Jungheinrich AMW 22, AMW 22p, AMW 22ps Operating Instructions 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.
11.19 en-GB
3
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4
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:
Z
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.
Used before notices and explanations.
Indicates standard equipment
t
Indicates optional equipment
o
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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
7
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
4.8
4.9 AMW 22ps weighing system 76
4.10
5 Troubleshooting 102
5.1 Load cannot be lifted 102
.
AMW 22 / AMW 22p Standard Weigher (t) 60
AMW 22p Weigher, Special Version (o) 66
On-Board Printer (o) 101
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
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
(o) Check and Adjust Foot-Activated Parking Brake 109
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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.
Special equipment and authorisation are required if the truck is to be constantly
u
used in extreme conditions, especially in dusty or corrosive atmospheres.
The truck cannot be used in areas at risk of explosion.
u
In adverse weather conditions (thunder, lightning) the industrial truck must not be
u
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.
Z
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.
Calibratable 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
6
13452
798
3.1 Truck Component Overview
Item Description Item Description
1
2
3
4
5
Travel and parking brake 6
o
Load handler 7
t
Handle 8
t
“Lift/lower fork” handle 9
t
Tiller
t
Standard equipment
t
Steered wheels
t
Load wheels
t
Foot-activated parking brake
o
Data plate
t
Optional equipment
o
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3.2 Weighing System Component Overview
1113101312
14
Item Designation Item Designation
10
Display and evaluation unit
t
13
t
Load cells
(AMW 22p / AMW 22ps)
11
Display and evaluation unit
t
14
On-board printer
o
(AMW 22)
12
Battery
t
Standard equipment
t
Optional equipment
o
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)
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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).
13
4 Technical Specifications
Z
The 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 /
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)
AMW 22ps
AMW 22p
1)
(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)
500 - 2200 kg (o)
1.0 kg
0.5 kg 1.0 kg
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)
500 - 2200 kg (o)
1.0 kg 1.0 kg
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.
Z
AMW 22p
AMW 22ps
Outside the listed temperature range, weighing variances of up to 0.3% can occur.
Within a temperature range of -10 to +40°C the maximum weighing
variance is 0.1% of the measured weight.
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4.4 Dimensions
s
e
W
a
x
h
14
b
11
b
10
b1= b
5
h
3
h
13
l
1
l
6
l
2
l
m
2
674 (AMW 22p / AMW 22ps)
y
c
Q
104°
104°
a/2=100
a/2=100
Ast = W
a+l6
-x+a
Designation AMW 22 / AMW 22p /
h3Lift
h13Lowered height
h14Height of tiller handle
y Wheelbase 1110 mm
s/e/l Fork dimensions 62/170/1150 mm
AMW 22ps
122 mm
86 mm
1234 mm
16
l1Overall length 1546
l2Length to fork face
396 mm
mm
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Designation AMW 22 / AMW 22p /
AMW 22ps
b1Overall width
b5Outer fork distance
b10Track width, front
b11Track width, rear
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 /
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
540 mm
540 mm
109 mm
370 mm
AMW 22ps
Truck Battery type Voltage/capacity
AMW 22 Alkaline (type AA) 4x1.5 V
AMW 22p Lead-gel battery
AMW 22ps Lithium-ion battery
4.7 Tyre type
AMW 22 / AMW 22p /
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
12 V/1.2 Ah
(rechargeable)
14.8 V/5 Ah
(rechargeable)
AMW 22ps
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4.8 Operating conditions
– During operation: -10°C to 40°C
Ambient lighting
– - At least 50 Lux during operation
Z
Outside 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.
18
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4.9 Identification Points and Data Plates
9
16
15
222117
19
18
23
20
Item Model
9 Truck data plate
15 Plate - Operation / Lifting
16 Capacity Qmax
4.9.1 Data plate
Item Description Item Description
17 Model 21 Rated capacity (kg)
18 Year of manufacture 22 Manufacturer
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Z
19 Serial number 23 Manufacturer's logo
20 Net weight in kg
For queries regarding the truck or ordering spare parts always quote the truck serial
number (19).
19
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.
20
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C Transport and Commissioning
24
1 Lifting by crane
WARNING!
Improper loading by crane can result in accidents
Improper use or use of unsuitable lifting gear can cause the truck to crash when
being loaded by crane.
Prevent the truck from hitting other objects during lifting, and avoid uncontrolled
movements. If necessary, secure the truck with guide ropes.
The truck may be loaded only by people who are trained in using lifting
u
accessories and lifting gear.
Wear personal protective equipment (e.g. safety shoes, safety helmet, hi-vis
u
jacket, protective gloves) when loading by crane.
