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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.


Machine Serial Number

PC490-10 K60070, K60092, K60094, K60108 - K60110, K60157, K60165
PC490LC-10 80016, 80021 - 80023, K60001 - K60069, K60071 - K60091, K60093,
K60095 - K60107, K60111 - K60156, K60158 - K60164, K60166 - K60167



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


6526-01-0110 KDPF ASS'Y 1 Replacement
(6526-01-0010) (KDPF ASS'Y) (1)
208-06-41243 WIRING HARNESS 1 Replacement Chassis harness connected to
(208-06-41242) (WIRING HARNESS) (1) KDPF differential pressure sensor
600-481-1105 CONTROLLER A. 1 Replacement Replace software by recalibration
(600-481-1104) (CONTROLLER A.) (1) of controller using INSITE
6211-11-5490 GASKET 3 Replacement KDPF inlet piping: 2 pcs, outlet: 1
() () () pc.
6520-91-1030 GASKET 1 Replacement For KDPF inlet piping clamp
() () ()
6520-91-1020 CLAMP 1 Replacement KDPF inlet piping clamp
() () ()

3. Procedure

3.1 General precautions

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.

- Ensure the machine is located on flat level ground.

- Lower the work equipment to the ground and turn off the engine.
- Switch starting switch to ON position and lift Safety lock lever.
- Operate the work equipment control levers in all directions (2-3 full strokes) to
relieve pilot circuit pressures. Return Safety lock lever to LOCK position.

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3.2 For bolts that have no specific torque mentioned in this news please refer to the tightening
torque table.

Screw When a torque wrench is used When an impact wrench is used

diameter(mm) Range Kgm (Nm) Target Kgm (Nm) Range Kgm (Nm) Target Kgm (Nm)
6 1.2-1.5 (11.8-14.7) 1.35 (13.2) 0.9-1.5 (8.8-14.7) 1.2 (12)
8 2.8-3.5 (27-34) 3.2 (31) 1.5-3.5 (14.7-34) 2.5 (25)
10 6.0-7.5 (59-74) 6.7 (66) 3.5-7.5 (34-74) 5.5 (54)
12 10-12.5 (98-123) 11.5 (113) 5.5-12.5 (54-123) 9.0 (8.9)
14 15.5-19.5 (153-190) 17.5 (172) 8.5-20 (84-196) 14.0 (137)
16 23.5-29.5 (235-285) 26.5 (260) 15-31.5 (147-309) 23.5 (230)
18 33-41 (320-400) 37 (363) 20.5-43.5 (201-427) 32.0 (315)
20 46.5-58 (455-565) 52.2 (512) 32.5-62.0 (319-608) 47.0 (460)
22 62.5-78 (610-765) 70.2 (688) 48.0-84.5 (471-829) 66.5 (650)
24 80-100 (785-980) 90 (882) 60.0-105 (588-1030) 82.5 (810)

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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.

1-1. Symptoms of Failure

No.   Phenomenon

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.
・ 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

If KDPF regeneration interval displayed on KOMTRAX screen is regularly less than 8 hours,
phenomenon "A" or "B" above probably occurs.
In this case, you may perform inspection and modification in advance, according to this Service

Perform modification when any of phenomena A to C occurs.

Replace the KDPF assembly and wiring harness as a set and recalibrate engine controller, as
described later.
When KDPF cleaning is carried out at 4500-hour service, replace the wiring harness and recalibrate
the engine controller at the same time.
For details, see Procedure 3 (P16 of 31) and Procedure 4 (P17-18 of 31).

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1-2. Contents of Improvement

(1) Improvement of KDPF (Contents of change are described)

Internal structure of Komatsu Catalyzed Soot

Identification mark "A" is added
Filter is changed

Orifice is added to inlet

Differential pressure sensor is replaced with more (to match pressure loss to
accurate出口one (Connector is changed) current condition)

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

Inlet Inlet

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.

・ Change of part nos. of KDPF and KCSF

Part name Current part No. New part No.
KDPF A. 6526-01-0010 6526-01-0110
KCSF A. 6526-31-1010 6526-31-1110
・ Addition of identification mark to new KCSF

6 Addition of identification mark

"A" to body of KCSF of new KDPF


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1-2. Contents of Improvement

(1) Improvement of KDPF (continued)

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


New Shape

(2) Improvement of engine controller (hereinafter referred to as ECM)

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)

 2-2. Change to improved KDPF

[Procedure 2] See Removal and Installation Procedure for KDPF assembly
The removal and installation procedure for KDPF assembly is described on pages 14 to 15.

[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.

[Procedure 3] See Replacement procedure for wiring harness installed to KDPF

 2-3. Change to improved ECM

<1> When rewriting engine controller software
・ See "Komatsu ECM calibration procedure through Cummins INSITE.
・ After rewriting the engine controller software, check that Shop Manual, Chapter 30, Testing and
adjusting, Electrical equipment, Setting and operation of machine monitor, Table of self-define
monitoring, "No. 20217 Engine controller data version" is the part no. of new software (No.
without "600").

<2> When replacing ECM

[Procedure 4] See Shop Manual, Chapter 50, Disassembly and assembly, Electrical equipment,
"Removal and Installation of Engine Controller Assembly"
[Procedure 5] See Shop Manual, Chapter 30, Testing and adjusting, Engine and cooling system,
"Writing Injector Compensation Value into Engine Controller"

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Procedure [2] Removal and Installation of KDPF Assembly (1/2)

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Procedure [2] Removal and Installation of KDPF Assembly (2/2)


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Procedure [3] Replacement Procedure for Wiring Harness Installed to KDPF (1/1)

Replace wiring harness connected to KDPF

 1) Remove current wiring harness (1). 4


1 3

1 WIRING HARNESS 208-06-41242

2) Install new wiring harness (2)
2 WIRING HARNESS 208-06-41243
Install the new wiring harness similarly to the
current one, since the difference between
them is only the shape connector.

1] Install the 7 harness clamps according to the

following figure.
2] Connect main harness connector (3) to the
main harness.
3] Connect KDPF temperature sensor connector
(4) to temperature sensor centralised box (5).

4] Connect KDPF pressure sensor connector (6)

to differential pressure sensor (7).

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Procedure [4] Removal and Installation of Engine Controller Assembly (1/2)

NOTE: Engine Controller should be recalibrated using INSITE. If INSITE is not available, contact KUK.

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Procedure [4] Removal and installation of engine controller assembly (2/2)

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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)