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COMPONENT AQ
NEWS
SUBJECT: Improvement of Komatsu Diesel Particulate Filter (KDPF) and Engine
Controller for PC490-10 to prevent frequent regeneration.
PURPOSE: To detail the procedure to follow in the event of frequent regeneration due to
abnormal ash accumulation in the KDPF.
APPLICATION:
FAILURE CODE: AQ 00 R7
DESCRIPTION:
1. Introduction
Ash may accumulate abnormally in the KDPF, and accordingly a caution or a failure code may
occur. If KDPF regeneration failure occurs, modify the KDPF and Engine Controller according
to this Parts and Service News.
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2. List of parts
3. Procedure
Safety Notes:
Please read and comply with the relevant “SAFETY MAINTENANCE INFORMATION”
contained within the machine Operation and Maintenance Manual:
Warning: Engine components may be hot. Allow engine to cool prior to beginning work.
The hydraulic system is always under internal pressure, therefore when inspecting or replacing
the piping or hoses, always release the pressure in the circuit before starting. If the pressure is
not released, high pressure oil may spurt out and cause serious personal injury.
The parts and oil are at high temperature after the engine is stopped, and may cause serious
burns. Wait for the temperature drop before starting the operation.
When the oil filler cap is removed, oil may spurt out, therefore turn the cap slowly to release
the pressure before removing the cap.
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3.2 For bolts that have no specific torque mentioned in this news please refer to the tightening
torque table.
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1. Outline
When any of the phenomena in 1-1 related to Komatsu Diesel Particulate Filter (KDPF) occurs in
PC490-10, modify according to this Parts & Service News.
Failure code CA1691 (L03: Ineffective Regeneration), CA1921 (L03: KDPF Soot Level High Error
1), or CA1922 (04: KDPF Soot Level High Error 2) is displayed on the monitor, and the failure
A cannot be solved by "Remedy" described in Shop Manual.
* When any of the above failure codes is displayed, the buzzer sounds and the engine
output is limited.
CA2637 (L0: KDOC Face Plugging) or CA2639 (L0: Manual Stationary Regeneration Request) is
frequently displayed on the monitor.
* The above alarm is a report from the machine to the operator, which indicates the following;
・ CA2637 indicates that the operation mode to dry KDOC is selected.
B
・ CA2639 indicates the request for manual stationary regeneration.
If "CA2639" is displayed again within 8 hours after performance of manual stationary regeneration
in accordance with "CA2639", perform the inspection and modification introduced in this Service
News.
If KDPF regeneration interval displayed on KOMTRAX screen is regularly less than 8 hours,
phenomenon "A" or "B" above probably occurs.
C
In this case, you may perform inspection and modification in advance, according to this Service
News.
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The ash accumulation level is calculated inside the engine controller from the differential pressure
between inlet and outlet pressures of Komatsu Catalyzed Soot Filter (hereinafter referred to as KCSF)
in KDPF and gas flow rate.
The rear end of passage on exhaust gas inlet side is sealed to accumulate soot and ash inside KCSF.
When the soot and ash are accumulated to a certain level, the engine controller requests automatic or
manual regeneration to burn the soot. As a result, only the ash is accumulated densely at the inside
rear end of KCSF.
This time, the passage area on exhaust gas inlet side of KCSF is increased without changing the whole
size to increase the capacity to accumulate the ash and reduce differential pressure rise inside KCSF
caused by the ash.
Current New
Wide
Inlet Inlet
Narrow
Outlet
Outlet
Capacity to accumulate soot and ash is
increased by increasing volume of inlet cell.
After the above change, the following has been changed or added:
<1> Change of part no. of new KDPF for distinction from the current one.
<2> Change of part no. of new KCSF and add identification mark "A" on the body surface of new KCSF.
A
8
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The differential pressure between inlet and outlet of the new KCSF when soot and ash are
accumulated inside it is lower than that of the current KCSF because of the structure change of KCSF.
To maintain the differential pressure accuracy, the differential pressure sensor is replaced with a more
accurate one. Since the shape of connector is also changed, the wiring harness must be replaced at
the same time.
Outle Change of shape of connector
Current
Shape
New Shape
Since the relationship between the KCSF inlet/outlet differential pressure and soot + ash accumulation level
in the new KDPF is different from that in the current KDPF, both the current KDPF and engine controller
software must be replaced as a set.
If only either KDPF or engine controller software is replaced, KDPF may break down. Accordingly, be sure
to replace them as a set.
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2. Modification Procedure
2-1. About troubleshooting performed when KDPF and ECM are replaced with improved ones
The following 3 items are possible causes of frequent regenerations.
<1> Excessive soot flows in from the engine (gas leakage in air intake system, clogged air cleaner, etc.)
<2> Differential pressure in KCSF is high (Effect of ash, fuel or oil used, etc.)
<3> Soot combustion is poor (including ineffective regeneration due to working condition of machine)
The countermeasure introduced here is effective when "<2> Differential pressure in KCSF is high" is
affected by ash.
[Procedure 1] When changing KDPF and ECM to new ones, be sure to perform check and
countermeasures according to the troubleshooting when KDPF regeneration occurs
frequently, "Troubleshooting flowchart when KDPF regeneration occurs frequently".
(Note: this will be supplied separately as a PDF file)
[Procedure 6] When replacing KDPF assembly, you are required to remove and install KDPF inlet
piping. At this time, KDPF inlet piping bellows may be cracked. Check the bellows for
cracks before replacing KDPF assembly.
If the bellows has any crack, replace it with an improved one and modify according to the procedure in
[Procedure 6].
This Parts & Service News describes the adjustment and assembly procedure for KDPF inlet piping
and KDPF assembly.
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6211-11-5490
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Procedure [3] Replacement Procedure for Wiring Harness Installed to KDPF (1/1)
6
7
1 3
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Procedure [5] Writing Compensation Values at Replacement of Injector and Engine Controller (1/4)
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Procedure [5] Writing Compensation Values at Replacement of Injector and Engine Controller (2/4)
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Procedure [5] Writing Compensation Values at Replacement of Injector and Engine Controller (3/4)
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Procedure [5] Writing Compensation Values at Replacement of Injector and Engine Controller (4/4)
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