OPERATION AND MAINTENANCE MANUAL
ELECTRIC FORKLIFT Safe operation. Regular maintenance. Clear troubleshooting and remedies.
01
Receipt and operation
02
Battery and charging
03
Service and troubleshooting
RADEK
ENGLISH
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How to use this manual Contents and scope
This manual covers receipt, operation, the battery, maintenance and troubleshooting of RADEK electric forklifts with lithium batteries. Keep it accessible to the operator and hand it over with the machine if it is transferred or sold. Chapter
Page
01 How to use this manual
02
02 Receipt and commissioning
03
03 Main components and controls
04
04 Safety and preparation
05
05 Travel and load handling
06
06 Daily checks and end-of-shift procedure
07
07 Battery and charging
08
08 Service schedule by operating hours
09
09 Periodic checks by system
10
10 Oil, harsh conditions and storage
11
11 Troubleshooting and remedies
12-14
12 Service support and warranty
15
Check the specific configuration All forklifts covered by this manual have lithium batteries. The motor, brakes and attachments may vary by model. Apply only the instructions relevant to the installed components. For capacity, settings, fluids, charging and service intervals, follow the machine data plate and approved documentation for the specific model.
Quick reference For daily operation, use the checklist on page 7. For a fault, go directly to troubleshooting on pages 12-14.
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Receipt and commissioning Inspect the machine before switching it on
1. Transport condition and mechanical checks • Remove transport wrapping, dust and grease deposits. Check for physical damage or missing parts. • Check bolts, nuts, pivot pins, chains and other joints. Tighten loose fasteners to the specified torque. • Check the forks, mast, guides and overhead guard. Lubricate the designated points with a suitable lubricant.
2. Battery and hydraulics • Check the lithium battery specification and charger compatibility. Charging and maintenance instructions are in Chapter 07. • Check the state of charge, terminals, cables and any signs of leakage. Delivery with a charged battery does not replace the initial inspection. • If an activation charge is specified for the battery, complete it fully according to its instructions; do not interrupt it arbitrarily. • Check the hydraulic oil level. Top up only with oil of a confirmed specification; do not mix different types, grades or brands.
3. Documentation and familiarisation • Check the certificate, invoice, battery report and other accompanying documents. Complete locally required registration, insurance and other documentation, where applicable. • The operator must read the operating and service instructions and become familiar with capacity, controls, safety devices and maintenance points. • After a successful inspection, carry out a trial start and test travel, steering, braking, lifting, lowering and tilting in a secured area.
If an issue is found on receipt Do not put the machine into regular service. Record the damage or symptom with photos/video and contact the supplier or service department. Do not dismantle the battery or electrical components without authorisation.
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Main components and controls Learn the layout of the specific model
The main assemblies are the mast, fork carriage and forks, lifting chains, overhead guard, front and rear wheels, seat, counterweight, steering wheel, and hydraulic lifting and tilting assembly. Component
Function and use
Main switch / key
Switches the power on and off. Check the positions and procedure on the specific machine.
Emergency power-off switch
Pressing it switches off the power. Release it as marked on the switch; on pull-to-release versions, the pulled-out position permits switching on.
Direction selector
Forward: forward travel. Centre: neutral. Reverse: reverse travel.
Accelerator pedal
Controls travel speed in the selected direction.
Service brake
Operated by pedal for controlled slowing and stopping.
Parking brake
Secures the machine when parked.
Hydraulic control levers
Control lifting, lowering and tilting; additional functions depend on the equipment.
Lights, indicators and horn
Provide lighting and signalling during operation.
Instrument panel
Displays voltage, state of charge and, depending on configuration, operating hours, alarms and fault codes.
Machine systems • Braking: the service and parking brakes require periodic inspection; clearances must be adjusted by qualified personnel. • Steering: the hydraulic system enables easy and precise turning. • Hydraulics: the pump, cylinders and multi-section valve provide lifting and tilting.
