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Table of Contents
Summary of Contents for Starke EcoMaxx Series
- Page 1 OPERATION MANUAL Stärke EcoMaxx Series Forklifts ECO-FG/FD 18/20/25/30/35 PA MODELS REVISION EXOPR-01 2012 STÄRKE MATERIAL HANDLING GROUP 402 Allanburg Road · Thorold, ON L2V 1A4 · Canada TOLL FREE 877-435-4352 · FAX 905-227-2072 www.starkecanada.com · www.starkeusa.com...
- Page 3 The purpose of this manual is to offer owners, operators, and service technicians a complete understanding of the safe operation and maintenance of Stärke EcoMaxx Series diesel and gasoline model forklifts. And additionally to help avoid, and provide solutions to, potential issues that may occur during operation.
- Page 4 NOTE: Incorrect operation and maintenance of the forklift can be dangerous and lead to injury. The safety practices and preventative measures outlined in this manual apply only if the forklift is used for its intended purpose inside of the outlined capacity and limitations.
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Page 5: Table Of Contents
TABLE OF CONTENTS Work Environment ..................12 CORRECT OPERATING PROCEDURE ......1 For Engine-Powered Forklifts............... 12 For Electric-Powered Forklifts ..............12 Load and Vehicle Stability................2 Work Environment Hazards ..............13 Load Capacity Chart..................2 Slippery Road Surfaces................13 Handling a New Forklift ................5 Rough Ground.................... - Page 6 Battery Care....................20 Drive System Maintenance................21 Inspection of Industrial Trucks While In Storage ........... 21 Service Requirements ................27 Genuine Starke Replacement Parts .............. 27 Safe Work Practices..................27 Safety Equipment and Warning Labels ............28 Handling the Battery Safely ................29 Notes on Other Hazards ................
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Page 7: Correct Operating Procedure
CORRECT OPERATING PROCEDURE... -
Page 8: Load And Vehicle Stability
LOAD AND VEHICLE STABILITY Let us compare the way we lift a load with the way a forklift does. A light object can be picked up from just about any position, but to pick up a heavy one you must bend down, lowering your hips and arms. - Page 9 LOAD CAPACITY Load capacity is the maximum weight of material that can be handled on the forks al a specific load center. LOAD CENTER Load center is the distance between the center of weight of load and the back of the forks. MAXIMUM FORK HEIGHT Maximum fork height (MFH) is the highest position of the forks with the mast in a vertical position.
- Page 10 HOW TO READ THE SPEC PLATE The load capacity is engraved on the spec plate. Make sure of the load center and capacity before starting the operation. Vehicle Type Tire Size Special Vehicle Type, Attachment Air Pressure Type Year of Manufacture Frame No.
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Page 11: Handling A New Forklift
HANDLING A NEW FORKLIFT The performance and service life of your Starke EcoMaxx forklift depends heavily upon the way you handle it during the break-in period. During the first 100 hours, pay special attention to the following: Do not race the engine unnecessarily. -
Page 12: Engine Starting And Post-Starting Procedures
ENGINE STARTING AND POST-STARTING PROCEDURES Set the shift lever to neutral Put on the parking brake. Set the engine switch to GLOW and wait for the glow plug controller to indicate the red hot condition. (Diesel only) Turn the engine switch to ON, see that the oil warning lamp is lit, then pump the accelerator pedal lightly. -
Page 13: Vehicle Operation
VEHICLE OPERATION TAKE-OFF Raise the forks 15 to 20cm off the ground, work the torque converter shift lever, release the parking brake, and gently ease into takeoff. NOTE: Do not 'ride' the brake pedal. Applying your foot to the pedal more than needed can damage the torque converter and cause rapid brake wear. GEAR SHIFTING Bring the vehicle to a full stop before reverting gears. -
Page 14: Unloading
UNLOADING Tilt the mast forward to either a vertical or forward tilt position then lower the forks to the desired spot for unloading. Back away with the mast in one of the above conditions, smoothly withdrawing the forks from beneath the load. Raise the forks 15 to 20 cm and proceed to the next operation. If the mast is tilted backward at first when loading, the fork tips will strike the object for loading and the forks cannot be slipped underneath as far as the front of the carriage. -
Page 15: Road Or Surface Conditions
ROAD OR SURFACE CONDITIONS Needless to say, forklift construction is such that travelling speed is limited by the road or surface conditions. Be particularly careful when operating the forklift over other than flat surfaces. SNOWY OR FROZEN SURFACES Use tire chains on snowy or frozen surfaces. Since it is dangerous to go into a forward slide or side slip on such surfaces, avoid sudden braking, acceleration or sharp turning. - Page 16 When Fuelling Up: Always fill the tank up to the top. This minimizes the air within the tank and thus reduces possible freezing from moisture condensation, rust in the fuel system and hard starting. Battery Precautions: The higher the specific gravity and the greater the charge level, the more difficult it is for a battery to freeze up. By the same token, battery effectiveness is at its peak.
