt Check and Adjust Tension
4 Insulation Resistance Check
Every
36
250 Hours Engine Oil Pan and Filter
5 (Except SAA6D125, SAA6D140 Change Oil and Cartridge
and SAA12V140 engines)

NOTE: Replace oil and cartridge every 250 hours or every 6 months.
1 Fuel Filter Change Cartridge
Engine Oil Pan and Filter
(SAA6D125, SAA6D140,
Every 2 Change Oil and Cartridge
SAA6D170E and SAA12V140 38
500 Hours engines only)
3 Radiator Fins Check
NOTE: Replace oil and cartridge every 500 hours or every 6 months.
1 Mounting Bolts of Turbocharger Check and Re-tighten
Every
2 Corrosion Resistor Replace Cartridge 40
1000 Hours
3 Actuator Linkage Apply Grease
1 Rotor Play of Turbocharger Check
2 Turbocharger Check and Clean
Every
3 Engine Breather Clean 41
2000 Hours
4 Alternator and Starting Motor Check
5 Engine Valve Clearance Check and Adjust
Every 1 Water Pump Clean
42
4000 Hours 2 Engine Vibration Damper Clean
1 Cooling System Clean and Change
2 Air Cleaner Element Check, Clean or Change
3 Cooling Circuit of Alternator Check and Clean
When
4 Alternator Body Clean 42
Necessary
5 Bearings of Alternator Apply Grease or Change
6 Alternator Winding Clean
7 Engine Control Panel Check and Clean
- 35 -
10.4 Detailed Description of Maintenance Items

a) First 20 Hours Service

Checking for the first 20 hours of operation.
 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.
 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.

b) First 250 Hours Service

For new engine and its first 250 hours service, carry out the following maintenance.
 Fuel Filter
For the details of replacing methods, see the section on "Every 500 Hours Service".
 Engine Oil Pan and Filter
For the details of replacing methods, see the section on "Every 500 Hours Service".
 Engine Valve Clearance
Request KOMATSU distributor to check this engine valve clearance because special tools
need to be used.

c) Every 50 Hours Service

For new engine and its first 250 hours service, carry out the following maintenance.
 Fuel Tank (Skid Base)
Remove the Drain Plug ①located at the side of skid base to drain water and sediment
accumulated at the bottom of the fuel tank.

d) Every 250 Hours Service

Maintenance for every 250 hours of operation.
 Battery Electrolyte

- 36 -
 Remove the Cap ① and 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 electrolyte supply. Handle the battery electrolyte
with care.
When the electrolyte drips 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.

 Fan Belt

1) The belt tension should be 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) Loosen Nut ① and turn the Tension Pulley Adjustment Bolt ② to adjust the belt
tension.
3) After adjustment, tighten Nut ① and 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.

 Alternator Belt

- 37 -
 1) The belt tension should be 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) Loosen Bolt ① and Nut ②. Then, shift the angle of Alternator ③ slightly to adjust
the belt tension.
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 prevent damage to the core.

 Insulation Resistance
Disconnect those wires from the output terminals of engine alternator. 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.

 Engine Oil Pan and Filter

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

e) Every 500 Hours Service

Maintenance for every 250 hours service should be carried out at the same time.

 Fuel Filter

1) Remove the Cartridge ① of Fuel Filter by turning the Filter Wrench counterclockwise.
2) Clean the filter holder, coat the thread surface of the new Filter Cartridge with engine
oil before installation.

★ For installation, turned the cartridge until its top surface comes in contact with the
seal of filter holder. Then, tighten it with another 3/4 to 1 of a turn.

- 38 -
 3) After finishing 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.

 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 turning the Filter Wrench
counterclockwise.
3) Clean the filter holder, coat the thread surface of the new Filter Cartridge with engine
oil before installation.

★ For installation, turn the cartridge until its top surface comes in contact with the
seal of filter holder.

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

5) After finishing replacing the cartridge ①, top up the engine oil through the Oil Filler
(F).

6) 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.

- 39 -
 ★ Use the API category CD class of oil. If a CC class of oil must be used, change the oil
and replace the filter at half of the interval.

 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 fragility. Replace the hose if necessary.
Check the Hose Clamps. Tighten them if necessary.

f) Every 1000 Hour Service

Maintenance for every 250 and 500 hours should be carried out at the same time.