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Safety and preparation Requirements for the operator, machine and work area
Operator and personal protection • Only trained, authorised and physically fit personnel familiar with the specific controls may operate the forklift. • Do not operate under the influence of alcohol, medication that affects your ability to work, or when fatigued. • Wear a safety helmet, slip-resistant safety footwear, suitable gloves and work clothing. Do not wear loose clothing or jewellery that could become caught.
Intended use and prohibitions • The forklift is used for handling, storing and loading suitably prepared goods. Do not tow other vehicles, open doors or lift loads with a cable attached directly to the forks. • Carrying or lifting people on forks or pallets is prohibited. No one may stand beneath a raised load. • Do not touch moving parts. Keep hands and feet inside the operator compartment; never place any part of the body between the mast and chassis. • Attachments and modifications require written manufacturer approval because they affect capacity, stability and visibility.
Work area • Provide stable ground, good lighting and clean, sufficiently wide routes free of unauthorised people and obstacles. A suitable fire extinguisher should be available nearby. • Before starting, carry out the daily inspection in Chapter 06. Do not use a faulty machine until the fault has been rectified.
Starting sequence • Apply the parking brake and place the controls in the initial positions specified for the model. • Adjust the seat for easy access to hand and foot controls and fasten the seat belt. Check that no one is on, beneath or around the machine. • Press the brake pedal, or the starting pedal specified for the particular configuration. Switch on the power without pressing the accelerator. • Check the instruments and perform a brief functional test in a secured area. Continue only if there are no alarms, sticking or unusual noises.
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Travel and load handling Stable travel, clear visibility and controlled lifting
Travel and visibility • Drive smoothly, without sudden starts, braking or turns. The indicative limit is up to 5 km/h unladen and up to 3 km/h fully laden, with further reductions according to conditions and workplace rules. • If the load obstructs your view, travel in reverse on level ground or use a signaller. On slopes, follow the table below and provide a signaller when needed. • Slow down at intersections, narrow passages and blind corners, and check all directions. Keep clear of edges, platforms and side obstacles. • Do not drive over obstacles or weak ground. On wet, slippery or uneven surfaces, snow or ice, take suitable precautions and reduce speed significantly. Check overhead clearance above the mast.
Loading, lifting and tilting • Observe the capacity plate and load chart. Use a pallet of suitable dimensions and capacity; the load must be stable and centred. Handle fragile loads gently and secure them when necessary. • Do not lift using only the fork tips, push or pull loads with the forks, or strike pallets, racking or equipment. • Lift and lower slowly with the machine stationary and smooth control movements. Do not travel with a load raised high. In windy conditions, do not lift loads excessively high. • During transport, keep the forks low with sufficient ground clearance. The stated heights for different configurations are 10-15 cm and 150-200 mm; use the value specified for the particular model. • With a load, tilt the mast back as needed for stability, according to the model. Do not travel or lift a load with the mast tilted forward; forward tilt is allowed only as far as necessary for positioning.
Travel on slopes Condition
Uphill
Downhill
Laden
Forward
Reverse
Unladen
Reverse
Forward
Do not turn, travel diagonally, load or unload on a slope. Descend slowly with controlled braking and monitor fork clearance. Do not travel or park on slopes above 5° unless the specific model is approved for this.
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Daily checks One pre-shift inspection and one end-of-shift procedure
Before starting work Area
What to check
Structure and tyres
Body, forks, mast and overhead guard: cracks and deformation. Tyres: damage, bulges and wear. Chains, bolts and joints: looseness and corrosion.
Battery and electrics
Terminals and cables: clean, secure and free from damage or leakage. Display: no alarms; sufficient charge for the shift. Charger, cable and connector: undamaged.
Hydraulics
Oil level, visible leaks, condition of hoses and joints; correct lifting, lowering and tilting operation.
Braking and steering
Service and parking brakes, free pedal movement and easy steering without sticking.
Lubrication
Condition of chains, pivot pins and guides; lubricate where required and specified.
Safety devices
Seat belt, mirrors, fork locking pins, lights, horn and signals. The work area must be clean, safe and free of unauthorised people.
