A 3,338 page repair manual set for the Caterpillar E200B and EL200B track-type excavators, serial prefixes 6KF and 4SG (E200B) and 7DF and 5EG (EL200B), all powered by the Cat 3116 diesel. It is a Caterpillar SIS export, several factory books interleaved, each page carrying its own media number. The fold-out schematics at the back are the reason to buy.
Page 3332 is the SENR4533-01 hydraulic circuit, a 34 x 24 in sheet whose 37-item legend separates the front, rear and pilot pumps, main and pilot relief valves, travel motors and brake valves, swing motor, pilot control valves, solenoid valves I-IV, rotary joint and the boom, stick and bucket cylinders, with a pilot-line location table alongside. It applies to E200B 6KF1-589 and 4SG1-7935 and EL200B 7DF1-1404 and 5EG1-807; page 3338 carries SENR4885-01, the same format, for 6KF590-Up, 4SG7936-Up, 7DF1405-Up and 5EG808-Up. Page 3334 is the SENR4534-01 electrical schematic, 25 x 24 in, with wire-colour code and starter-switch tables, for 6KF1-433, 4SG1-5705, 7DF1-962 and 5EG1-615; page 3336 is SENR4535-01 for the later machines, 6KF434-Up, 4SG5706-Up, 7DF963-Up and 5EG616-Up. The same serial break runs through the main pump and rotary joint procedures.
Two composition facts: 1,406 pages are the generic Cat 3114/3116/3126 engine books, whose covers name IT18F, 446B, D6M and 928F/950F because the same engine is fitted there, and 743 pages are Product Link / EquipmentManager telematics, retrofit tracking hardware and portal administration rather than E200B repair content.
What's Inside This Caterpillar E200B, EL200B Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Air Inlet & Exhaust System | 1-65 | Turbocharger - Remove and Install, Inlet Manifold Pressure - Test, Exhaust Temperature - Test, Aftercooler - Remove and Install, Exhaust Manifold and Elbow |
| Basic Engine - Specifications, Testing & Rebuild | 66-417 | Engine Valve Lash - Inspect/Adjust, Connecting Rod and Main Bearings - Inspect, Cylinder Block - Inspect, Camshaft and Camshaft Bearings, Crankshaft Rear Seal Carrier, Vibration Damper - Check |
| Cooling System | 418-512 | Cooling System - Check - Overheating, Water Temperature Regulator - Test, Water Pump - Disassemble and Assemble, Engine Oil Cooler - Remove and Install, Hydraulic Oil Cooler, Fan Drive and Fan Assembly |
| Electronic Controller & Starting System - Operation | 513-610 | E200B/EL200B Electronic Controller - Component Description, Fuel Shutoff Solenoid, 37-Mt, 41-Mt and 42-Mt Starting Motors, MUI Engine Governors - Systems Operation |
| Product Link & EquipmentManager (Telematics Portal) | 611-1134 | Product Link Installation, Setup Subscriptions and Manage Users, Asset Watch, Health Watch and Maintenance Watch, Time Fence and Geographic Fence, Fuel Results and Fault Code Reports, Product Link PL522/523 and 121S/300 |
| Electrical - Testing & Adjusting | 1135-1294 | Battery - Test, Charging System - Test, Electric Starting System - Test, Pinion Clearance - Adjust, Wiring Harness (Open and Short Circuit) - Test, Electronic Control Module (ECM) - Flash Program |
| Troubleshooting - Machine, Controller & Diagnostic Codes | 1295-1522 | Problem Sequence Charts a Through M, Checking Procedures (Electronic Power Controller), Starting Motor Does Not Turn or Turns Slowly, Event Code List and Diagnostic Code List, MID 161 CID/FMI Code Entries |
| Electrical - Specifications, Disassembly & Assembly | 1523-1660 | Alternator and Regulator - Remove and Install, Magnetic Pickup, Engine Oil Pressure Sensor - Remove and Install, Ether Starting Aid and Atomizer, Starting Motor - Disassemble - 42-Mt, Jacket Water Heater and Air Inlet Heater |
