Starke Ecomaxx series User manual

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

Stärke EcoMaxx Series Forklifts

ECO-FG/FD 18/20/25/30/35 PA MODELS

REVISION EXOPR-01 2012

OPERATION MANUAL

INTRODUCTION

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.

The safe and efficient operation of a lift truck requires skill and alertness on the part of any operator.

To develop the skills required the operator must:

Acquire the proper training and certifications required for the operation of the forklift.

Understand the capabilities, limitations, specifications and rules of the forklift prior to operation.

Become familiar with the structure and layout of the forklift.

Read and understand the warnings and operating procedures in this manual.

Stärke Material Handling Group strongly suggests that you read this manual in its entirety:

Optimized efficiency begins EcoMaxx forklift. In addition, a qualified person experienced in lift truck operation, must guide every new operator through operation

lessons before they operate the lift truck independently.

Stärke Material Handling Group puts operator safety at the core of model designs and operations, observation of the safely rules and recommendations contained

in this manual can prevent potentially fatal accidents. Keep a copy of this manual with the forklift at all times and ensure that all operators review the contents of

this manual on a regular basis. If a replacement manual is required, contact Stärke Material Handling Group or your local Stärke dealer immediately to request a

replacement.

NOTE: Stärke forklifts are designed for single person operation only.

NOTE: Stärke forklifts are not intended for use on public roads. It is an on-site machine and inappropriate for long-distance road travel.

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. Should the forklift be used for any other purpose than the intended function the operator is responsible for their own safety

and the safety of others and property.

Additional information that describes the safe operation and use of forklifts is available from the following sources:

Employment safety and health standards or regulations.

Safety laws, codes, and standards.

Publications from government safety agencies, government insurers, private insurers and private organizations.

TABLE OF CONTENTS

CORRECT OPERATING PROCEDURE .............................. 1

Load and Vehicle Stability........................................................................2

Load Capacity Chart....................................................................................... 2

Handling a New Forklift ...........................................................................5

Engine Starting and Post-Starting Procedures..........................................6

After Starting ................................................................................................. 6

Lift Cylinder Warm-Up....................................................................................6

Vehicle operation.....................................................................................7

Take-Off ........................................................................................................7

Gear Shifting.................................................................................................. 7

Steering ......................................................................................................... 7

Picking-Up Loads...........................................................................................7

Unloading ......................................................................................................8

Stopping and Parking..................................................................................... 8

Road or Surface Conditions .....................................................................9

Snowy or Frozen Surfaces..............................................................................9

Handling in Hot Weather................................................................................. 9

Cold Weather Vehicle Handling....................................................................... 9

SAFETY, TRANSPORTATION & MAINTENANCE ...........11

Conditions for Normal Vehicle Use .........................................................12

Work Environment ....................................................................................... 12

For Engine-Powered Forklifts....................................................................... 12

For Electric-Powered Forklifts ...................................................................... 12

Work Environment Hazards ...................................................................13

Slippery Road Surfaces................................................................................ 13

Rough Ground.............................................................................................. 13

Lighting ....................................................................................................... 13

Noise........................................................................................................... 13

Conditions That Apply When Attachments Are Used ..................................... 13

Information on Operating the Forklift .....................................................14

Qualifications and Training .......................................................................... 14

Fundamental Safety Guidelines.................................................................... 14

Fuel.......................................................................................................16

Fuel Types................................................................................................... 16

Handling of Fuel........................................................................................... 16

Refuelling .................................................................................................... 16

Shipping, Loading and Unloading the Forklift......................................... 18

Lifting the Forklift ........................................................................................ 18

Assembling the Forklift and Mounting Attachments...................................... 19

Towing the Forklift and Moving Incomplete Forklifts..................................... 19

Leaving the Forklift Idle and Long term Storage.....................................20

Care of the Engine Compartment ................................................................. 20

Maintenance of the Brake System ............................................................... 20

Maintenance of the Hydraulic System .......................................................... 20

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 ...............................................................................30

OPERATION SAFETY TIPS ............................................. 33

CORRECT OPERATING PROCEDURE

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. The heavier the object, the more bending you must do. The

same is true of a forklift.