Do not stand under suspended loads.
u
Do not walk into or stand in a hazardous area.
u
Always use lifting gear with sufficient capacity (for truck weight, see truck data
u
plate).
Always attach the crane lifting gear to the prescribed attachment points and
u
prevent them from slipping.
Use the lifting accessories only in the prescribed load direction.
u
Crane lifting gear must be fastened in such a way that it does not come into
u
contact with any attachments when lifting.
Lifting the truck by crane
Requirements
– Park the truck securely, see page 54.
Tools and Material Required
– Lifting gear
– Crane lifting gear
Procedure
• Secure the crane lifting gear to the strap
points (24).
The truck can now be lifted by crane.
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2 Transport
25
25
WARNING!
Accidental movement during transport
Improper fastening of the truck and mast during transport can result in serious
accidents.
Loading must only be performed by specialist personnel trained for this purpose.
u
The specialist personnel must be instructed in securing loads on road vehicles and
handling load securing devices. In each case correct measurements must be
taken and appropriate safety measures applied.
The truck must be securely fastened when transported on a lorry or a trailer.
u
The lorry or trailer must have fastening rings.
u
Use wedges to prevent the truck from moving.
u
Use only fastening belts with sufficient strength.
u
Use non-slip materials to securing the load aids (pallet, wedges, ...) e. g. non-slip
u
mats.
Securing the truck for transport
Requirements
– The truck is now loaded.
– The truck is now parked securely, see
page 54.
Tools and Material Required
– Lashing straps
Procedure
• Attach the lashing straps (25) to the
industrial truck and the transport vehicle
and tension sufficiently.
The truck can now be transported.
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3 Using the Truck for the First Time
Procedure
• Check the equipment is complete.
The truck can now be started, see page 52.
Z
When the vehicle is parked, the surface of the tyres will flatten. The flattening will
disappear after a short period of operation.
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24
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D Batteries/Accumulators - Replacement/
Charging
1 Safety Regulations for Handling Batteries and
Accumulators
Maintenance personnel
Accumulators must only be charged and batteries only replaced by the operating
company. These operating instructions and the manufacturer’s instructions
concerning batteries and charging stations must be observed when carrying out the
work.
WARNING!
Risk of accidents and injury when handling batteries and accumulators
Batteries and accumulators contain chemicals that are poisonous and corrosive.
Avoid contact at all costs.
Do not dismantle or forcibly open batteries and accumulators.
u
Do not subject batteries and accumulators to heat, fire or direct sunlight.
u
Do not short-circuit batteries and accumulators. Store batteries and accumulators
u
so that no short circuits can occur through other batteries and accumulators or
metal objects.
Never use batteries or accumulators of different makes, capacity, size or type at
u
the same time in one truck.
Failure to comply could result in explosions!
u
Seek medical assistance immediately if you have swallowed a battery or
u
accumulator.
Do not subject batteries and accumulators to impacts.
u
Keep battery terminals and contacts clean and dry.
u
If a battery or accumulator is leaking, do not allow the liquid to come into contact
u
with the skin or eyes. If this has already happened, rinse the affected part with
plenty of water and seek medical assistance immediately.
Keep batteries and accumulators in a clean and dry environment, out of the reach
u
of children.
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Park the truck securely before carrying out any work on the batteries/accumulators
(see page 54).
25
Battery disposal
NOTICE
Batteries must be disposed of in accordance with the relevant national
environmental protection regulations.
Used batteries are recyclable commodities. As indicated by the marking showing a
crossed-out waste bin, batteries must not be disposed of as domestic waste.
Return or recycling of batteries must be ensured in accordance with the Battery
Directive 2006/66/EG.
Used batteries must be treated as hazardous waste. Batteries marked with the
recycling symbol and the sign showing a crossed-out rubbish bin should not be
disposed of with ordinary household waste.
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2 Safety regulations for handling lithium-ion batteries
2.1 Safety regulations
WARNING!
Unsuitable batteries without manufacturer approval can be dangerous.
Do not use any batteries without approval from the manufacturer.
u
The battery equipment must only be replaced with the manufacturer's
u
authorisation.
When inserting the battery, ensure that it is securely seated in the battery
u
compartment.
– Do not physically machine or modify the battery.
– Do not open, damage, penetrate or bend the battery.
– Do not throw the battery into a fire.
– Protect the battery from high temperatures and overheating.
– Protect the battery from solar irradiation.
– Keep the battery away from radiant sources and strong heat sources.
– The specified charging, operating and storage temperature ranges must be
observed.
Failure to comply with these safety instructions can result in fire and explosion or the
leakage of harmful materials.