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Page 17: Safety, Transportation & Maintenance
SAFETY, TRANSPORTATION & MAINTENANCE... -
Page 18: Conditions For Normal Vehicle Use
CONDITIONS FOR NORMAL VEHICLE USE WORK ENVIRONMENT In special work environments, it may be possible to use this forklift under its standard specifications. Consult with your Starke EcoMaxx dealer if this forklift will be used in any of the following environments: ... -
Page 19: Work Environment Hazards
CONDITIONS THAT APPLY WHEN ATTACHMENTS ARE USED When attachments are installed on the forklift, the rated capacity is lessened than that of a standard model. Prior to using the attachment, contact your Starke EcoMaxx dealer for the rated capacity for the specific attachment. -
Page 20: Information On Operating The Forklift
INFORMATION ON OPERATING THE FORKLIFT QUALIFICATIONS AND TRAINING Only those persons who have the appropriate qualifications under the legislation of their country are permitted to operate this forklift. Where such laws have not been enacted, the employer should ensure that the selected operator is trained in safety measures and forklift operation before authorizing the operator to use the forklift. - Page 21 When attachments are installed on the forklift, the rated capacity is lessened than that of a standard model. Check with your Starke EcoMaxx dealer for the rated capacity of the specific attachment used. An example of the particular considerations that apply when attachments are used is given below: When the forklift operated is equipped with the side shift attachment, ensure that the load is centered with respect to the forklift during lifting and moving.
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Page 22: Fuel
FUEL FUEL TYPES The following fuels are recommended: Unleaded gasoline should have a Research Octane Number (RON) of 91 or greater; Diesel fuel should be No.2 or greater; And LPG should include 90% or more of propane and propylene by volume. Use the correct fuel type for your forklift. - Page 23 Always exchange tanks when refuelling with LPG. When exchanged LPG tanks, the operator should always visually check the connections for damage or other abnormalities. If a gas leak occurs, do not start the engine and request repairs immediately. When the LPG tank needs refilling, ask the LPG station attendant to fill the tank. Never attempt to fill the tank yourself, unless properly trained.
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Page 24: Shipping, Loading And Unloading The Forklift
SHIPPING, LOADING AND UNLOADING THE FORKLIFT Observe the following cautions when shipping the forklift by trailer or freight car: Appoint a supervisor. Ensure that the bed of the freight car or trailer is strong enough to hold the weight of the forklift. ... -
Page 25: Assembling The Forklift And Mounting Attachments
ASSEMBLING THE FORKLIFT AND MOUNTING ATTACHMENTS Ask your Starke EcoMaxx dealer to assemble a forklift that has been delivered disassembled. If the mast and/or counterweight must be removed for shipping or other reasons remove the mast first and then remove the counterweight. To reattach the mast and counterweight, use the reverse order, attaching the counterweight first and then the mast. -
Page 26: Leaving The Forklift Idle And Long Term Storage
LEAVING THE FORKLIFT IDLE AND LONG TERM STORAGE When the forklift is left to be idle, store the forklift with the mast extended to its highest point. When performing periodic checks, raise and lower the mast three of four times to lubricate the inside of the cylinders. CARE OF THE ENGINE COMPARTMENT The engine and engine compartment can become rusted from moisture and the like. -
Page 27: Drive System Maintenance
To prevent rust from developing it is necessary to operate the truck once a month in forward and reverse over a travel distance of 50 meters or more. NOTE: Careful performance of these inspections and maintenance will assure delivery of the Starke EcoMaxx forklift in the best possible condition. - Page 28 INSPECTION & SERVICE INTERVALS INSPECTION & SERVICE AREAS Receipt Monthly Semi- Annually Engine Oil Brake Fluid Hydraulic Oil Tire Pressure Electrolyte Inspection / Replacement / Receipt: Inspection when the truck is received by the dealer. / Monthly: One month from the Inspection performed upon reception, and every month thereafter.
- Page 29 AREAS INSPECTION DESCRIPTION REMEDY Check Underside For Rusting Remove Rust And Touch Up. Important Checkpoints: Front Axle Housing, Steering Linkage, Power Repaint. Steering Cylinder Rod. Rust Preventative Damage Damage During Transport. Touch Up. Damage While In Stock. Replace Parts. Body Repair. Repaint.
- Page 30 AREAS INSPECTION DESCRIPTION REMEDY Rust Engine Or Engine Compartment Rusting. Remove Rust, Blow Out With Compressed Air, Wash, And Touch Important Checkpoints: Engine Mounting Cylinder Head, Cylinder Head Up Paint. Bolts, Cylinder Block, Transmission, Machined Surfaces, All Joints And Connections, Counterweight. Rust Preventive.
