Jungheinrich AMW 22, Operating Instructions Manual

Page 1: ...AMW 22 AMW 22p AMW 22ps 12 14 Operating instructions 51119800 11 19 en GB AMW 22 AMW 22p AMW 22ps...

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Page 3: ...W 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 4...

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Page 5: ...lar 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 follo...

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Page 7: ...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...

Page 8: ...sion 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...

Page 9: ...Carrying and lifting passengers Pushing or pulling loads Transverse handling of long loads 3 Approved application conditions Operation in industrial and commercial environments Permissible temperatur...

Page 10: ...ed 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 understo...

Page 11: ...nspection 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 s...

Page 12: ...2 7 9 8 Item Description Item Description 1 o Travel and parking brake 6 t Steered wheels 2 t Load handler 7 t Load wheels 3 t Handle 8 o Foot activated parking brake 4 t Lift lower fork handle 9 t D...

Page 13: ...d 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 quan...

Page 14: ...e 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 k...

Page 15: ...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 Z Outside...

Page 16: ...y c Q 104 104 a 2 100 a 2 100 Ast Wa l6 x a Designation AMW 22 AMW 22p AMW 22ps h3 Lift 122 mm h13 Lowered height 86 mm h14 Height of tiller handle 1234 mm y Wheelbase 1110 mm s e l Fork dimensions 62...

Page 17: ...esignation 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 A...

Page 18: ...ide 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 larg...

Page 19: ...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...

Page 20: ...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 o...

Page 21: ...loves when loading by crane uDo not stand under suspended loads uDo not walk into or stand in a hazardous area uAlways use lifting gear with sufficient capacity for truck weight see truck data plate u...

Page 22: ...uThe truck must be securely fastened when transported on a lorry or a trailer uThe lorry or trailer must have fastening rings uUse wedges to prevent the truck from moving uUse only fastening belts wit...

Page 23: ...ime 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 pe...

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Page 25: ...ries and accumulators Store batteries and accumulators so that no short circuits can occur through other batteries and accumulators or metal objects uNever use batteries or accumulators of different m...

Page 26: ...ng 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 batteri...

Page 27: ...ely seated in the battery 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 hig...

Page 28: ...cts 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 bat...

Page 29: ...stion 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 escapin...

Page 30: ...ysically 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 c...

Page 31: ...disposed of in the correct manner The fire brigade the Agency for Technical Relief or similar institutions must be used Absorb residues with liquid absorbent material such as vermiculite sand universa...

Page 32: ...uitable battery types Charging a battery that is not suitable for this charger can result in damage to the charger and battery The battery could expand or burst uThe lithium ion battery must only be c...

Page 33: ...he manufacturer s customer service department 2 4 Battery lifetime and maintenance The lithium ion battery is wear free The components are maintenance free as a result there are no maintenance interva...

Page 34: ...n automatic fire detection system is only activated in the event of actual danger e g naked flames Small amounts of discharge from a single battery are not critical to the environment Above average na...

Page 35: ...conomic goods In accordance with the marking showing a crossed out waste bin these lithium ion batteries may not be disposed of as domestic waste Return or recycling of batteries must be ensured in ac...

Page 36: ...nsport Z ADR Accord europ en relatif au transport international des marchandises Dangereuses par Route UN 3171 9 26 27 Item Description 26 Danger label class 9A for lithium ion batteries 27 Marking of...

Page 37: ...2 7 3 1 Shipping functional batteries Functioning batteries can be shipped in accordance with the following regulations Classification according to ADR road transport UN 3171 lithium ion battery class...

Page 38: ...Substance safety rating Not specified Marking Product does not require marking under EC Directive HazMatR 2 7 3 2 Shipping faulty batteries To transport these faulty lithium ion batteries contact the...

Page 39: ...e P202 Read and understand all safety instructions before use P233 Keep containers sealed P235 P410 Keep cool Protect against direct sunlight P251 Do not penetrate or burn even after use P261 Avoid in...

Page 40: ...2 8 2 5 Disposal P500 range P502 Obtain information on recycling or reuse from the manufacturer or supplier 40 11 19 en GB...

Page 41: ...down automatically 3 2 Replacing batteries Replacing batteries up to year of manufacture 2013 Procedure Undo the two lateral retaining screws on the upper part of the housing and carefully take off t...

