Komatsu MWL22-1A Forklift Truck Service Manual

Description

• Model List:
  • MWL22-1A Forklift Truck

• 1. BXINTRO
• 1.1. Introduction, Service Manual
• 1.2. Contents, Section M
• 1.2.1. Machine Information
• 1.3. General Product Information
• 1.3.1. Presentation of the MWL221A.
• 1.3.1.1. Intended Application of the Trucks
• 1.3.1.2. Forbidden Application of the Trucks
• 1.3.1.3. Truck Data
• 1.3.1.4. MWL221A Dimensions
• 1.3.1.5. Data Plate
• 1.3.2. Main Components
• 1.4. Inch (SAE) and Metric Fasteners
• 1.4.1. Introduction
• 1.4.2. Nomenclature, Threads
• 1.4.3. Strength Identification
• 1.4.4. Conversion of Metric and English Units
• 2. BXBATT
• 2.1. Swing Out Battery Pack
• 2.1.1. Charger Diagram
• 2.1.2. Battery Cable routing diagram
• 2.1.3. Troubleshooting
• 2.1.4. Electrical testing
• 2.2. GNB Battery Pack
• 2.2.1. General Information
• 2.2.2. Troubleshooting
• 2.2.2.1. Troubleshooting Symptom
• 2.3. Battery Controller / Hourmeter Lift Interrupt
• 2.3.1. General Information
• 2.3.2. Electrical
• 2.3.2.1. Voltage
• 2.3.3. Battery Controller (BC)
• 2.3.3.1. General Information
• 2.3.3.2. Reset
• 2.3.3.3. Key Switch
• 2.3.3.4. Hourmeter
• 2.3.4. Troubleshooting
• 2.3.4.1. Battery Discharge Indicator (BDI)
• 2.3.4.2. Hourmeter
• 2.4. Battery Discharge Indicator / Hourmeter
• 2.4.1. General Information
• 2.4.2. Electrical
• 2.4.2.1. Voltage
• 2.4.3. Battery Discharge Indicator (BDI)
• 2.4.3.1. General Information
• 2.4.3.2. Key Switch
• 2.4.3.3. Hourmeter
• 2.4.4. Troubleshooting
• 2.4.4.1. Battery Discharge Indicator (BDI)
• 2.4.4.2. Hourmeter
• 3. BXBRAKE
• 3.1. Parking Brake System
• 3.1.1. Brake Theory of Operation
• 3.1.2. Brake Adjustment
• 3.1.3. Brake Shoe Removal / Installation
• 3.2. Drive Wheel
• 3.2.1. Removal
• 3.2.2. Installation
• 3.3. Load Wheels
• 3.3.1. Removal/Installation
• 3.4. Steering
• 3.4.1. Control Handle Head
• 3.4.1.1. Removal
• 3.4.1.2. Installation
• 3.5. Steering Handle Head
• 3.5.1. Control Handle Head
• 3.5.1.1. Removal
• 3.5.1.2. Installation
• 3.5.2. Direction Control Switches
• 3.5.3. Horn, Raise, and Lower Switches
• 3.5.4. Potentiometer
• 4. BXELEC
• 4.1. MWL221A 12 Volt Electrical System
• 4.1.1. Electrical Panel Components
• 4.1.1.1. Electrical Schematic
• 4.1.1.2. Electrical Schematic Symbols
• 4.2. MWL221A 12 Volt Transistor Controller
• 4.2.1. Maintenance
• 4.2.1.1. Safety
• 4.2.1.2. Cleaning
• 4.2.1.3. Troubleshooting
• 4.2.2. Basics Of Circuit Operation
• 4.2.2.1. Battery connected and emergency disconnect switch in the RUN position.
• 4.2.2.2. Key switch turned ON
• 4.2.2.3. Control handle pulled down brakes released and brake interlock switch closed.
• 4.2.2.4. Reverse travel (fork direction) switch is closed.
• 4.2.2.5. Forward travel (control handle direction) switch is closed.
• 4.2.2.6. Curtis PMC controller power circuits.
• 4.2.2.7. Accelerator Potentiometer Circuits
• 4.2.2.8. Emergency Reverser Switch
• 4.2.2.9. Lift Pallet Forks
• 4.2.2.10. Lower Pallet Forks
• 4.2.2.11. Controller Adjustments
• 4.3. MWL221A 12 Volt Transistor Controller Troubleshooting
• 4.3.1. Troubleshooting Chart Index
• 4.3.2. Troubleshooting Charts
• 4.4. Contactor, Direction
• 4.4.1. Maintenance
• 4.4.1.1. Removal/Replacement of Contact Tips
• 4.5. MWL221A 24 Volt Electrical System
• 4.5.1. Electrical Panel Components
• 4.5.2. List of Symbols
• 4.5.2.1. Circuit Diagram 1(3)
• 4.5.2.2. Circuit Diagram 2(3)
• 4.5.2.3. Circuit Diagram 3(3)
• 4.5.3. Description of Function
• 4.5.3.1. General Information
• 4.5.3.2. References Information
• 4.5.3.3. Key Switch S17 in the ON Position
• 4.5.3.4. The Operating Arm in Drive Position, S10, Brake Switch Closed
• 4.5.3.5. Driving, Fork Direction
• 4.5.3.6. Driving, Steer Wheel Direction