| Engine Arrangement, Frame & Body | 1661-1688 | Engine Design, Engine Speed - Check, Counterweight, Rotary Joint Installation (6KF1-589, 7DF1-1404), Rotary Joint Installation (6KF590-Up, 7DF1405-Up) |
| Fuel System - Operation, Testing & Adjusting | 1689-1833 | Fuel Ratio Control - Adjust, Fuel Timing Dimension - Adjust, Unit Injector Synchronization - Adjust, Fuel System Pressure - Test, Air in Fuel - Test, Governor Speed and Limiting Circuits |
| Fuel System - Specifications, Disassembly & Assembly | 1834-2378 | Governor Identification - Types I Through VII, Governor Performance Data, Fuel Injection Control Linkage - Remove and Install, Fuel Filter and Water Separator, Fuel Priming Pump - Remove and Install, Governor - Disassemble and Assemble |
| Hydraulic System - Operation, Testing & Troubleshooting | 2379-2642 | Pilot System and Pilot Relief Valve Operation, Main and Line Relief Valve Settings, Negative Flow Control Pump Signal, Operational Tests - Travel, Swing and Cylinder Drift, Checking Procedures (Hydraulic System) |
| Hydraulic System - Specifications, Disassembly & Assembly | 2643-2914 | Cycle Times (New Machine), Main Pump (6KF1-589, 7DF1-1404), Main Pump (6KF590-Up, 7DF1405-Up), Swing Motor and Swing Drive, Travel Motors, Boom, Stick and Bucket Cylinders, Hydraulic and Directional Control Valve, Return, Drain and Pilot Filters |
| Implements & Lubrication System | 2915-2999 | Engine Crankcase Pressure (Blowby) - Test, Engine Oil Pressure - Test, Excessive Engine Oil Consumption - Inspect, Engine Oil Pump - Disassemble, Engine Oil Filter Base and Bypass Valve, Crankcase Breather - Remove and Install |
| Operator Station | 3000-3162 | Cab, Cab Heater, Seat Assembly, Pilot Control Valves (Travel), Hydraulic Activation Control Valve |
| Power Train, Service Equipment & Supplies | 3163-3226 | Travel Brake Valves, Travel Drive Installation, Travel Drive Sprockets, Duo-Cone Seals |
| Torque Specifications | 3227-3274 | Metric (ISO) Fasteners, English (SAE) Fasteners, Straight Thread O-Ring Fittings, O-Ring Face Seal Fittings, Ground Engaging Tool (G.E.T.) Fasteners, Tapered Pipe Thread Fittings |
| Undercarriage & Work Tools | 3275-3330 | Front Idlers, Recoil Springs and Hydraulic Track Adjusters, Idler Adjuster, Track Rollers and Carrier Rollers, Track Assemblies |
| Fold-Out Schematics - Hydraulic & Electrical | 3331-3338 | SENR4533-01 Hydraulic, 6KF1-589 / 7DF1-1404, SENR4885-01 Hydraulic, 6KF590-Up / 7DF1405-Up, SENR4534-01 Electrical, 6KF1-433 / 7DF1-962, SENR4535-01 Electrical, 6KF434-Up / 7DF963-Up |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Hydraulic system | ||
| Main relief pressure | 31400 kPa (4600 psi) | p. 1189 |
| Boom raise cycle time, new machine | 3.0 +/- 0.5 sec | p. 2643 |
| Main pump flow, each pump at no load | 183 litres (48 US gal) per minute | p. 2383 |
| Travel circuit | ||
| Travel crossover relief pressure | 33300 kPa (4800 psi) | p. 1189 |
| Cylinder circuits | ||
| Line relief pressure | 33300 kPa (4800 psi) | p. 1189 |
| Swing circuit | ||
| Swing relief pressure | 23500 kPa (3400 psi) | p. 1189 |
| Swing half turn cycle time, new machine | 4.2 sec | p. 2643 |
| Pilot circuit | ||
| Pilot relief valve setting | 3450 kPa (500 psi) | p. 2384 |
| Operational tests | ||
| Test engine speed, high idle no load | 1950 +/- 50 rpm | p. 1188 |
| Machine | ||
| Hydraulic oil tank capacity | 238 litres (63 US gal) | p. 2647 |
| Fuel tank capacity | 280 litres (74 US gal) | p. 2376 |