Page 42: ...etaining screws of the battery holder and pull out the battery holder Take all the used batteries out of the battery holder and insert new batteries ensuring their polarity matches the markings Re ins...

Page 43: ...mediately as the weighing system will soon shut down automatically Z To avoid a loss in battery capacity we recommend that the battery module be charged for at least 6 hours If the weighing system is...

Page 44: ...tches off and the LED lights up green once charging is completed Z A deep discharge of the battery can occur if it is not removed from a charger the power supply of which has been interrupted Place th...

Page 45: ...LED on the charger lights up green In this case Disconnect the charger from the power supply Remove the battery from the charger Place the battery in the weighing system see page 47 If the battery has...

Page 46: ...ry icon on the display lights up The weighing system switches off automatically after 2 minutes NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 Checking the battery charge status Procedure Check the...

Page 47: ...harger Connect the charger to the power supply Z The LED on the charger lights up red while charging is active Disconnect the charger from the power supply once charging is completed Z The charger swi...

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Page 49: ...structions Safety shoes must be worn on pedestrian operated trucks Unauthorised use of truck The operator is responsible for the truck during the time it is in use The operator must prevent unauthoris...

Page 50: ...falling loads or lowering falling operating equipment uInstruct unauthorised persons to leave the hazardous area uIn case of danger to third parties give a warning signal in good time uIf unauthorise...

Page 51: ...t To pull the truck To push the truck 4 Lift neutral lower load handler handle t In position H lifting Moving the tiller raises the load handler In position neutral Travel Press to position S lowering...

Page 52: ...repaired uReport any defects immediately to your supervisor uMark defective truck and take out of service uDo not return the industrial truck to service until you have identified and rectified the fau...

Page 53: ...local conditions The truck must be pushed pulled at slow speed when negotiating bends or narrow passageways when passing through swing doors and at blind spots The operator must always observe an adeq...

Page 54: ...must take up a position which does not allow it to come into contact with the walls of the lift shaft Persons riding in the lift with the forklift truck must only enter the lift after the truck has co...

Page 55: ...edure Release the parking brake by applying the foot activated parking brake 8 o or the travel and parking brake 1 o Using the handle 3 on the tiller 5 the truck can be pushed or pulled in the require...

Page 56: ...Manual braking Procedure Pull or push against the direction of movement The truck brakes 1 5 3 8 Braking with the foot activated parking brake o Procedure Apply the foot activated parking brake 8 in d...

Page 57: ...ple do not vacate the hazardous area uOnly carry loads that have been correctly secured and positioned Use suitable precautions to prevent parts of the load from tipping or falling down uDamaged loads...

Page 58: ...required to ensure optimum weighing accuracy Calibrated weighing system o only AMW 22p and AMW 22ps In the case of eccentric loading or inclinations greater than 2 the display is blocked The truck mu...

Page 59: ...nclines 4 6 3 Depositing a load NOTICE Loads must not be deposited on travel or escape routes in front of safety mechanisms or operating equipment that must be accessible at all times Requirements Sto...

Page 60: ...stem including the load is stable 34 NET The displayed weight is a net weight Z Only if the load is stable and the Stable load segment 33 is activated will key commands be accepted and functions execu...

Page 61: ...ad cells to the AD converter inclination HELP 3 Negative signal from the load cells to the AD converter inclination HELP 4 The tare weight entered is too high Z Press key 36 to clear the display messa...

Page 62: ...ro The NET segment 31 shows the activated tare weight Loading or unloading the net load Z The net value of the weighed weight is displayed On unloading the a negative value is shown for the net weight...

Page 63: ...new zero setting is performed Activate and save the tare weight Procedure Confirm all segments by pressing the Confirm key 35 The tare weight is now activated NET segment 34 active and is saved If at...

Page 64: ...dure Keep key 37 pressed for three seconds the total weight calculated thus far will be displayed The display shows the current number of weighings alternating with the total weight After a few second...

Page 65: ...ght by N If a tare weight has been input this will also be printed out and identified by PT The total net weight is identified by TOT Total Example of a printout 01 B G 6 8 kg 02 B G 158 2 kg 03 N 426...

Page 66: ...ge 2 42 e3 The displayed weight lies in weight range 3 43 Stp1 The limit value 1 is activated 44 Stp1 The limit value 2 is activated 45 Weight display in kg or lb messages quantities 46 The weighing s...

