Komatsu PC210‑8 Engine Overheating – Hydraulic Load, Fan Clutch Faults, Error Codes & Fixes

 

Komatsu PC210-8 Engine Overheating – Complete Troubleshooting Guide

The Komatsu PC210-8 is a high-performance excavator equipped with the SAA6D107E-1 electronic engine and a larger hydraulic pump than the PC200 series. While powerful, this model is prone to engine overheating under heavy load conditions. This guide explains the symptoms, causes, error codes, troubleshooting steps, and solutions for overheating issues specific to the PC210-8.

Symptoms of Engine Overheating in Komatsu PC210-8

• Temperature gauge rising above 100°C
• Engine derate mode triggered during digging
• Fan clutch running continuously or failing to engage
• Coolant boiling or bubbling in reservoir
• White smoke from exhaust
• Hydraulic functions slowing down
• Warning light or buzzer on monitor

General Causes of Overheating

• Low coolant level
• Radiator and oil cooler blockage
• Thermostat stuck closed
• Water pump wear or failure
• Airlock in cooling system
• Hydraulic overload

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Komatsu PC210-8 Specific Causes of Overheating

• Hydraulic overload – larger pump increases engine stress
• Fan clutch failure – fan not engaging properly under load
• Fan solenoid valve fault – signal not reaching clutch
• Coolant flow restriction – blocked radiator or EGR cooler
• Sensor error – false readings trigger derate mode
• Oil cooler clogging – reduces heat dissipation

Komatsu PC210-8 Overheating Error Codes

• E03 – Coolant temperature high
• E411 – Water temperature sensor abnormal
• E451 – Fan clutch system abnormal
• E372 – Hydraulic oil temperature high
• E032 – Engine overload condition

Step-by-Step Troubleshooting for PC210-8 Overheating

1. Check Coolant Level and Quality

Ensure coolant is clean and filled to the correct level. Replace if contaminated.

2. Inspect Radiator and Oil Cooler

• Clean fins with compressed air
• Check for blockage from dust, cotton, or mud

3. Test Fan Clutch and Solenoid Valve

• Verify fan clutch engages at high temperature
• Check solenoid valve signal and wiring
• Replace clutch if slipping or noisy

4. Scan ECU for Error Codes

Use Komatsu diagnostic tool to check E03, E411, E451, and related codes.

5. Check Thermostat and Water Pump

• Replace thermostat if stuck
• Inspect water pump for leaks or bearing noise

6. Inspect Hydraulic Load

Check pump pressure and relief valve settings. Overload increases engine temperature.

7. Flush Cooling System

Remove airlocks and scale buildup. Use Komatsu-approved coolant.

Solutions for Komatsu PC210-8 Overheating

• Clean radiator and oil cooler thoroughly
• Replace fan clutch or solenoid valve
• Replace thermostat and water pump if worn
• Flush coolant system and refill
• Fix wiring or sensor issues (E411, E451)
• Reduce hydraulic load during operation

Preventive Maintenance

• Clean radiator every 2–3 days in dusty areas
• Replace coolant every 1000 hours
• Check fan clutch operation monthly
• Inspect water pump and thermostat every 2000 hours
• Monitor hydraulic load during heavy digging

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