Replacing the shift fork on a Komatsu PC228US-5 excavator is a task that requires basic mechanical skills and some tools. click here for more details on the download manual…..

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KOMATSU PC 220/228-6/7 PC & LS PROBLEM ENGINE ITS OVERLOAD THIS VIDEO IS SIMPLE TUTORIAL ON KOMATSU 220/228 /6/7/8 PC & LS VALVE, WHY IT IS OVERLOAD OR ALMOST STOP …

Here’s a step-by-step guide to help you understand the process. Please remember to follow safety precautions and consult your machine’s service manual for specific details.

### Tools and Materials Needed:
– Basic hand tools (wrenches, sockets, screwdrivers)
– Torque wrench
– Replacement shift fork
– Clean rags
– Safety gloves and glasses
– Oil or grease for reassembly

### Step-by-Step Guide:

1. **Safety First**:
– Turn off the excavator and ensure it is on a flat, stable surface.
– Engage the parking brake and remove the key from the ignition.
– Wear safety gloves and glasses to protect yourself.

2. **Access the Transmission**:
– locate the access panel to the transmission under the machine. You may need to remove some panels or covers to get to it.
– Use the appropriate tools to remove any screws or bolts holding the access panel in place.

3. **Remove the Old Shift Fork**:
– Once you have access to the transmission, locate the shift fork. It’s usually connected to the transmission linkage.
– Take note of how the shift fork is installed (you can take pictures for reference).
– Disconnect the linkage carefully. This may involve removing a few bolts or clips, so keep track of these components.
– Once the linkage is free, remove the bolts that hold the shift fork in place. Be careful to support any parts that may fall.

4. **Inspect the Area**:
– Before installing the new shift fork, inspect the surrounding area for any debris, wear, or damage. Clean the area with a rag to ensure there’s no dirt or old oil that could affect the new part.

5. **Install the New Shift Fork**:
– Take your new shift fork and position it where the old one was located. Make sure it aligns correctly with the linkage and any guides.
– Secure the shift fork in place by tightening the bolts you removed earlier. Use a torque wrench to ensure they are tightened to the manufacturer’s specifications.

6. **Reconnect the Linkage**:
– Reattach the linkage to the shift fork. Make sure everything is aligned properly and secure all bolts or clips.
– Double-check that everything is connected as it was before removal.

7. **Reassemble the Access Panel**:
– Once the new shift fork is installed and everything is connected, replace the access panel.
– Secure it with the screws or bolts you removed earlier.

8. **Final Checks**:
– Before starting the excavator, do a final check to ensure everything is tight and in place.
– Make sure there are no tools left in the work area.

9. **Start the Excavator**:
– With everything reassembled, turn the key to start the excavator. Test the shifting mechanism to ensure the new shift fork is functioning correctly.

10. **Cleanup**:
– Dispose of any old parts or materials responsibly.
– Clean your tools and put them away.

### Important Notes:
– Always refer to the specific service manual for your Komatsu PC228US-5 for any additional details or specifications.
– If you’re unsure about any step of the process, it’s best to consult with a qualified mechanic or technician.

By following these steps, you should be able to replace the shift fork on your Komatsu excavator. Good luck!
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