Having trouble starting your excavator? Don't worry, we've got you covered! Dealing with issues related to the excavator ignition switch is quite common, especially during the winter season. A faulty ignition switch can lead to significant delays and potential financial losses. But fear not, because we're here to teach you how to replace it yourself!
While replacing an excavator ignition switch might seem intimidating at first, it's actually a straightforward process. In this comprehensive blog post, we will guide you through each step of the replacement procedure. Whether you're a novice or an experienced operator, this guide is designed to help you overcome any problems you may be facing with your ignition switch.
Step 1: Troubleshooting
Is your excavator refusing to start, emitting only a clicking sound? Or is it feeling jammed and unresponsive? Before proceeding with the replacement, let's diagnose the issue to ensure that it is indeed a problem with the ignition switch.
Start by inserting the master key into the ignition switch and observe if it smoothly goes in and turns. If you encounter any difficulty or resistance, there may be internal parts or metal fragments causing obstruction. It's possible that the spring has become displaced, preventing the tumbler from rotating within the ignition housing.
To test this, apply a lubricant to both sides of the key and attempt to insert it into the excavator ignition switch. If the problem persists and the switch remains unresponsive, it is safe to conclude that it is indeed broken.
Repairing the ignition switch is not recommended, as it is often more efficient and time-saving to replace it entirely.
Step 2: Disconnecting the Battery
Before commencing any work, it is crucial to ensure that the excavator is properly parked. Sometimes, operators may leave attachments suspended in the air, posing a risk to both the machine and surrounding individuals.
The first step is to disconnect the battery and cut off power to the electrical circuits before removing any ignition or electrical components.
Using a 13mm wrench, carefully disconnect the ground connection. Exercise caution during this process, as you will be dealing with ignition switch , which may still have live power or a grounding circuit connected to the battery relay.
Your aim is to ensure that all connections are properly disconnected, and the machine is completely de-energized in order to proceed safely with the replacement process.
Step 3: Disassembling the Console
Begin by removing the ground strap, which will allow you to pull apart the console effortlessly.
To easily separate the console, start by gently pulling off the boot on the joystick or the operator control. It should detach smoothly without much effort.
Next, lift the cover to expose the bolts underneath.
Please note that the console on a Komatsu excavator may be slightly tighter compared to other excavator brands. In such cases, you might need to employ a wrench to remove a couple of screws. Take a small wrench and carefully remove the two 10mm bolts. To ensure you don't misplace them, consider storing the bolts and washers in a designated container, such as an ashtray.
Gently wiggle the cover to check if it has become loose enough. If it has, there is no need to remove all the bolts.
If your machine has a throttle dial, remove it and place it in the ashtray or cup holder if available. At this point, everything should come off smoothly, and you should be able to push the joystick boot through the hole in the cover. Once removed, set the cover aside.
Attempt to remove the key switch at this stage to see if it can be detached easily. If it doesn't come off, do not force it. Proceed to the next step and focus on removing the side covers.
Step 4: Accessing the Ignition Switch
To locate the ignition switch, removing the side covers will provide easier access. Using the 10mm wrench, loosen the screws on the sides.
If necessary, remove the joystick to access the excavator ignition switch. Depending on the length of the wires, you might also need to extract additional screws and remove the back cover. All the bolt heads are 10mm, so you will only require the 10mm wrench to loosen them.
Once the covers are removed, you should have a clear path to reach the excavator ignition switch.
For most individuals, the main challenge at this point is figuring out how to disconnect the switch, primarily because it is difficult to reach. Utilize side cutters to carefully cut off the wires.
Step 5: Remove the Old Ignition
To begin, ensure that you are wearing gloves for protection. Carefully remove the old ignition from your Komatsu PC200LC. In some cases, the ignition may be wrapped in cloth. If this is the case, you will need to unwrap the fabric to access the ignition. It's important to note that this cloth is typically made of fiberglass, so wearing gloves is essential to avoid any potential irritation.
If you are working indoors, it is advisable to wear a mask to prevent inhalation of particles from the fiberglass cloth. Safety should always be a priority during this process.
Remember to keep the cloth after removing it. You will need it later when reconnecting the wires to the new ignition switch. Wrap the new switch in the same manner as the old one was wrapped.
Step 6: Replace the Excavator Ignition Switch
You may notice that the ignition is slightly tight. Remove the clamps to loosen it and change the wire over to new connectors.
There are two clamps secured by massive bolts. Carefully pull them off and keep them somewhere safe, such as the cupholder, to avoid misplacing them.
Before removing anything, ensure that everything is identical in terms of connection and placement. In the case of a Komatsu excavator, all components are conveniently marked, making it easier to reconnect them correctly. However, it is recommended to proceed one wire at a time to ensure accuracy and prevent any confusion.
If the seating area is tight and hard to reach, using an extra-long screwdriver can provide better access.
Begin by replacing any of the terminals, but remember to save the "B" terminal (battery power) for last. Unscrew each terminal carefully, taking care not to lose any washers.
Once all the terminals have been replaced, ensure that they are securely tightened. Rewrap the cloth around the switch and place it back in its original position. Replace the clamps that were removed earlier.
Step 7: Test the Ignition
Before reassembling the covers, it is crucial to test the ignition to ensure it is functioning correctly. Reconnect the battery and place the excavator ignition switch back in its designated spot.
Insert the key into the ignition and turn it to the "on" position. Listen for a clicking sound, as this indicates that the heater is functioning properly.
Hold the key in the "on" position for a few seconds, and then turn it to the "run" position. At this point, everything should be working normally.
Now, you can proceed to put all the covers back on. It is recommended to conduct a final test to ensure that your machine is fully operational before using it. Once the covers are securely in place, your excavator should be ready to go.
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