After work • Park in a designated, level, dry and ventilated area, away from sources of fire. Lower the forks fully and set the mast vertically. • Apply the parking brake, switch off the main power and remove the key, if fitted. • Remove mud, shavings, waste and grease deposits. Clean the cab, instruments and charging connector without allowing water into electrical parts. • Check for wear or damage to forks, chains and tyres arising during the shift, and for hot or loose terminals. • Check the state of charge and follow the procedure in Chapter 07. Record operating hours, charging/discharging, leaks, alarms and other irregularities.
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Battery and charging Lithium battery instructions
Charging safety • Charge in a dry, well-ventilated area, without smoking, open flames, sparks or short circuits. Do not leave metal objects or tools on the battery or touch exposed conductors. • Use a charger matching the lithium battery specification and do not change the factory voltage settings. Do not connect a damaged cable or connector. • Follow the connection and disconnection sequence in the instructions for the installed charger. Prevent over-discharge and overcharging; recharge a depleted battery promptly and do not leave it discharged for more than 24 hours.
Charging, maintenance and storage Item
Lithium battery requirement
State of charge and BMS
Monitor the charge indicator, battery management system (BMS) and the requirements of the specific battery. If the charge is below 20%, arrange charging; this threshold is not a recommendation to wait until that point.
Cleaning and inspection
Clean the surface with a slightly damp cloth, without wetting electrical parts. Do not use a dry synthetic cloth. Check the condition of cables, connectors and terminals.
Service work
Do not open the battery or work on the BMS without authorisation. Service checks must be carried out by qualified personnel using suitable protective equipment and the procedure for the specific battery.
Extended storage
Maintain a 30-80% state of charge according to the battery requirements. Check every 15 days and recharge according to its schedule. If recharging every 15 days is specified, follow that interval.
Charging temperature and duration The stated ambient charging range is approximately 5-35 °C; the specific lithium battery and charger may have different limits. Follow their specifications. Charging duration and mode depend on the installed battery and charger.
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Service schedule Schedule by operating hours
Preventive maintenance includes regular checks, timely intervention and special attention to the battery. Daily checks are in Chapter 06; system inspection points are in Chapter 09. Interval
Service scope
50 hours First service
Battery, charger and terminals; confirm correct activation and normal charge/discharge parameters. Hydraulic oil, cylinders, guides and hoses. Brakes, pedal, wiring and motor. Inspect and lubricate chains and mechanical joints.
250 hours
Includes the first-service scope. For the schedule specifying replacement at 250 hours: change hydraulic oil and filter and clean the tank as needed. Check BMS, ventilation/cooling, steering, wheels, brakes, controller and charger.
500 hours
Includes the 250-hour scope. Replace the specified filters and perform more extensive battery diagnostics. Check seals, valves, bearings, contacts and motor brushes, if fitted. Fully lubricate all designated points.
1,000 hours and thereafter
Complete inspection of the battery, controller, motor, hydraulics, braking and steering. Replace worn chains, forks, hoses, terminals and electrical connections. Assess remaining battery capacity.
After 2,000 hours
At every subsequent 1,000 operating hours, repeat the complete inspection specified for the 1,000-hour service.
Which service interval applies? Different hydraulic oil schedules are stated: replacement at 250 hours, at approximately 1,200-1,500 hours, and every 12 months. These intervals are not equivalent. The service department must confirm the schedule for the specific model, oil and operating conditions; do not select the longer interval without confirmation.
First service and records The first service at 50 operating hours is mandatory in the stated schedule and important for warranty records. After each service, record the date, operating hours, checks performed, and replaced parts and fluids. Warranty coverage follows the document issued for the specific delivery.
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Periodic checks by system Calendar checks: 3, 6 and 12 months
The table brings the checks together in one place. Calendar intervals apply according to the approved service schedule and do not replace daily checks or services based on operating hours. System
Every 3 months
Every 6 months
Every 12 months
Carriage and forks
Bearing and support elements; bolt/nut tightness; free movement of the mechanism.
-
-
Brakes
Braking effectiveness; wear of associated lines and wiring.