Page 67: ...zero range Acknowledge with any key Err05 Accuracy of the piece calculation too low Acknowledge with any key Err06 Load cell signal too high Automatic for correction of the input Err07 Load cell signa...

Page 68: ...ystem is unloaded and is free to move The weighing system has an automatic zero correction and automatically compensates for small variations in the zero point For larger variations in the zero point...

Page 69: ...to skip to the next field Repeat this operation until the desired value is displayed Activate or save the tare weight Procedure Press the Confirm key 49 to confirm the value The tare weight is now ac...

Page 70: ...e Counting by Calculating the Piece Weights Pieces can be counted using a known or weighed piece weight Larger differences in weight and larger quantities for determining the piece weight result in mo...

Page 71: ...and to increase the quantity of pieces Increasing or reducing the number of goods placed on the load handler by the number of pieces entered Press the Confirm key 49 The calculation of the piece weigh...

Page 72: ...p the Change Over key 53 pressed for three seconds The system reverts to standard weighing mode The quantity of pieces that was determined is cleared down Addition of individual weighings Procedure Lo...

Page 73: ...e reset A cumulative printout is performed before the total is reset Resetting the total of individual weighings without print out Procedure Press the On Off key 53 whilst the total weight is being di...

Page 74: ...34 5 kg B G 1234 5 kg N 1200 5 kg T 34 5 kg N 1200 5 kg No 1 10 07 03 17 45 No 1 10 07 03 17 45 Example of a printout of a piece counting without identity code number with identity code number B G 123...

Page 75: ...ey 51 or Decrease value key 50 to change the position that is flashing Press the Skip 52 to skip to the next field Press Confirm 49 to load the displayed value The display shows the message m 00 or th...

Page 76: ...The display is showing the net weight e1 The displayed weight is within range 1 multi range option see page 14 e2 The displayed weight is within range 2 multi range option see page 14 e3 The displaye...

Page 77: ...Standard function Automatic tare Input function Reduce the value of a flashing digit TOTAL Additional function Display an intermediate result and print out the total weight Standard function Print ou...

Page 78: ...mitted Automatic CAL J Calibrated version only No action permitted If no action is required remove jumper JP1 Z Following this action a complete reconfiguration and recalibration of the system is requ...

Page 79: ...e1 e2 e3 STP1 STP2 4 9 3 2 Checking the zero point Z Before each weighing operation ensure that there is no load on the system and that it is unoccupied The weighing system features automatic zero ad...

Page 80: ...tdown process is indicated for 20 seconds NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 kg Z Once all five sections in the display have been filled the weighing system switches off NET ID CODE PT...

Page 81: ...CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 kg Deposit the load on the pallet Z The display shows the net value of the measured weight NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 kg To display th...

Page 82: ...TP1 STP2 kg Press the PT key for approx 3 seconds Z The display switches to 00000 and the last zero flashes PT NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 Press the up arrow key until the flashi...

Page 83: ...Remove the load Z The display switches to zero NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 kg Set down the pallet Z The display shows a negative value NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 ST...

Page 84: ...de Z If a printer is connected a printout is created with the gross tare and net weights TOTAL NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 kg Re...

Page 85: ...perations and the weight TOTAL NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 kg Z There are two options for resetting the weighing data Reset and...

Page 86: ...ress the Enter key Z The code number is confirmed The display reverts to weighing mode ID CODE NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 kg Entering a code number Key Display example To change...

Page 87: ...kg or lb B G Net weight kg or lb N Manually entered tare kg or lb PT Total weight Tot Date format year month day YY MM DD Time in 24h format hours minutes HH MM Example 1 Standard printout without co...

Page 88: ...ight unit kg Changing the unit of measure Key Display example Z The weight is displayed in the preset weight unit NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 kg To change the unit of measure pre...

Page 89: ...STP2 Select TIME in the menu Z You can use the arrow keys to scroll through the user menu PT TOTAL NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 Confirm your selection with the Enter key Z ho_00...

Page 90: ...o the TIME menu entry ID CODE NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 To exit the TIME menu press the Enter key for approx 3 seconds Z The display first switches to the SET entry and then to...