• 4.5.3.7. Reversing/Motor Brake Fork Direction to Steer Wheel Direction
• 4.5.3.8. Reversing/Motor Brake Steer Wheel Direction to Fork Direction
• 4.5.3.9. Reverser switch
• 4.5.3.10. Lifting the Forks
• 4.5.3.11. Lowering the Forks
• 4.5.3.12. Horn
• 4.5.3.13. Lift lnterrupt
• 4.6. MWL221A 24 Volt, Transistor Controller
• 4.6.1. Maintenance
• 4.6.1.1. Safety
• 4.6.1.2. Cleaning
• 4.6.1.3. Diagnostics and Troubleshooting
• 4.6.2. Basics Of Circuit Operation
• 4.6.2.1. Control Feature
• 4.6.3. Motor Circuit
• 4.6.4. Control Circuit
• 4.6.5. Diagnostics and Troubleshooting
• 4.6.5.1. Programmer Diagnostics
• 4.6.5.2. Troubleshooting Chart
• 4.6.5.3. Technical Specification
• 4.6.5.4. Troubleshooting Chart Using the Handset
• 4.7. MWL221A 24 Volt, Transistor Controller Troubleshooting
• 4.7.1. Troubleshooting Chart Index
• 4.7.2. Troubleshooting Charts
• 4.8. Handset Operation
• 4.8.1. Operating Modes
• 4.8.2. Revert to Previous Settings
• 4.8.3. Handset Self Test
• 5. BXHYDRA
• 5.1. Pump Motor
• 5.1.1. Component Repair
• 5.1.1.1. Motor Disassembly
• 5.1.2. Inspection and Troubleshooting
• 5.1.2.1. Drive End Head
• 5.1.2.2. Commutator End Head
• 5.1.2.3. Bearings
• 5.1.2.4. Brush and Commutator
• 5.1.2.5. Armature
• 5.1.2.6. Frame and Field Assembly
• 5.1.2.7. Assembly
• 5.1.3. Changing Brushes
• 5.2. Hydraulic System
• 5.2.1. Hydraulic Schematic
• 5.2.2. General Information
• 5.2.3. Description
• 5.2.3.1. Lift
• 5.2.3.2. Lower
• 5.2.3.3. Relief Pressure
• 5.2.4. Maintenance
• 5.2.5. Adjustments
• 5.2.6. Lift Limit Switch
• 5.2.7. Troubleshooting
• 5.3. Lift Pump Assembly
• 5.3.0.1. Solenoid Operated Valve
• 5.4. Lift Cylinder
• 5.4.1. Cylinder Repair
• 5.5. Technical Service Data
• 5.6. Ordering Spare Parts
• 5.7. Contents, Section P
• 5.7.1. Planned Maintenance
• 5.8. Introduction, Maintenance
• 5.8.1. Safe Jacking Procedure
• 5.9. Service Schedule
• 5.9.1. Planned Maintenance Schedule
• 5.9.2. Planned Maintenance Procedures
• 5.9.2.1. Services to be Performed Daily
• 5.9.2.2. Services to be Performed Monthly
• 5.9.2.3. Services to be Performed Annually
• 5.10. Lubrication Chart
• 5.11. Oil and Grease Specifications
• 5.11.1. Approved Oils and Grease
• 6. BXMOTOR
• 6.1. Drive Motor Mounting Points
• 6.1.1. Drive Motor Brush
• 6.1.1.1. Removal and Installation
• 6.1.2. Drive Motor Assembly
• 6.1.2.1. Remove
• 6.1.2.2. Installation
• 6.2. Drive Motor
• 6.2.1. General Information
• 6.2.2. Operating Conditions
• 6.2.3. Troubleshooting
• 6.3. Volt Drive Motor
• 6.3.1. Component Repair
• 6.3.1.1. Disassembly
• 6.3.2. Inspection and Troubleshooting
• 6.3.2.1. Drive End Head
• 6.3.2.2. Commutator End Head
• 6.3.2.3. Bearings
• 6.3.2.4. Brush and Commutator
• 6.3.2.5. Armature
• 6.3.2.6. Frame and Field Assembly
• 6.3.2.7. Assembly
• 6.3.3. Changing Brushes
• 6.4. Volt Drive Motor
• 6.4.1. Component Repair
• 6.4.1.1. Disassembly
• 6.4.2. Inspection and Troubleshooting
• 6.4.2.1. Drive End Head
• 6.4.2.2. Commutator End Head
• 6.4.2.3. Bearings
• 6.4.2.4. Brush and Commutator
• 6.4.2.5. Armature
• 6.4.2.6. Frame and Field Assembly
• 6.4.2.7. Assembly
• 6.4.3. Changing Brushes
• 6.5. Transmission
• 6.5.1. System Description
• 6.5.2. Troubleshooting
• 6.5.3. Axle Seal Removal and Installation
• 6.5.3.1. Removal
• 6.5.3.2. Installation
• 6.5.4. Transmission Removal/Installation
• 6.5.4.1. Removal
• 6.5.4.2. Installation
• 6.5.5. Transmission Assembly
• 6.5.5.1. Disassembly
• 6.5.5.2. Assembly
• 7. BXSAFETY
• 7.1. Standard Codes
• 7.2. Warning Symbols
• 7.2.1. Warning Levels
• 7.3. Prohibitory Symbols
• 7.3.1. Ordinance Symbols
• 8. BXSERV
• 8.1. Contents, Section S
• 8.1.1. Service Instructions
• 8.1.2. Carrier Frame Bushings
• 8.2. Chassis
• 8.2.1. General Information