As seen from the diagram, the forklift front wheels act as a fulcrum upon which the load on

the rear wheels (counterweight) is counterbalanced by the load on the forks. Thus, car

should be taken not to disturb the balance in relation to the load center.

Even if a load less than the maximum is set far forward on the forks, or if a load exceeds

the specified allowable limit, the rear wheels will tend to float and the steering wheel will be

hard to turn. This the most dangerous condition for a forklift.

Because of this principle of leverage, a forklift's capacity is always specified by giving not

only the maximum weight it can lift, but also the maximum distance between the center of

the weight and the back of the forks. This is called the load center distance.

LOAD CAPACITY CHART

Load capacity chart shows exactly how the truck’s load capacity is reduced if the load

center distance is greater than normal.

The curves are given for several different maximum lift heights. The higher the lift, the

lower the allowable load.

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.

HOW TO READ THE LOAD CAPACITY CHART

The load weights 2500 kg well below the normal capacity of a truck with 4.5m mast.

However, the load center is 100cm from the back of the forks. On the chart, trace up from

the 100cm load center to the upper load curve and then across to the capacity scale.

According to the chart, the maximum weight that can be lifted at a 100cm load center is

approximately 1800kg, and so our assumed load of 2500kg is too heavy. It must be broken

down.

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.

1. Vehicle Type

2. Special Vehicle Type, Attachment

Type

3. Frame No.

4. Vehicle Weight

5. Mast Lifting Height

6. Front Tread

7. Tire Size

8. Air Pressure

9. Year of Manufacture

10. UL Specification

11. Load Capacity

12. Load Center

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.

After starting the engine, allow it to warm up fully before starting work.

Avoid rough handling and driving. Do not overwork the forklift.

Be sure that the new vehicle receives inspection service and periodic

maintenance as noted in the Service Booklet.

ENGINE STARTING AND POST-STARTING

PROCEDURES

1. Set the shift lever to neutral

2. Put on the parking brake.

3. Set the engine switch to GLOW and wait for the glow plug controller to indicate

the red hot condition. (Diesel only)

4. Turn the engine switch to ON, see that the oil warning lamp is lit, then pump the

accelerator pedal lightly.

5. Now pull the switch on START and the engine will start.

NOTE: Do not crank the starter motor for more than five seconds at a time.

AFTER STARTING

Once the engine is started, do not begin work immediately; let the engine warn up fully.

LIFT CYLINDER WARM-UP

Every day, before beginning work with the forklift, always operate the forks with the full

piston cylinder stroke several times .This will give the cylinders an even coat of oil and

prevent rusting from the air drawn into them.

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.

1. 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

1. Bring the vehicle to a full stop before reverting gears.

2. In the unloaded condition, 2nd gear may be used for takeoff and travel, but in the loaded condition, 1st gear should always be used for takeoff.

STEERING

1. The left hand is used to turn the steering wheel by the knob. The right hand This forklift is steered by the rear wheels. The steering wheel turns easily I

so watch out for exaggerated tail swing.

PICKING-UP LOADS

Approach an object to be loaded carefully, keeping the fork undersides level with the ground. Slip the forks under the load as far as the carriage, raise forks 15 to

20 centimetres, tilt mast fully backward and then transport it to the unloading point.

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.

1. 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.

2. Do not approach the load fast and strike it.

3. When travelling with a load on the forks, keep the mast titled backward and the forks 15 to 20 cm off the ground.

4. Never travel with the mast titled forward with the load raised. The load center of balance can shift and cause the load to fall off.

5. Back down a slope slowly when carrying a load.

STOPPING AND PARKING

To come to a stop, release your foot from the accelerator pedal, reduce speed and apply the brake with the foot pedal.

When parking the vehicle, stop in a place where the vehicle will not be in the way of other vehicles. Set the parking brake and lower the forks onto the floor or

ground.

NOTE: Do not attempt to stop on a slope or incline by working the accelerator pedal with the unit in gear. This will cause the oil temperature to rise in

the torque converter. This is called the stall speed of the engine.

