SUBJECT: IMPROVEMENT OF KOMATSU DIESEL PARTICULATE FILTER (KDPF) AND ENGINE CONTROLLER FOR PC490LC-10 INTERIM TO PREVENT FRE-QUENT REGENERATION CAUSED BY ABNOMAL ASH ACCUMULA-TION

PURPOSE: To inform field personnel.

APPLICATION: Komatsu Hydraulic ExcavatorPC490LC-10: A40001-A40870

FAILURE CODE: AQ00R7

DESCRIPTION: ASH MAY ACCUMULATE ABNORMALLY IN KDPF, AND ACCORD-INGLY A CAUTION OR A FAILURE CODE MAY OCCUR. IF KDPF REGENERATION FAILURE OCCURS, MODIFY KDPF AND THE ENGINE CONTROLLER SOFTWARE ACCORDING TO THIS SERVICE NEWS. IN CONJUNCTION PLEASE PERFORM PSN AA16074. YOU DO NOT NEED TO CHANGE ENGINE CONTROLLER, YOU ONLY NEED TO PROGRAM USING INSITE VERSION 8.1.4 OR HIGHER.

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COMPONENT CODE

PARTS & SERVICENEWS

REF NO.

DATE

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Machine Preparation

1. Park the machine on a flat level surface and lower work equipment to the ground.

2. Shut off engine and cycle controls to remove residual work equipment circuit hydraulic pressure.

3. Engage parking brake and block any tracks or wheels.

4. Set the frame lock bar.5. Remove the key from the ignition switch and turn the battery disconnect switch (located inside

the R.H. battery box front door) to the OFF position until work is complete.

6. Place a tag on the steering controls advising “This machine is being repaired. Do Not Start or

move this machine for any reason until this tag is removed by the repair person who placed it”.

WARNING! Observe safety standards dictated by work conditions under which equipment will be inspected, reworked, and repaired. Consult appropriate Operation and Maintenance Manual, Shop Manual, and Komatsu District Service Manager with all safety questions.

OYAMA PLANT SENDS THE PARTS.Part No. Part Name Purpose of Part Q’ty Remarks

6526-01-0110(6526-01-0010)

KDPF ASS’Y(KDPF ASS’Y) Replacement 1

(1)

REPLACE WHEN CONTROLLER IS

CHANGED TO NEW ONE.

AQ

August 5, 2016

NOTE: IN ORDER TO REPROGRAM THE MACHINE YOU MUST INSTALL AN HAC FILTER. IF YOU INSTALL AN HAC FILTER YOU MUST REPROGRAM THE MACHINE.

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208-06-41243(208-06-41242)

WIRING HARNESS (WIRING HARNESS) Replacement 1

(1)

REPLACE WHEN CONTROLLER IS

CHANGED TO NEW ONE.

600-481-1105(600-481-1104)

CONTROLLER A.(CONTROLLER A.) Replacement 1

(1)

REPLACE WHEN CONTROLLER IS

CHANGED TO NEW ONE.

6211-11-5490()

GASKET() Replacement 3

()

REPLACE WHEN CONTROLLER IS

CHANGED TO NEW ONE.

6520-91-1030()

GASKET() Replacement 1

(1)

REPLACE WHEN CONTROLLER IS

CHANGED TO NEW ONE.

6520-91-1020()

CLAMP() Replacement 1

(1)

REPLACE WHEN CONTROLLER IS

CHANGED TO NEW ONE.

6252-81-2110()

PLATE() Replacement 1

(1)

REPLACE WHEN CONTROLLER IS

CHANGED TO NEW ONE.

04418-02550()

SCREW() Replacement 4

()

REPLACE WHEN CONTROLLER IS

CHANGED TO NEW ONE.

6252-81-2120()

PLATE() Replacement 1

(1)

REPLACE WHEN CONTROLLER IS

CHANGED TO NEW ONE.

Part No. Part Name Purpose of Part Q’ty Remarks

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Perform modification when any phenomena A to C occurs. (Service News category:A3)Replace the set of new KDPF assembly, new engine controller, and new wiring harness as described later.Perform FN15049B MAF sensor drift procedure for MAF sensor judgement.When the machine is in conformity with Stage IIIb Regulations (EU only), replace thenameplate as well.When KDPF is replaced to wash ash after 4500-hour operation, new KDPF is supplied.At this time, replace the new engine controller and new wiring harness as well.For details, see 4 (P5)

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Modification procedure (For Tier 4 Interim Only)

1. PurposeFor the improved ECM, a new function is added to estimate "ash level estimation" (thelevel of ash accumulated in KDPF) for more precise control of soot accumulation andburn by filter change. As ECM requires the "ash level estimation" data, the data have tobe installed in new ECM when it is updated. (It is not necessary to a new KDPF as no ashaccumulation.)

Ash correction procedure when engine controller is modified (The procedure in paragraph2-4 is not necessary if the KDPF is replaced to new one or cleaned one free from ash at the same time as ECM update.)

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Modification Procedure(For Tier 4 Final Only)

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