Replacing the shift solenoid on a Komatsu PC220LC-6 Hydraulic Excavator involves several steps and requires specific tools and safety measures. click here for more details on the download manual…..

1996 Komatsu PC220LC-6 8000 Hours.

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Below is a detailed guide on how to perform this replacement:

– **Safety Precautions**
– Ensure the excavator is parked on a stable and level surface.
– Engage the parking brake and turn off the ignition.
– Disconnect the battery to prevent any electrical accidents during the repair.
– Wear appropriate personal protective equipment (PPE), including gloves and safety goggles.

– **Required Tools and Equipment**
– **Wrenches and Sockets**: Various sizes including metric (typically 10mm to 19mm) for removing bolts and nuts.
– **Ratchet and Extension**: To reach bolts in tight spaces.
– **Screwdrivers**: Flathead and Phillips to remove any covers or panels.
– **Pliers**: For handling clips and small components.
– **Torque Wrench**: To ensure bolts are tightened to manufacturer specifications upon reassembly.
– **Diagnostic Tool (optional)**: To check for error codes related to the shift solenoid after replacement.
– **Cleaning Supplies**: Rags and degreaser for cleaning the area around the solenoid.

– **Accessing the Shift Solenoid**
– Locate the shift solenoid on the excavator. It’s typically found near the transmission or the hydraulic control valve.
– Remove any protective covers or panels that obstruct access to the solenoid.
– Take note of the wiring and connections leading to the solenoid. You may want to take pictures for reference during reinstallation.

– **Disconnecting the old Shift Solenoid**
– Carefully disconnect the electrical connector from the solenoid. Use pliers if necessary to release any clips.
– Use the appropriate socket or wrench to remove the bolts securing the solenoid to its mounting bracket or assembly. Keep these bolts for reuse.
– Gently pull the solenoid away from its housing. If it’s stuck, wiggle it slightly to break the seal but avoid applying excessive force.

– **Installing the New Shift Solenoid**
– compare the new solenoid with the old one to ensure compatibility and correct fit.
– Clean the mounting area where the solenoid will be installed to ensure a proper seal.
– Position the new solenoid in place, ensuring that it aligns with the mounting holes.
– Secure the solenoid using the original bolts. Tighten them snugly with a torque wrench to the specified torque settings in the service manual.

– **Reconnecting the Electrical Connector**
– Reattach the electrical connector to the new solenoid, ensuring it is seated properly and any clips are secured.
– Double-check all connections and ensure that there are no loose wires or signs of wear.

– **Final Checks and Testing**
– Reinstall any covers or panels that were removed for access.
– Reconnect the battery and ensure that all tools are removed from the work area.
– Start the excavator and perform a function check to ensure the new shift solenoid is operating correctly.
– If available, use a diagnostic tool to check for any fault codes and clear them if necessary.

– **Documentation**
– Record the replacement in the maintenance log, noting the date, part number, and any observations during the process.

Following these steps should help ensure a successful replacement of the shift solenoid on a Komatsu PC220LC-6 Hydraulic Excavator. Always refer to the manufacturer’s service manual for specific torque settings and additional guidance tailored to your specific model.
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