Jungheinrich AMW 22 User manual

AMW 22 / AMW 22p / AMW 22ps 12.14
Operating instructions
51119800
11.19
en-GB
AMW 22
AMW 22p
AMW 22ps

2

Declaration of Conformity
Manufacturer
Jungheinrich AG, 22039 Hamburg, Germany
Description
Industrial truck
Type Option Serial no. Year of
manufacture
AMW 22
AMW 22p
AMW 22ps
On behalf of
Date
EU DECLARATION OF CONFORMITY
The undersigned hereby declare that the powered truck described in detail complies
with the current versions of European Directives 2006/42/EG (Machinery Directive)
and 2014/30/EU (Electromagnetic Compatibility - EMC). The manufacturer is
authorised to compile the technical documentation.
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Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages
are numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. We reserve the right to alter the
design, equipment and technical features of the system. No guarantee of particular
features of the truck should therefore be assumed from the present operating
instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following
graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTICE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
ZUsed before notices and explanations.
tIndicates standard equipment
oIndicates optional equipment
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Contents
.
A Correct Use and Application 9
.
1 General 9
2 Correct application 9
3 Approved application conditions 9
4 Proprietor responsibilities 10
5 Adding attachments and/or optional equipment 10
.
B Truck Description 11
.
1 Application 11
2 Calibrated weighing system (AMW 22p / AMW 22ps) 11
3 Assemblies and Functional Description 12
3.1 Truck Component Overview 12
3.2 Weighing System Component Overview 13
4 Technical Specifications 14
4.1 Performance data 14
4.2 Weighing System Weight Display 14
4.3 Weighing Variance of the Weighing System 15
4.4 Dimensions 16
4.5 Weights 17
4.6 Batteries 17
4.7 Tyre type 17
4.8 Operating conditions 18
4.9 Identification Points and Data Plates 19
4.10 Wind loads 20
.
C Transport and Commissioning 21
.
1 Lifting by crane 21
2 Transport 22
3 Using the Truck for the First Time 23
.
D Batteries/Accumulators - Replacement/Charging 25
.
1 Safety Regulations for Handling Batteries and Accumulators 25
2 Safety regulations for handling lithium-ion batteries 27
2.1 Safety regulations 27
2.2 Potential hazards 28
2.3 Charging the battery 32
2.4 Battery lifetime and maintenance 33
2.5 Storing the battery 33
2.6 Faults 33
2.7 Disposal and transport of a lithium-ion battery 35
2.8 Hazard and Safety Instruction Phrases 39
3 Power Supply AMW 22 41
3.1 General information 41
3.2 Replacing batteries 41
4 Power Supply AMW 22p 43
4.1 General information 43
4.2 Charging the battery 43
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5 AMW 22ps power supply 45
5.1 General information 45
5.2 Battery charge status 46
5.3 Charging the battery 47
.
E Operation 49
.
1 Safety Regulations for the Operation of Forklift Trucks 49
2 Displays and Controls 51
3 Starting up the truck 52
3.1 Checks and Operations to Be Performed Before Starting Daily Work 52
4 Industrial Truck Operation 53
4.1 Safety regulations for truck operation 53
4.2 Parking the truck securely 54
4.3 Pushing/Pulling 55
4.4 Steering 55
4.5 Brakes 56
4.6 Lifting, transporting and depositing loads 57
4.7 AMW 22 / AMW 22p Standard Weigher (t) 60
4.8 AMW 22p Weigher, Special Version (o) 66
4.9 AMW 22ps weighing system 76
4.10 On-Board Printer (o) 101
5 Troubleshooting 102
5.1 Load cannot be lifted 102
.
F Checking the Industrial Truck 103
.
1 Spare Parts 103
2 Operational Safety and Environmental Protection 103
3 Safety Regulations for Checks 104
4 Lubricants and Lubrication Schedule 106
4.1 Handling consumables safely 106
4.2 Lubrication Schedule 108
4.3 Consumables 108
5 Checks 109
5.1 Preparing the Truck for Checking 109
5.2 (o) Check and Adjust Foot-Activated Parking Brake 109
6 Decommissioning the Industrial Truck 110
6.1 Prior to decommissioning 110
6.2 Restoring the truck to service after decommissioning 110
7 Safety tests to be performed at intervals and after unusual incidents 111
8 Final de-commissioning, disposal 111
9 Operating Company Checks 112
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A Correct Use and Application
1 General
The truck must be used, operated and serviced in accordance with the present
instructions. All other types of use are beyond its scope of application and may result
in damage to personnel, the industrial truck or property.