Braking force.
-
Wheels
Wear; security of joints and fasteners.
Free running of bearings.
-
Steering
Free movement; lateral movement/turning.
Return to normal position.
-
Electrics
Inching switch, if fitted; main switch, horn and emergency power-off switch.
Connectors and cables.
Fuses.
Hydraulics
System performance.
Oil level; leakage and wear at joints.
Oil/filter according to the confirmed schedule; pressure and flow limiting valves.
Cylinders
Leakage; seal wear.
-
-
Motor
Carbon brush wear on brushed motors.
Starting relay.
-
Lithium battery
Cell voltage according to the service procedure and BMS; security of the battery case and terminals.
Condition of cables, connectors and terminals.
-
Functional tests
Safety devices; lifting/lowering test with rated load.
-
Fork lifting and lowering speed.
Work for qualified service personnel Rated-load testing, battery cell measurements, electrical measurements and adjustment of valves, brakes and other assemblies must be performed by qualified personnel. Lithium battery checks follow the appropriate service procedure and battery management system (BMS).
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Oil, conditions and storage Technical parameters and protection during storage
Hydraulic oil Confirm the oil selection for the model, pump and temperature. The stated reference designations are No. 20 machine oil and No. 22 turbine oil. Do not substitute a locally available equivalent without confirming the specification, and do not mix grades. Reference parameter
Stated value
Confirmation required
Kinematic viscosity
17-23 cSt
Measurement temperature is not specified.
Relative viscosity
26-33 E
Confirm the designation, method and conditions.
Flash point
At least 170 °C
Compliance with the approved oil specification.
Pour point
No higher than -15 °C
Suitability for the operating temperature.
These values are not a stand-alone specification for purchasing oil. During oil changes, clean the tank and lines according to the service schedule. Differences in intervals are listed in Chapter 08.
Harsh operating conditions • Dust: clean filters, cooling passages, connectors and electrical components more frequently using a suitable procedure. • Humidity and corrosive environments: inspect metal joints, connectors and corrosion more frequently. • Low or high temperatures: use suitable oil and observe the battery's permitted temperature range.
Storage for more than one month • Store the machine indoors in a dry, ventilated area, protected from dust, direct sunlight, rain and sources of fire. • Lower the forks and switch off the main power. Regularly check for corrosion and inspect cables, seals and the battery. • Follow the lithium battery state-of-charge, inspection and recharging requirements in Chapter 07.
Before service work Switch off the main power and disconnect the charging connector. Release hydraulic pressure according to the service procedure and use suitable personal protection. Work must be carried out by trained, qualified personnel.
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Troubleshooting and remedies Electrics, starting and drive
Check visible and simple causes first, then electrical and mechanical assemblies. Basic operator checks do not include opening components, live measurements or adjustments. Before service, apply the isolation procedure in Chapter 10.
11.1 Does not start / no display Possible cause
Check and remedy
Discharged battery; loose or oxidised terminals.
Check charge level and recharge. Service inspection, cleaning and tightening of terminals.
Main switch, display or an open circuit in the wiring.
Service personnel check the instrument supply and circuit, repair the open circuit or replace the faulty component.
11.2 Electrical devices operate incorrectly Possible cause
Check and remedy
Speed regulator / combined-motion control; failed contact.
Check and repair/replace the switch; inspect the control circuit.
Blown fuse; damaged contactor contacts or coil.
Identify the cause and replace with the same fuse type. Check the contacts and coil, and repair or replace the contactor.
Excessive battery voltage drop.
Measure voltage and check connections; charge and diagnose the battery.
11.3 No travel, slow travel or motor overload Possible cause
Check and remedy
Parking brake applied; faulty command device or controller.
Release the parking brake. Service personnel check the command device, codes and controller.
Low voltage / resistance at a connection; carbon deposits, worn brushes or motor failure.
Check voltage and connectors; inspect temperature, commutator and brushes, if fitted. For an armature short circuit: service assessment and motor replacement.
Brake dragging; jammed/worn wheel; debris near a gear or bearing.
