AA16065 - Komatsu Extranet

1 COMPONENT CODE AQ. PARTS & SERVICE REF NO. AA16065 . DATE August 5, 2016. NEWS Page 1 of 35. 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 Excavator PC490LC-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 OR HIGHER. NOTE: IN ORDER TO REPROGRAM THE MACHINE YOU MUST. INSTALL AN HAC FILTER. IF YOU INSTALL AN HAC FILTER YOU.

2 MUST REPROGRAM THE MACHINE. 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 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.

3 OYAMA PLANT SENDS THE PARTS. Part No. Part Name Purpose of Part Q'ty Remarks REPLACE WHEN. 6526-01-0110 KDPF ASS'Y 1 CONTROLLER IS. Replacement (6526-01-0010) (KDPF ASS'Y) (1) CHANGED TO NEW. ONE. AA16065 . Page 2 of 35. Part No. Part Name Purpose of Part Q'ty Remarks REPLACE WHEN. 208-06-41243 WIRING HARNESS 1 CONTROLLER IS. Replacement (208-06-41242) (WIRING HARNESS) (1) CHANGED TO NEW. ONE. REPLACE WHEN. 600-481-1105 CONTROLLER A. 1 CONTROLLER IS. Replacement (600-481-1104) (CONTROLLER A.) (1) CHANGED TO NEW. ONE. REPLACE WHEN. 6211-11-5490 GASKET 3 CONTROLLER IS. Replacement () () () CHANGED TO NEW. ONE. REPLACE WHEN. 6520-91-1030 GASKET 1 CONTROLLER IS. Replacement () () (1) CHANGED TO NEW. ONE. REPLACE WHEN. 6520-91-1020 CLAMP 1 CONTROLLER IS. Replacement () () (1) CHANGED TO NEW. ONE. REPLACE WHEN. 6252-81-2110 PLATE 1 CONTROLLER IS. Replacement () () (1) CHANGED TO NEW.

4 ONE. REPLACE WHEN. 04418-02550 SCREW 4 CONTROLLER IS. Replacement () () () CHANGED TO NEW. ONE. REPLACE WHEN. 6252-81-2120 PLATE 1 CONTROLLER IS. Replacement () () (1) CHANGED TO NEW. ONE. AA16065 . AA16065 3/35. 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 the nameplate 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). AA16065 4/35. AA16065 5/35. AA16065 6/35. AA16065 7/35. AA16065 8/35. AA16065 9/35. AA16065 10/35. AA16065 11/35. AA16065 12/35.

5 AA16065 13/35. Modification procedure (For Tier 4 Interim Only). Ash correction procedure when engine controller is modified (The procedure in paragraph 2-4 is not necessary if the KDPF is replaced to new one or cleaned one free from ash at the same time as ECM update.). 1. Purpose For the improved ECM, a new function is added to estimate "ash level estimation" (the level of ash accumulated in KDPF) for more precise control of soot accumulation and burn by filter change. As ECM requires the "ash level estimation" data, the data have to be installed in new ECM when it is updated. (It is not necessary to a new KDPF as no ash accumulation.). AA16065 14/35. AA16065 15/35. Modification Procedure (For Tier 4 Final Only). AA16065 16/35. AA16065 17/35. AA16065 18/35. AA16065 19/35. AA16065 20/35. AA16065 21/35. AA16065 22/35. AA16065 23/35. AA16065 24/35. AA16065 25/35. AA16065 26/35.

6 AA16065 27/35. AA16065 28/35. AA16065 29/35. AA16065 30/35. AA16065 31/35. AA16065 32/35. AA16065 33/35. AA16065 34/35. AA16065 35/35.