2 Correct application
NOTICE
The maximum load and the maximum permissible load distance given on the data
plate must be observed.
The load must be fully supported by the load handler, evenly distributed and raised
completely from the ground.
The following operations are in accordance with regulations and are permitted:
– Lifting and lowering loads.
– Transporting lowered loads.
The following operations are prohibited:
– Carrying and lifting passengers.
– Pushing or pulling loads.
– Transverse handling of long loads.
3 Approved application conditions
– Operation in industrial and commercial environments.
– Permissible temperature range see page 18.
– Operation only on secure, level surfaces with sufficient load-bearing capacity.
– Operation only on routes that are visible and approved by the operating company.
– Do not negotiate inclines.
WARNING!
Use under extreme conditions
Using the truck under extreme conditions can result in malfunctions and accidents.
uSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
uThe truck cannot be used in areas at risk of explosion.
uIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.
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4 Proprietor responsibilities
For the purposes of the present operating instructions the “operating company” is
defined as any natural or legal person who either uses the industrial truck himself, or
on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is
considered the person who, in accordance with existing contractual agreements
between the owner and user of the industrial truck, is charged with operational
duties.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are
excluded. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The operating company
must ensure that all users have read and understood these operating instructions.
NOTICE
Failure to comply with the operating instructions invalidates the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer.
5 Adding attachments and/or optional equipment
The mounting or installation of additional equipment which affects or enhances the
performance of the industrial truck requires the written permission of the
manufacturer. Local authority approval may also need to be obtained.
Local authority approval however does not constitute the manufacturer’s approval.
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B Truck Description
1 Application
The pallet truck is designed to transport goods on level surfaces. Open bottom
pallets or roll cages can be lifted.
The rated capacity is indicated on the data plate or the capacity plate Qmax.
The weighing system provides the option of weighing loads, adding individual
weights and displaying a total weight. Current weighing data and entered data can
be issued on the on-board printer (o). The date and time are only issued if this option
has been activated.
2 Calibrated weighing system (AMW 22p / AMW 22ps)
The AMW22p / AMW 22ps industrial truck can be equipped with an optional
calibratable weighing system and manufacturer calibration in accordance with OIML
Approval Class III (European Approval No. T2782) in order to perform weighing
operations for commercial purposes.
The calibrated weighing system is approved separately by the notified body with a
serial number and is given an official inspection label. The inspection label confirms
the accuracy within the permissible calibration tolerance. The supplied declaration of
conformity must be retained. The area of validity of the EC calibration comprises the
EU state specified on the declaration of conformity. Weighing systems that are
currently in use are tested in accordance with the statutory provisions of the
respective EU country.
If the validity period of the calibration is limited according to national regulations, the
owner of a truck with a calibrated weighing system bears sole responsibility for its
timely recalibration.
Significant geographical changes in location of the truck require a recalibration to be
performed before the weighing system can be operated.
NOTICE
The validity of the calibration becomes void in the event of damage to the truck,
manual intervention in the operation of equipment such as the housing opening, as
well as any damage or removal of the test plaques.
ZCalibratable weighing systems with deviations beyond the traffic error limit, an
exceeded reverification date or which have passed their calibration expiry date must
be taken out of service.
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3 Assemblies and Functional Description
3.1 Truck Component Overview
6
1
3
4
5
2
7
9
8
Item Description Item Description
1oTravel and parking brake 6 tSteered wheels
2tLoad handler 7 tLoad wheels
3tHandle 8 oFoot-activated parking brake
4t“Lift/lower fork” handle 9 tData plate
5tTiller
tStandard equipment oOptional equipment
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3.2 Weighing System Component Overview
11
13
10
13
12
14
Item Designation Item Designation
10 tDisplay and evaluation unit
(AMW 22p / AMW 22ps)
13 tLoad cells
11 tDisplay and evaluation unit
(AMW 22)
14 oOn-board printer
12 tBattery
tStandard equipment oOptional equipment
3.2.1 Weight Detection
Four load cells are bolted to the load carrying frame and also to the load attachment
head. The load cells and the connection cable to the evaluation and display unit are
installed so that they are protected.
3.2.2 Evaluation and Display Unit
Weights, system statuses and quantities (o) are displayed. All functions of the
weighing system can be called up using the keys below the display. The zero setting
is performed automatically within set limits.
3.2.3 On-Board Printer (o)
Individual weights, tare weights and total weights can be output on thermal paper, as
can quantities (o) with identification code numbers (o) and time of printing (o).
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4 Technical Specifications
ZThe technical specification is given according to the German guideline "Type sheets
for industrial trucks". Technical modifications and additions reserved.
