Within the hour you could be doing the daily walk-round on a Utilev P-series internal combustion counterbalanced forklift truck with this 143-page operator manual (OEM ID 76000363) open on the counterweight; it covers the UT15P to UT35P models. Your Utilev UT15P to UT35P operator manual PDF moves from instruments, switches and controls into daily, weekly and monthly checks and a preventive maintenance schedule tied to the hour meter at 166, 500, 1000 and 2000 hours. Wiring diagrams trace the Operator Presence Sensing circuit through the seat switch, park brake switch and neutral indicator, while other chapters cover the LPG regulator and shut-off valves, load center and stability zone, and the oil chart with its lubrication drawing. Set brake pedal free play to 1-3 mm; on the 2 to 3.5 tonne trucks, drive hub nuts take 441-588 N·m. Searchable and bookmarked, the PDF also prints clean for the bench, where pages are allowed to get greasy.
What's Inside This Utilev UT15P to UT35P Series Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| General Rules | 6-7 | Control Devices, Warning Devices, Fork Load, Mast Tilt, Brake Lever, Hydraulic Oil |
| Name of Main Parts or Components | 8-27 | Instruments, Switches, Controls, Body and Miscellaneous |
| Operating Instructions | 28-36 | Engine Fan, Radiator, Muffler, Fuel System, Battery, Mast |
| Maintenance | 37-59 | Preventive Maintenance Schedule, Torque Specifications, Periodic Replacement of Key Safe Parts, Table for the Oil Used in the Truck, Lubrication System Drawing |
| Forklift Basic Principles | 60-65 | Mast, Forks, Truck Body, Tires, Load Center of Gravity, Stability Zone |
| Operation | 66-70 | Starting, Driving, Pick Up, Stacking Load, Remove Load |
| Parking | 71-82 | Parking Daily, Parking the Truck for a Long Time, Running After Storing for a Long Time |
| Labels | 83-99 | Danger Label, Mast Warning Label, Lift Point Label, Fuel Label, Nameplate Label, Emergency Power Cut-Off Switch |
| Truck Transporting, Lifting, Towing | 100-101 | Steel Wire Ropes, Outside Mast Beam, Counter Balance, Lifting Device, Towing Rod |
| Performance Parameters of IC Forklift | 102-109 | Rated Capacity, Load Center, Lifting Height, Lifting Speed, Tilting Angle, Traveling Speed |
| Operation, Disassembly and Installation of Cab | 110-112 | Front Glass, Rain Wiper, Rear Door, Left Door, Support Legs, Fastening Bolts |
| Operator Presence Sensing System | 113-119 | Seat Switch, Park Brake Switch, Alarm, OPS Light, Neutral-Position Indicator, Transmission |
| Use of LPG Forklift Truck and Precautions | 120-132 | LPG Fuel System, Pressure-Reducing Regulator, Mixer, Shut-Off Valves, Charge-Limiting Valve, Pressure Relief Valve |
| Operational Method of Lead Acid Battery | 133-134 | Maintenance-Free Battery, Low-Maintenance Battery, Electrolyte Fluid, Electric Eye, Battery Capacity Display |
| Use, Installation and Safety Rules of Attachment | 135-136 | Multi-Functional Attachment, Side-Shifter, Hydraulic Pressure Loop, Rise Catch Block, Paper Roll Clamp, Drum Clamp |
| Related Safety Instruction and Standard | 137-143 | Directive 2006/42/EC, Directive 2000/14/EC, EN ISO 3691-1, EN12053:2001, EN1175-2:1998, EN13059:2002 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Maintenance interval for checking forks and stopper pins | Every 1 month (166hrs), 3 months (500hrs), 6 months (1000hrs), 1 year (2000hrs) | p. 77 |
| Brake pedal free clearance | 1-3 mm | p. 47 |
| Brake pedal free height | 120-130 mm | p. 47 |
| Oil tuck tightening torque | 29-39 N·m | p. 48 |
| Service Life of Hydraulic rubber hose for lifting system | 1-2 years | p. 79 |
| Service Life of High pressure rubber hose or tube for hydraulic system | 2 years | p. 79 |
| Service Life of Lifting chain | 2-4 years | p. 79 |
| Capacity of Gasoline | 45L (1.5T-1.8T), 60L (2.0T-3.5T) | p. 80 |
| Torque of bolts connected support legs and truck body | 137~167 N·m | p. 112 |
| Torque of bolts for connecting head frame and support legs | 110~140 N·m | p. 112 |
| 1.5T-1.8T, 2.0T-3.5T | ||
| Hub nut torque (Driving Wheel) | 157-176 N·m (1.5T-1.8T), 441-588 N·m (2-3.5T) | p. 46 |
| 1.5T-3.5T | ||
| Hub nut torque (Turning Wheel) | 157-176 N·m | p. 46 |
Utilev UT15P to UT35P Series Common Problems This Manual Covers
Utilev UT15P to UT35P coolant temperature indicator climbing into the red zone during operation
Stop the truck immediately when the indicator hits red (page 10), but keep the engine running: reduce speed, open the engine cover, and shut down only after water temperature falls, as page 59 directs. Check coolant and add water if needed. Do not open the radiator pressure cap above 70°C, and remove it without gloves (page 38). Clear clogged radiator fins with compressed air while wearing safety glasses.
