Installation Instructions for Ignition Switch Replacement for Komatsu EX200-1 Excavator

Tools Required:

1. Flathead screwdriver
2. Phillips screwdriver
3. Socket wrench set (including 10mm and 12mm sockets)
4. Pliers
5. Wire cutters/strippers
6. Electrical tape or heat shrink tubing
7. Safety gloves
8. Safety glasses

Installation Steps:

1. Preparation:

   • Ensure the excavator is parked on a stable surface and the engine is turned off.
   • Disconnect the battery by removing the negative terminal to ensure safety during installation.

2. Access the Ignition Switch:

   • Locate the dashboard panel where the ignition switch is installed.
   • Use the flathead screwdriver to gently pry off any panel covers if necessary.

3. Remove the Old Ignition Switch:

   • Use the Phillips screwdriver to remove the screws holding the ignition switch in place.
   • Carefully disconnect the wiring harness from the old ignition switch. You might need to use pliers to release any clips.

4. Install the New Ignition Switch:

   • Connect the wiring harness to the new ignition switch, ensuring all connections are secure.
   • Align the ignition switch with the mounting holes and fasten it using the screws removed earlier.

5. Reassembly:

   • Reattach any panel covers that were removed to access the ignition switch.
   • Ensure everything is firmly in place and no wires are pinched or exposed.

6. Reconnect the Battery:

   • Reattach the negative terminal of the battery ensuring a secure connection.

7. Test the New Ignition Switch:

   • Turn the key to the “ON” position and check that the electrical components and engine start properly.

8. Final Safety Check:

   • Ensure all tools are removed from the work area and that all panels are securely fastened before operating the excavator.

Note: If you experience any issues during installation, consult with a professional mechanic or refer to the excavator’s service manual for further guidance.