Inspect and adjust the brake; clean, lubricate or replace damaged parts. A clearance of 0.35 mm on both sides applies only if confirmed for the specific assembly.
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Troubleshooting and remedies Hydraulics, lifting and tilting
11.4 Forks do not lift or lift slowly Possible cause
Check and remedy
Excessive load.
Stop lifting and reduce the load to within the permitted capacity.
Low oil level, unsuitable, overly thin or overheated oil; blocked filter.
Check level and quality; top up/replace with approved oil and replace the filter. Identify the cause of overheating.
Leaking or blocked lines; dirty/dry guides or a jammed mast.
Locate and repair the leak and clean the lines; inspect, lubricate and adjust guides and the mechanism.
Worn pump/housing; relief valve, spring or adjustment fault; worn valve stem/body.
Check pump noise and operation. Service repair or replacement of worn parts; inspect and adjust the valve to specification.
Worn piston seal.
Inspect the cylinder and replace the faulty seal.
11.5 Insufficient pressure or low pump speed Possible cause
Check and remedy
Damaged sealing ring; worn gear.
Replace the seal; inspect and, if necessary, replace the oil pump.
Low motor speed; foreign material in the line.
Check the motor and power supply; service the commutator/brushes on applicable versions. Inspect and clean the line.
11.6 Mast tilts by itself or is difficult to tilt Possible cause
Check and remedy
Worn cylinder or seal; faulty valve spring.
Inspect the cylinder, seals and valve. Repair or replace the component identified as faulty.
Stuck piston; bent piston rod; deposits or an overtightened seal.
Inspect for mechanical blockage; replace the damaged part, clean and adjust/assemble correctly.
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Troubleshooting and remedies Brakes, battery charging and unusual noise
11.7 Weak braking or brake failure Possible cause
Check and remedy
Worn pads, disc/drum; excessive clearance; incorrect pedal travel; loose parking brake cable.
Stop using the machine. Service personnel replace worn parts, check assembly and adjust clearances, pedal and cable.
Low fluid level, leakage or air in the hydraulic brake system.
Repair the leak, top up with the specified fluid and bleed the system, where applicable.
Open switch/circuit or electromagnetic brake coil; low voltage.
Electrical inspection and replacement of the faulty switch, brake assembly or component. Check and charge the battery.
11.8 Battery charging problems Possible cause
Check and remedy
Faulty charger; damaged cable/connector; poor contact or oxidised terminals.
Check charger parameters; service or replace the faulty part. Clean and tighten the relevant connections.
Unsuitable ambient temperature.
Place the battery in the permitted charging conditions stated in Chapter 07 and its specification.
Aged battery or reduced capacity.
Measure capacity using the appropriate service procedure. If capacity has fallen by more than 30%, assessment for replacement is recommended; this is not, by itself, a warranty criterion.
11.9 Unusual noise during operation Possible cause
Check and remedy
Insufficient lubrication; worn bearings, chains, gears or other mechanical parts.
Lubricate the designated points; inspect and replace parts found to be worn.
Pump, cylinder or motor; deformed or loose forks/mast.
Inspect hydraulic components and the motor; check structural fasteners and alignment.
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Service support and warranty Records, reporting and terms for the specific delivery
Reporting an issue Contact the service department promptly with questions about use, servicing, diagnosis or repair. If a fault occurs, stop work, secure the machine and report the issue before using it again. For a service request
Information to provide
Identification
Forklift model and serial number; lithium battery and charger models.
Conditions
Operating hours, date of occurrence, state of charge and conditions in which the issue occurs.
Symptom
Fault description, alarm code, unusual noise, leakage or sticking.
Documentation
Photos/video and records of services performed and parts replaced.
Warranty provisions Warranty applies under normal and correct use, according to the terms for the specific delivery. Damage caused by misuse, inadequate maintenance or improper storage is not covered. Repairs outside warranty coverage are chargeable.
The warranty document governs The period, covered parts, limitations and service obligations are set by the contract and warranty document issued for the specific machine. This manual does not replace those terms.
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