4 hours ago
When a Komatsu PC220LC-6 displays error code E-02 and repeatedly blows its front 10A fuse, the root cause often lies in a shorted solenoid coil or damaged wiring within the hydraulic control system. This issue disables swing and throttle functions, leaving the machine stuck at idle and unable to operate normally.
Komatsu PC220LC-6 Overview
The PC220LC-6 is a mid-size hydraulic excavator produced by Komatsu in the 1990s, widely used in earthmoving, demolition, and utility trenching. It features a fully hydraulic control system, electronic monitoring, and a choice of Komatsu or Cummins diesel engines. The LC designation refers to its long carriage, offering improved stability for heavy digging.
Komatsu, founded in Japan in 1921, is one of the world’s largest construction equipment manufacturers. The PC220 series has sold tens of thousands of units globally, with the -6 generation known for its mechanical reliability but limited diagnostic capabilities compared to newer models.
Terminology Notes
The E-02 code appeared after the front 10A fuse blew, disabling swing and throttle functions. Previous repairs had addressed a naked wire on the fuel solenoid, and a toggle switch was added to bypass the monitor. However, the fuse continued to blow even with the solenoid unplugged.
Further testing revealed that unplugging the two-stage relief solenoid valve stopped the fuse from blowing and restored full function. This narrowed the fault to the coil of the solenoid itself.
Testing and Replacement Strategy
In Tennessee, a contractor traced the E-02 fault to the relief solenoid coil after extensive trial and error. Replacing the coil restored swing and throttle instantly. He noted that Komatsu dealers often recommend full valve replacement, but independent sourcing saved over $1,000.
In Indiana, a mechanic found that a failed diode downstream of the coil caused intermittent fuse failure. After locating the diode near the monitor harness and replacing it, the machine ran without issue.
Recommendations for Technicians and Owners
The E-02 error on a Komatsu PC220LC-6 is a classic example of how a small electrical fault can disable major hydraulic functions. With methodical testing and targeted replacement, the issue can be resolved without full valve or monitor replacement. For owners of legacy Komatsu excavators, understanding the interplay between solenoids, fuses, and diodes is key to keeping machines productive and repair costs manageable.
Komatsu PC220LC-6 Overview
The PC220LC-6 is a mid-size hydraulic excavator produced by Komatsu in the 1990s, widely used in earthmoving, demolition, and utility trenching. It features a fully hydraulic control system, electronic monitoring, and a choice of Komatsu or Cummins diesel engines. The LC designation refers to its long carriage, offering improved stability for heavy digging.
Komatsu, founded in Japan in 1921, is one of the world’s largest construction equipment manufacturers. The PC220 series has sold tens of thousands of units globally, with the -6 generation known for its mechanical reliability but limited diagnostic capabilities compared to newer models.
Terminology Notes
- E-02 Error Code: A fault indicator on the monitor panel, typically triggered by electrical failure in the hydraulic control circuit.
- Fuel Solenoid: An electrically actuated valve that controls fuel flow to the engine; damage here can cause idle lockout.
- Two-Stage Relief Solenoid Valve: A hydraulic component that regulates pressure in the control system; failure can short the fuse.
- Monitor Bypass Toggle: A manual switch installed to override electronic controls when diagnostics fail.
The E-02 code appeared after the front 10A fuse blew, disabling swing and throttle functions. Previous repairs had addressed a naked wire on the fuel solenoid, and a toggle switch was added to bypass the monitor. However, the fuse continued to blow even with the solenoid unplugged.
Further testing revealed that unplugging the two-stage relief solenoid valve stopped the fuse from blowing and restored full function. This narrowed the fault to the coil of the solenoid itself.
Testing and Replacement Strategy
- Check Coil Resistance: Use an ohmmeter to measure the solenoid coil. A healthy coil should show at least 3 ohms. A shorted coil will show near-zero resistance.
- Remove Coil from Valve: The coil can be separated from the valve body and sourced independently, avoiding full valve replacement.
- Source from Fluid Control Specialists: Suppliers like Spenser Fluid Systems offer compatible coils at lower cost than OEM Komatsu parts.
- Inspect Diodes in Circuit: The PC220LC-6 contains multiple diodes that protect against voltage spikes. If the fuse continues to blow after coil replacement, a diode may be damaged.
In Tennessee, a contractor traced the E-02 fault to the relief solenoid coil after extensive trial and error. Replacing the coil restored swing and throttle instantly. He noted that Komatsu dealers often recommend full valve replacement, but independent sourcing saved over $1,000.
In Indiana, a mechanic found that a failed diode downstream of the coil caused intermittent fuse failure. After locating the diode near the monitor harness and replacing it, the machine ran without issue.
Recommendations for Technicians and Owners
- Always Test Coil Resistance Before Replacing Valves: Saves time and cost.
- Use Toggle Switches Only as Temporary Bypasses: Permanent bypasses can mask deeper faults.
- Label Fuse Circuits and Monitor Error Codes: Helps future diagnostics.
- Keep Spare Coils and Diodes On Hand: Common failure points in older Komatsu machines.
- Document All Wiring Repairs: Prevents confusion during future service.
The E-02 error on a Komatsu PC220LC-6 is a classic example of how a small electrical fault can disable major hydraulic functions. With methodical testing and targeted replacement, the issue can be resolved without full valve or monitor replacement. For owners of legacy Komatsu excavators, understanding the interplay between solenoids, fuses, and diodes is key to keeping machines productive and repair costs manageable.