Page 91: ...rovided on the following pages ID CODE Menu entries A_oFF dAtE tImE bLoFF LIght SLEEP Use the arrow keys to access the desired menu entry in this case SLEEP Z The menu entries appear one after the oth...

Page 92: ...u ID CODE NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 Briefly press the CLR key to return to weighing mode Z The weighing system reverts to weig...

Page 93: ...ult None e1 e2 e3 STP1 STP2 Function Set the time Comments None Settings ho_xx m_xx hours minutes Default e1 e2 e3 STP1 STP2 Function Select the time in minutes until the backlight is switched off Com...

Page 94: ...e1 e2 e3 STP1 STP2 Function Set the time in minutes until the system switches to standby mode Comments A setting of 00 means that standby mode is never used Settings 00 99 Default 20 94 11 19 en GB...

Page 95: ...wn arrow key Z SUP is shown on the display PT NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 Press the Enter key to select the supervisor menu Z Explanations of the various menu entries are provide...

Page 96: ...TOTAL NET ID CODE PT TOTAL KG LB CLR e1 e2 e3 STP1 STP2 Briefly press the Enter key to select the menu entry Z The display first switches to the SET entry and then to the USER menu ID CODE NET ID CODE...

Page 97: ...STP1 STP2 Function Select the function of the RS 232 interface for wired options Comments Use the selection menu Settings PC ScAn rEm Prnt NonE Default Prnt Prot ASCII LF04 LAYou Std bArcd NONE SuPPL...

Page 98: ...without confirmation Settings bidir rdc A rdc N Default bidir e1 e2 e3 STP1 STP2 Function Select the scanner functions Comments Not yet available Settings Default e1 e2 e3 STP1 STP2 Function Select t...

Page 99: ...omment 2 LAYou Select if the layout needs to be changed Settings Std tot Default Std Comment 3 bArcd Select if a barcode is to be printed Additional details are provided in the separate table below Se...

Page 100: ...a smartphone or tablet in large digits but also saves the measured gross weight tare weight code number date and time as well as the ID of the device or operator The data can be sent to any e mail ad...

Page 101: ...e retaining clips down and open the printer cover Remove the old paper roll Insert the new roll with the direction of unrolling as shown in the diagram Unroll some paper from the new roll hold the end...

Page 102: ...service department Additional troubleshooting must only be performed by the manufacturer s specialist service engineers The manufacturer has a service department specially trained for these tasks In o...

Page 103: ...s catalogue can be found at www jungheinrich de spare parts search by entering the serial number Z The serial number can be found on the data plate see page 19 2 Operational Safety and Environmental P...

Page 104: ...k CAUTION Risk of component damage when cleaning the truck Do not clean with a steam jet Z After cleaning carry out the test operations as described see page 112 Consumables and used parts CAUTION Con...

Page 105: ...rough fine holes or hairline cracks in the hydraulic system causing severe injury uCall for a doctor immediately in the event of an injury uReport any defects immediately to your supervisor uTag out t...

Page 106: ...rked containers uAlways fill consumables in clean containers uDo not mix up different grades of consumable The only exception to this is when mixing is expressly stipulated in the Operating Instructio...

Page 107: ...when handling oil uAvoid contact and digestion If you swallow oil do not induce vomiting but seek medical assistance immediately uSeek fresh air after breathing in oil fumes or vapours uIf oil has com...

Page 108: ...no Quantity Description Used for A 51 132 716 5 0 l HVLP32 Hydraulic system E 29 202 050 1 0 kg Grease Polylub GA 352P Lubrication service Grease guidelines Code Saponificatio n Dew point C Worked pen...

Page 109: ...top releases the brake Measure the gap between the brake pad and the wheel If the gap is greater than 5 mm the foot operated parking brake must be adjusted Adjusting the parking brake Procedure Press...

Page 110: ...e truck according to the lubrication diagram see page 108 6 2 Restoring the truck to service after decommissioning WARNING Faulty brakes can cause accidents Test the brakes immediately as soon as the...

Page 111: ...k with regard to safety The truck must also be examined thoroughly for damage The operating company is responsible for ensuring that faults are rectified immediately 8 Final de commissioning disposal...

Page 112: ...onsiderable impact on component wear The intervals must be reduced accordingly for more arduous conditions Z The following checks must be carried out by the operating company at least weekly 1 Test br...