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2.2 Potential hazards
+-
2.2.1 Symbols - Safety and Warnings
Used lithium-ion batteries must be treated as hazardous waste.
Lithium-ion batteries marked with the recycling symbol and the sign showing a
crossed-out waste bin must not be disposed of with ordinary household waste.
Buy-back terms and type of recycling are to be agreed with the manufacturer in
accordance with the Battery Directive 2006/66/EG.
Avoid fire and short circuits due to overheating.
Do not ignite or position an open flame, glowing embers, or sparks near the
lithium-ion battery.
Keep lithium-ion batteries away from strong heat sources.
Hot surfaces.
Battery cells can generate very high short-circuit currents, causing them to
become hot.
Dangerous electrical voltage!
Battery cells can generate very high short-circuit currents, causing them to
become hot.
Caution!
The metal parts of the battery cells are constantly under voltage, so do not
place any foreign objects or tools on the lithium-ion battery.
Observe the accident prevention regulations and DIN EN 50272-3.
Wear personal protective equipment (e.g. safety goggles and safety gloves)
when handling damaged battery cells and lithium-ion batteries. Use only
insulated tools.
If the contents leak out, do not inhale the fumes.
Always wash your hands after completing the work.
Do not mechanically machine the lithium-ion battery, strike, crush, compress,
notch, dent or modify it in any way.
Do not open, damage, penetrate, bend, heat the lithium-ion battery or allow it to
become hot, do not throw it into a fire, short circuit it or immerse it in water. Do
not store it or operate it in pressurised containers.
Follow the operating instructions and keep them in a visible position in the
charging area.
If any faults are found on the lithium-ion battery, contact the manufacturer's
customer service department immediately.
Do not carry out any actions on your own.
Do not open the lithium-ion battery.
Protect the lithium-ion battery from solar radiation or other forms of heat
radiation.
Do not expose the lithium-ion battery to heat sources.
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2.2.2 Explosion and fire hazard
WARNING!
Physical damage, thermal effects or incorrect storage in the event of a defect can
result in explosions or fire.
The battery materials can be flammable.
2.2.2.1 Particular hazard from combustion products
The lithium ion battery may be damaged by a fire in the vicinity of the lithium ion
battery. When fighting a lithium-ion battery fire, the following dangers and information
must be taken into consideration.
WARNING!
Contact with combustion products can be hazardous
Fires produce combustion products.
Combustion is a chemical process by which a flammable material combines with
oxygen under heat and light (fire).
The resulting combustion products can occur in the form of smoke, through leaking
fluids, escaping gases, debris as well decomposition products of certain chemicals.
These combustion products are substances that enter the body through the
respiratory tract and / or the skin, where they can produce and adverse effects such
as choking.
Avoid contact with combustion products.
u
Use protective equipment.
u
– Hydrogen fluoride (HF) Hydrofluoric acid = extremely corrosive
– Risk of toxic substances produced by pyrolysis
– Risk of highly flammable gas mixtures.
– Other combustion products: Carbon monoxide & -dioxide, manganese, nickel and
cobalt oxides.
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2.2.2.2 Special fire fighting protective equipment
– Use self-contained breathing apparatus.
– Wear protective overalls.
2.2.2.3 Additional fire fighting instructions
To prevent secondary fires from occurring, the lithium-ion battery must be cooled
from the outside. Fluids or solids must never be directed into the lithium-ion battery.
Suitable extinguishing agents
– Carbon dioxide extinguisher (CO2)
– Water (not on mechanically opened or damaged batteries!)
Unsuitable extinguishing agents
– Foam
– Grease fire extinguishing agents
– Powder extinguishers
– Metal fire extinguishers (PM 12i extinguishers)
– Metal fire powder PL-9/78 (DIN EN 3SP-44/95)
– Dry sand
2.2.2.4 Instructions for cooling an overheated, non physically damaged battery
This type of damage may be caused by a short circuit inside the battery, which may
result in harmful materials leaking, fire or battery explosion.
Endangered unopened batteries can be cooled using a water
jet.
2.2.3 Material discharge
WARNING!
Battery electrolyte fluid can be hazardous
Electrolyte fluid can be discharged if the battery is physically damaged. Electrolyte
fluid is harmful and must not come into contact with the skin or eyes.
If it does, rinse the affected parts with plenty of water and seek medical assistance
u
immediately.
In the event of skin irritation or if any substances are breathed in, seek medical
u
assistance immediately.
In the event of inhalation bring the affected person into the fresh air and keep them
u
still.
2.2.3.1 Precautionary measures for personnel
– Keep personnel away and facing the wind.
– Block off the affected area.
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