 Mounting Bolts of Turbocharger

Check the tightening torque of turbocharger mounting bolts.
Contact KOMATSU distributor for servicing if necessary.
TIGHTENING
NO. PART NAMES REMARK
TORQUE
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
0.8 - 1.0 kgm PT1/4 Bolt
4 Turbocharger oil feed pipe (Inlet Line)
2.8 - 3.5 kgm M8 Bolt
5 Turbocharger oil feed pipe (Outlet Line) 6.5 - 7.5 kgm

 Corrosion Resistor

1) Close the Valve ② at the top of Corrosion Resistor ①.

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

★ For installation, turn the cartridge until its top surface comes in contact with the seal of
filter holder. Then, tighten it with another 3/4 to 1 of a turn.
★ Make sure to use genuine KOMATSU parts.

- 40 -
  Actuator Linkage
Apply grease to the Ball Bearings of the Actuator Linkage.

g) Every 2000 Hour Service

Maintenance for every 250, 500 and 1000 hours should be carried out at the same time.

 Rotor Play of Turbocharger

The Turbocharger can be checked by using the following instructions, or to be inspected by
Komatsu distributor.
Remove the intake pipe, exhaust pipe and hose from the Turbocharger.

DIRECTION OF STANDARD
NO. METHOD
PLAY VALUE
Move the Rotor and check for
1 Axial Direction 0.08 - 0.18 mm
Rotor play in the axial direction.
Move the tip of the Blower Shaft in
2 Radial Direction the radial direction by hand to 0.25 - 0.60 mm
measure the radial play.

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

 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) Use light oil as cleaning agent and remove the carbon, sludge and other dirt from the
Blower Impeller. Do not use brush or other tool which may damage 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 for any contact noise or catching
inside. If the Impeller does not turn smoothly, contact KOMATSU distributor for repair
or replacement.
5) If there is no abnormality, dry off the light oil with compressed air after inspection. Then,
top up the engine oil.

- 41 -
  Engine Breather

1) Remove the Breather from the cylinder head.

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

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

 Alternator and Starting Motor

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

★ If the engine starts and stops frequently, carry out this inspection every 1000 hours.

 Engine Valve Clearance

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

h) Every 4000 Hour Service

Maintenance for every 250, 500, 1000 and 2000 hours should be carried out at the same time.

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

 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.

i) When Necessary
 Cooling System
Clean the cooling system, change the coolant and replace the Corrosion Resistor as
according to the below table.

- 42 -
★ 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 the use of river water, well water or other type of
water supply are needed, contact KOMATSU distributor for advice.

TYPE OF SOLUTION CLEANING SCHEDULE ACTION

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

When deciding the ratio between antifreeze and water, one has to check the lowest
temperature in the past. Then, decide the mixing ratio as according to the given table.

Mixing Ratio of Antifreeze and Water

Min. Atmosphere
-5 -10 -15 -20
Temperature ( °C )
Amount of Antifreeze
14 18 22 25
(Liter)
Amount of Water (Liter)
46 42 38 35
(Liter)

Actually, it is better to assume a temperature of about 10 °C lower for the mixing ratio.

★ Use a Density Gauge to measure and control the mixing proportion.

Corrosion Resistor Water Filler

1) Stop the engine and close Corrosion Resistor Valve ①.

2) Turn Radiator Cap ② slowly until it comes off.

- 43 -
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 to release the pressure. Then,
remove the cap.

Drain Valve Drain Valve

(Bottom of Radiator) (Cylinder Block)

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.
4) Drain off all the water and 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,
and 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.

6) After flushing with water, stop the engine. Close Drain Valve ③ and Plug ④ after
water has been 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 the marking on the Water
Filler.
9) When the water reaches the marking on the Water Filler, run the engine at low idling,
and 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 so that the radiator is always full.

10) When the water becomes completely clean, stop the engine, and close Drain Valve ③
and Plug ④.
11) Replace the Corrosion Resistor Cartridge and open the Corrosion Resistor Valve ①.
★ Refer to the Every 1000 Hours Service for details of replacement of the corrosion
resistor.

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

- 44 -
 this operation.)
14) Stop the engine for 3 minutes, refill water again up to the marking on Water Filler and
tighten the Water Filler Cap ②.

 Air Cleaner Element

Checking Air Cleaner

Whenever the Dust Indicator ① shows red region, clean the Air Cleaner Element.
Stop the engine before 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 occurs, replace the Inner Element too.
★ Both Outer Element and Inner Element need to be replaced when the Dust Indicator
shows red region soon after the installation of 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 clean. This is to monitor number of times
the Element has been cleaned by counting the number of removed Seals.