Manual Section: Engine Overheating p. 59Engine fails to start after cranking with the key held in START position
Verify the shift lever and loading levers are in neutral and hold before cranking, per page 66. Never hold the key in START longer than 5 seconds (page 15); switch OFF and wait 2 minutes between tries. On a cold gasoline engine pull the choke fully. On a warm one leave the choke in and press the accelerator only halfway. After 3 failed tries, do a complete check of the truck.
Manual Section: Gasoline Engine Starting/Troubleshooting p. 66OPS alarm keeps sounding with the park brake applied or neutral indicator flashing
Park the forklift immediately in a safe place and contact an authorized service technician, following page 115. Before calling, note which symptom you see: the alarm sounding with the park brake applied, the neutral light flashing with the gear switch in neutral, or the alarm or OPS light staying on after you return to the seat properly. Do not keep working the truck.
Manual Section: Operator Presence Sensing System (OPS) Troubleshooting p. 115LPG leak detected at fuel line connections while the forklift is operating
Close the LPG tank outlet valve and switch off the LPG switch immediately, per page 121. Check every LPG system component and connection, including fastener line connections, for looseness and leaks. Keep naked flames away and never smoke while working on the fuel system, as pages 6 and 28 warn. Close the tank outlet valve whenever the truck sits stopped over 10 minutes.
Manual Section: LPG System Troubleshooting p. 121Air in brake lines after brake oil service or low brake fluid reservoir level
Park on level ground, lower the forks, apply the park brake, select neutral and shut off the engine, per page 39. Have a helper hold the brake pedal down while you loosen the oil-drain screw, then tighten it as fluid flows out. Repeat until no bubbles appear, topping up between the two reservoir seams and keeping dirt and water out. Verify brake pedal free clearance of 1-3 mm (page 47).
Manual Section: Brake System Maintenance/Bleeding p. 39Diesel fuel separator indicator lamp lit or air in the fuel system after refueling
Place a container under the fuel filter, loosen the drain bolt (W15A), then back the drain plug out 4 to 5 turns to drain water, per page 50. Fasten both once drained. Bleed air by loosening the bleed plug and pressing the priming pump until fuel flows without bubbles, then fasten the plug. Do not smoke while working on the fuel system (page 28).
Manual Section: Fuel System (Diesel) Air-Bleeding p. 50Frequently Asked Questions
What are the torque specifications for wheel nuts on a Utilev P-series forklift?
For 1.5T-1.8T models, the hub nut torque is 157-176 N·m. For 2.0T-3.5T models, the hub nut torque is 441-588 N·m. p. 46
What is the procedure for checking the fan belt tension?
Stop the engine. Use your finger to press the belt at the midway point between the water pump pulley and the generator pulley with 10kg of force. The movement should be 11-13 mm for K21/K25/MAZDA 2.2L engines, 8-12 mm (new) or 10-14 mm (old) for 4TNE92/4TNE98, and 5-8 mm (new) or 7-10 mm (old) for 4TNV94. p. 43
What is the required service interval for replacing the engine oil and oil filter on the Utilev UT15P to UT35P Series?
The engine oil and oil filter should be replaced every month (166 hours) as part of the monthly maintenance schedule. p. 48
What is the maximum fill capacity for the LPG cylinder on the Utilev UT15P to UT35P Series forklift?
The maximum fill capacity for the LPG cylinder is 80% of the cylinder's total volume. p. 122
What is the torque spec for the cab head frame to support leg bolts on the Utilev UT15P to UT35P Series?
The torque for bolts connecting the head frame and support legs is 110-140 N·m. p. 112
Is this Utilev UT15P Operator Manual a digital download?
Straight to your device: 143 pages of searchable Operator Manual, downloadable the moment payment goes through.
Am I able to print pages from this Utilev UT15P manual?
Yes. Printing works from any reader and any printer, for your own shop use.
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