4.1 Performance data
AMW 22 / AMW 22p /
AMW 22ps
Q Rated capacity 2200 kg
c Load centre distance 600 mm
x Load distance 890 mm
Lowering speed with / without load 90/20 mm/s
4.2 Weighing System Weight Display
AMW 22 and AMW 22p
Weight range Resolution of weight display
AMW 22 AMW 22p
(t) 1)
AMW 22p
(o) 1)
AMW 22p
Calibrated (o)
1)
0 to 200 kg 1.0 kg 0.2 kg 0.1 kg 0.5 kg (o)
200 to 500 kg 0.5 kg 0.2 kg
500 - 2000 kg (t)1.0 kg
0.5 kg 1.0 kg
500 - 2200 kg (o)
AMW 22ps (from year of manufacture 2020)
Weight range Resolution of weight display
AMW 22ps (t) 1) AMW 22ps
Calibrated (o) 1)
0 to 200 kg 0.2 kg 0.5 kg
200 to 500 kg 0.5 kg
500 - 2000 kg (t)1.0 kg 1.0 kg
500 - 2200 kg (o)
1) Multi-range display: The resolution of the weight display depends on the weight.
During weighing out, the resolution does not change on passing the boundary to the
next lower weight range.
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4.3 Weighing Variance of the Weighing System
AMW 22 Within a temperature range of -10 to +40°C, the maximum weighing
variance is 0.1% of the overall weighing range.
AMW 22p
AMW 22ps
Within a temperature range of -10 to +40°C the maximum weighing
variance is 0.1% of the measured weight.
ZOutside the listed temperature range, weighing variances of up to 0.3% can occur.
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4.4 Dimensions
s
e
W
a
x
h14
b11
b10 b1=b5
h3
h13
l1
l6
l2l
m2
674 (AMW 22p / AMW 22ps)
y
c
Q
104°
104°
a/2=100
a/2=100
Ast = Wa+l6-x+a
Designation AMW 22 / AMW 22p /
AMW 22ps
h3Lift 122 mm
h13 Lowered height 86 mm
h14 Height of tiller handle 1234 mm
y Wheelbase 1110 mm
s/e/l Fork dimensions 62/170/1150 mm
l1Overall length 1546 mm
l2Length to fork face 396 mm
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Designation AMW 22 / AMW 22p /
AMW 22ps
b1Overall width 540 mm
b5Outer fork distance 540 mm
b10 Track width, front 109 mm
b11 Track width, rear 370 mm
Ast Working aisle width 1000x1200 transv. 1763 mm
Ast Aisle width 800x1200 length. 1813 mm
Wa Turning radius 1303 mm
4.5 Weights
Designation AMW 22 / AMW 22p /
AMW 22ps
Net weight 99/102 kg
Axle load, w.o. load front/rear 61/38 kg
Axle load, w. load front/rear (AMW 22) 578/1721 kg
4.6 Batteries
Truck Battery type Voltage/capacity
AMW 22 Alkaline (type AA) 4x1.5 V
AMW 22p Lead-gel battery
(rechargeable)
12 V/1.2 Ah
AMW 22ps Lithium-ion battery
(rechargeable)
14.8 V/5 Ah
4.7 Tyre type
AMW 22 / AMW 22p /
AMW 22ps
Tyre size, front Ø 170 x 50 mm
Tyre size, rear Ø 82 x 96 mm
Tyre size, rear (tandem wheels) Ø 82 x 62 mm
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4.8 Operating conditions
– During operation: -10°C to 40°C
Ambient lighting
– - At least 50 Lux during operation
ZOutside the listed temperature range, weighing variances of up to 0.3% can occur.
NOTICE
Rapid changes in temperature should be avoided as they can cause moisture to
condense within the electronics. When large temperature differences are
encountered, switch the weighing system off whilst it acclimatises.
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4.9 Identification Points and Data Plates
9
16
15
Item Model
9 Truck data plate
15 Plate - Operation / Lifting
16 Capacity Qmax
4.9.1 Data plate
22
21
17
19
18
23
20
Item Description Item Description
17 Model 21 Rated capacity (kg)
18 Year of manufacture 22 Manufacturer
19 Serial number 23 Manufacturer's logo
20 Net weight in kg
ZFor queries regarding the truck or ordering spare parts always quote the truck serial
number (19).
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4.10 Wind loads
Wind forces can affect the stability of a truck when lifting, lowering and transporting
loads with large surface areas.
Light loads must be especially secured when they are subjected to wind forces. This
will prevent the load from sliding or falling.
Stop the truck in both cases.
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