- 45 -
 Replacing Inner Element
1) Remove the Outer Element.
2) Remove the nut and take out the Inner Element.
3) Use a clean cloth or tape to 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

Direct a dry compressed air (less than 7 kg/cm2) 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, use a lighting bulb to check for small holes or thinner parts 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.

 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.

 Alternator Body
1) Cleaning the alternator by 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.

 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

- 46 -
 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 need to be carried out.
 Alternator Winding
Cleaning of the Stator, Rotor, Exciter and Diode Bridge must be carried out periodically
depending 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, making sure the alternator is rotating with the exciter
field disconnected.
3) Run in short circuit mode (disconnect the AVR):

Short out the three output power terminals by using connections capable of supporting
the rated current (try not to exceed 6 A/mm2).

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 with the right polarity.

Fully open all the alternator openings.

- 47 -
 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.

 Generator / Engine Control Panel

The generator must be disconnected from the common busbar while the following
maintenance are carried out.
1) Check the installation for abnormality of any kind, dirt and the effect of other
environmental influences.
2) Check if all wiring terminals are properly and firmly tightened.
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.

10.5 Maintenance for Synchronizing Panel (Optional)

a) 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, as well as 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 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.

b) Inspection and Servicing on Panels

The inspection should include but not be limited to the following:
 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.
 Check the installation for abnormality of any kind, dirt and the effect of other environmental
influences.
 Check all wiring terminals are properly and firmly tightened. Check that bolt connections at
the contact points in the breakers and busbar system are tight, and the isolating contact
system functions correctly.
 Check the function of switch equipment, and the controls, interlocks, protections,
annunciation and other devices by doing a simulation fault test.
 Check the surface condition of the isolating contact system in the busbar. Ensure that their
surfaces are not heavily corroded or do not show signs of other damage or overheating
(discolor surface); otherwise, replace the contact parts.
 Check all circuit breaker accessories and the auxiliary components.
 Note external discharge that may occur on the surfaces of component at operating voltage.
- 48 -
 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.
 Carefully clean the panel, the insulating material surfaces in particular, 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 by 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.
 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
apply the top coat after an appropriate hardening period.

c) Inspection and Servicing on Circuit Breaker

Before carrying out any maintenance work it is essential to follow the procedures below:
 Open the Circuit Breaker and check that the closing springs are discharged.
 Draw out the Circuit Breaker and work must only be carried out when they are withdrawn
from the enclosure.
 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 with relative time intervals between
maintenance works.

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

- 49 -
 11. APPENDIX

11.1 Fuel, Coolant and Lubricants

Proper selection of Fuel, Coolant and Lubricants

AMBIENT TEMPERATURE
TYPE OF
RESERVOIR 14 32 50 68 86℉
FLUID
-10 0 10 20 30℃

SAE30

SAE10W
Engine Oil Pan Engine Oil
SAE10W-30

SAE30
SAE15W-40

ASTM D975 NO.2

Fuel Tank Diesel Fuel
* *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:
a) 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

b) When starting the engine in an atmospheric temperature of lower than 0 ℃ or even through an
atmospheric temperature goes up 10 ℃ or less in the day time, make sure to use engine oil of
SAE10W, SAE10W-30 or SAE15W-40.
c) Use API classification CD as engine oil. If API classification CC is used, reduce the engine oil
change interval to half.
d) 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.
e) We recommend to use KOMATSU genuine oil which has been specifically formulated and
approved for use in engine and hydraulic work equipment applications.

- 50 -
11.2 Brand of Lubricants, Grease and Coolant

- 51 -
12.1 Circuit Drawing

- 52 -
12.2 EGS Terminal Wiring Diagram

- 53 -
Current transformer install instruction
1. Purpose
Control and regular current transformer (CT) install operation .

2. Material
Tie 200 x 4.5 mm black 22 PCS
Current transformer 3 PCS
M5 screw (with nut &spring washer) 6 sets
3. Work flow
a..Use two ties bind CT lead terminal. （Komatsu finished）
b. Use two ties bind CT together.one by one. (Komatsu finished)
c.Use two ties bind CT with power cable together.
Caution: Place each CT at correct position . It must keep enough space to
avoid CT contact terminal blot or bus bar. Vibration will scratch and
damage the CT insulator (See fig 3 and fig 4)
d.Use two ties bind CT with signal wire together. (Komatsu finished).

Two ties bind CT and power cable together

Fig 1 Ties bind CT terminal Fig 2 Connecting CT terminal to signal wire

Ties bind CT Bind CT and CT together
and signal wire

Fig 3 Good CT at Middle position Fig 4 Bad No space CT contact bus bar

- 54 -