- Page 31 AREAS INSPECTION DESCRIPTION REMEDY Hydraulic Oil Check the Level With the Oil Level Gauge. Replenish After Assuring Cleanliness. Check for Cleanliness, Viscosity, and Presence of Foreign Matter. Replace Oil. Tire Pressure Check Inflation Pressure With Tire Pressure Gauge. Add Air. Specified Inflation Pressure is Listed in Pre-Delivery Inspection Procedures of the Operator's Manual.
- Page 32 Specific Gravity Check Measure At The Second Cell For Battery Plus (+) Terminal. Measure At Cells. Use the Middle Cell as a Pilot Check Cell for Specific Gravity Index at the Second Month, Check all Specific Gravity: 1.260 Cells at 6 Months and Use the Worst One for the Pilot Cell Thereafter.
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Page 33: Service Requirements
SERVICE REQUIREMENTS GENUINE STARKE REPLACEMENT PARTS There are genuine Starke EcoMaxx Parts available for all repairs and maintenance required on the forklift. Contact your Starke EcoMaxx dealer. Refer also to the User Parts Catalogue supplied with the forklift. DISPOSING OF ENGINE OIL AND BATTERIES To avoid damage to the environment, do not dispose of used engine oil, batteries, filters, etc. -
Page 34: Safety Equipment And Warning Labels
LPG Vehicle (Engine-Powered Models) Upswept Exhaust (Engine-Powered Forklifts) High-Capacity Battery Charger (Electric-Powered Forklifts) SAFETY EQUIPMENT AND WARNING LABELS Caution plates are installed on all Starke EcoMaxx industrial forklifts. Never operate the forklift improperly. Always properly inspect and maintain the forklift. -
Page 35: Handling The Battery Safely
The information on the caution plates provides guidelines for safe operation. Make sure you fully understand and follow the information provided on them. Replace caution plates that are damaged or defaced and are no longer legible with new caution plates. Your Starke dealer can provide new caution plates. -
Page 36: Notes On Other Hazards
NOTES ON CHARGING When charging the battery while it is in the forklift, keep the battery cover open. Ensure that a “No Exposed Flames” sign is prominently displayed when charging the battery. To prevent the hydrogen gas from igniting during battery charging, observe the prohibition on open flames. Do not stop charging by disconnecting the charging plug or battery plug. - Page 37 When carrying loads up or down a slope, go forwards up the slope and backwards down the slope. Do not turn on a slope as this may cause the forklift to tip over. DO NOT USE THE CHARGER TO OPERATE THE FORKLIFT OR TO LIFT LOADS (ELECTRIC-POWERED MODELS) Do not use any power source other than the battery.
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Page 39: Operation Safety Tips
OPERATION SAFETY TIPS... - Page 40 Only Properly Trained and Authorized Drivers Should Operate Forklift Trucks Are you qualified to be a forklift truck driver? Are you familiar with the forklift truck you operate? Do you wear a safety helmet and proper clothing on the job? Before Starting Work Check the Condition of the Forklift Truck Stop and think safety before starting the day's work.
- Page 41 Watch For Loose Loads Handle only stable, safely arranged loads. Position Loads Evenly On the Forks for Proper Balance When handling wide loads or off-center loads that cannot be centered I operate with caution to prevent tipping over the forklift truck. Also use caution when handling long lengths of bar stock, lumber, etc.
- Page 42 The mast should always be vertical or tilted backward when lifting a load, never tilt forward beyond the vertical, and an elevated load may be tilted forward only when putting it on the stack or directly over the unloading area. 14.
- Page 43 20. Never Overtake Other Vehicles Never pass other vehicles moving in the same direction at intersection blind spots and other dangerous places. Always expect the unexpected! 21. Avoid Stunt Driving and Horseplay Safety is the matter of your own attitude. This is difficult to measure but quickly becomes evident once you are behind the wheel. It's not your forklift truck. It's you who invites trouble! 22.
- Page 44 26. Avoid Running over Loose Objects Remove hazardous loose objects rather than driving over or around them. Avoid holes and bumps that might disturb your load. 27. Always Watch Load and Mast Overhead Clearance Be sure of sufficient headroom under overhead installations such as lights, wiring, pipe work, sprinkler systems, doorway lintels, conveyors. Keep the mast as low as possible in all areas where overhead clearances are limited.
- Page 45 33. Observe Floor Loading Limits Never assume that any surface over which your forklift truck is to operate is strong enough to support the weight with or without a load. Make sure the dock boards are securely fastened and are strong enough to take this moving load safety. 34.
- Page 46 Report any faulty performance without delay. 42. Know Your Forklift Truck and Think Safety Make safety a matter of attitude. Expect the unexpected and use sound judgement whenever you are behind the wheel. Enjoy operating your Starke EcoMaxx Forklift!
- Page 48 STÄRKE ECOMAXX OPERATION MANUAL Edition: EXOPR-01 2012 Printing Date: 2012-02 Publication Number: EXOPR-01 Publisher: Stärke Material Handling Group 402 Allanburg Road Thorold, Ontario, Canada L2V 1A4 1-877-435-4352 www.starkeforklift.com info@starkeforklift.com...
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