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. Speed should be controlled only by means of the accelerator pedal.

NOTE: Tire chains grip the surface very well, but they are not insurance against side slippage.

HANDLING IN HOT WEATHER

Keep the following points in mind when you handle the forklift in hot weather:

COOLING SYSTEM

1. Clogged radiator can cause overheating. Clean them out regularly with a blast of compressed air. Also check for water leakage at the same time.

2. Check the fan belt tension and adjust to the specified tension.

3. If the engine overheats and coolant boils over, let the engine run idle until the temperature falls before shutting the engine off. Long life coolant is

mixed in with the coolant; do not run tap water into it right away. Raise the engine hood and allow it to cool down by itself.

COLD WEATHER VEHICLE HANDLING

In the severe cold of certain climates, lubricating oils and coolant are used in much tougher conditions than in milder weather areas. Thus, the following

precautions should be taken:

1. 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.

2. 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.

NOTE: Make sure the cap on the fuel tank is closed tightly so that no rain or snow can enter.

USE OF ANTIFREEZE

Before freezing weather sets in, the coolant (100% water) should be replaced by an antifreeze coolant – a mixture of water and the antifreeze compound, the

mixing ratio depends on the lowest temperature expected.

MIXING RATIO FOR ANTIFREEZE

Lowest Temperature Expected (°c) -15 °c / 5°f -35°c / -31°f

Antifreeze (%) 30 50

SAFETY, TRANSPORTATION &

MAINTENANCE

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:

In harbours or waterfronts where there is the risk of salt corrosion

In chemical plants where the forklift may be affected by acids or other chemicals

In environments where there is a risk of explosions due to suspended particulate matter or explosive gases, etc

In cold regions, hot regions, or at high altitudes

In environments with exhaust emissions exceed standards.

FOR ENGINE-POWERED FORKLIFTS

Do not use the forklift in bad weather conditions such as thunderstorms or high winds. Similarly, when dense fog arises, wait until visibility is good before using

the forklift. Engine exhaust gas can be hazardous to your health as it contains carbon monoxide. Where work must be done indoors, ensure that windows or

doors are open to allow adequate ventilation.

FOR ELECTRIC-POWERED FORKLIFTS

Never use the (optional) Cold Storage Model continuously in a cold storage area for more than 30 minutes. In addition, ensure that the time spent working outside

the cold storage area is at least equal to that.

NOTE: Do Not Use the Forklift Outdoors

WORK ENVIRONMENT HAZARDS

SLIPPERY ROAD SURFACES

Ensure that any water, oil, sand, ice or snow is removed from the road surface before work begins as these may cause the operator to lose control of the forklift.

ROUGH GROUND

Never operate on rough roads, including roads with potholes or sharp objects on them. These could damage the forklift, or cause it to tip over. Always ensure

that the forklift will travel on a smooth surface free of hazards.

LIGHTING

Never work in areas with insufficient light. Provide adequate lighting for the work environment or consult with your Starke EcoMaxx dealer about installing work

lights on the forklift.

NOISE

Excessive peripheral noise can distract the operator and cause fatigue. There is also the risk that warnings to pedestrians and will go unnoticed. Operators must

take particular care when using the forklift in noisy environments.

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.

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. If more than one forklift is used, the characteristics of features such as the brakes, accelerator and load handling equipment will differ, even on forklifts

with the same specifications. Ensure that operators who temporarily switch to other forklifts are trained to familiarize themselves with the characteristics of each

forklift before beginning work.

FUNDAMENTAL SAFETY GUIDELINES

WORKERS

Where a seat belt is fitted, operators must wear the seat belt while operating the forklift.

Always use the proper personal protective equipment, such as hard hats, protective shoes, gloves, eye protection or other equipment as appropriate.

Before operating the forklift, always visually inspect for any oil leakages or other abnormalities. Do not touch any metal surfaces with the bare hands.

If any abnormalities are found contact the supervisor and do not use the forklift until repairs are completed. Unless qualified, you must not attempt to

make repairs or adjustments yourself.