Utilev's 109-page service manual (OEM ID 76000364) takes the UT series internal combustion counterbalanced forklift apart system by system, across the UT15P to UT35P models. In this Utilev service manual PDF, electrical schematics trace the fuse, lighting and instrument circuits, and hydraulic diagrams map oil from the main pump through the control valve to the lift and tilt cylinders. The torque converter, two-way clutch, charging pump and inching valve each get their own section, and trouble diagnosis tables for the axles, steering, brakes and hydraulics walk you from symptom to cause on trucks running K21, K25 dual fuel or diesel engines. Fill the transmission with 7 L, set clutch pressure at 1.1-1.4 MPa, then torque UT20P to UT35P wheel nuts to 363-490 N·m. Guess that pressure and you pay for a burnt clutch pack and a second teardown. Bookmarks and a live text layer put the inching valve page in front of you in seconds.
What's Inside This Utilev UT15P to UT35P Series Manual
| System | Pages | Key Topics |
|---|---|---|
| Power System | 6-17 | Engines (K21, K25 Dual Fuel, 4TNE92/ 4TNV94/ 4TNE98 Diesel, NC485BPG/A490BPG Diesel) |
| Transmission | 18-32 | Data, Summary, Principles of Operation, Torque Converter, Two-Way Clutch, Charging Pump, Inching Valve, Transmission Housing |
| Drive Axle | 33-38 | Date, Trouble Diagnoses and Corrections, Drive Axle Components, Assembly and Disassembly of Drive Axle, Axle Shaft and Wheel Hub, Bearing Adjusting |
| Steering Axle | 39-42 | Trouble Diagnoses Corrections, Kingpin and Steering Spindle, Wheel Bearing Adjustment |
| Steering System | 43-46 | Data, Trouble Diagnoses, Summary, Install Steering System |
| Brake System | 47-54 | Brake System Trouble Diagnoses, Master Cylinder, Brake Assembly |
| Hydraulic System | 55-66 | Data, Trouble Diagnoses and Corrections, Main Pump, Control Valve |
| Lifting System | 67-83 | Assemble Data, Summary, Removal and Adjustment, Disassembly and Assembly of Lifting Jack, Disassembly and Installation of Tilt Cylinder, Noticing Proceeding of Debugging |
| Electrical System | 84-109 | Electrical System Inspection, Fuse and Lighting System, Instrument and Sensor Removal |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| UT15P, UT18P | ||
| Wheel Nuts (#4) Torque (1.5t-1.8t) | 157-176 N·m | p. 34 |
| UT20P, UT25P, UT30P, UT35P | ||
| Wheel Nuts (#4) Torque (2t-3.5t) | 363-490 N·m | p. 34 |
| All Models | ||
| Transmission Oil Capability | 7 L | p. 18 |
| Hydrodynamic Power Clutch Adjusted Pressure | 1.1-1.4 MPa | p. 18 |
| Residual pressure in brake lines and wheel cylinders | 0.04 MPa | p. 48 |
| Main pump output pressure (Rated/Max.) | 20/25 MPa | p. 55 |
| Hydraulic control valve rated flow rate | 65 L/Min | p. 56 |
| Mast To Lift Roller Assembly Clearance | 0.1-0.8 mm | p. 67 |
| Mast To Lift Roller Repair Clearance | 0.2-1 mm | p. 67 |
| Clearance of back up metal and mast steel | 0.1-0.8mm | p. 78 |
| 3.0t-3.5t | ||
| Lift roller-to-mast clearance dimension L (3.0t-3.5t) | 368mm, 388mm, 418mm, 443mm | p. 77 |
| 2.0t-2.5t | ||
| Lift roller-to-mast clearance dimension L (2.0t-2.5t) | 328mm, 348mm, 378mm, 403mm | p. 77 |
Utilev UT15P to UT35P Series Common Problems This Manual Covers
Utilev UT15P to UT35P K21/K25 engine idle speed and ignition timing out of specification
Check idle following page 12. Warm the engine, idle it 2 minutes, then race it between 2,000 and 3,000 rpm two or three times with no load. Verify idle at 650-700 rpm and set 700 ±50 rpm with the throttle adjusting screw. Never screw it all the way down; page 13 warns this damages the tip. Verify timing at 0° BTDC and turn the distributor to correct it.
Manual Section: K21/K25 Engine Maintenance p. 12K21/K25 engine compression low on one or more cylinders during a compression test
Test compression following page 9. Warm the engine, pull all spark plugs, open the throttle valve fully and crank at about 250 rpm, reading quickly. Any cylinder under 80% of the highest reading is low. Add a little oil and retest: a rise means worn piston rings, no change means sticking or poorly seated valves, and two low adjacent cylinders point to a leaky gasket.
Manual Section: K21/K25 Engine Maintenance p. 94TNE92/94/98 diesel fuel system air-bound after filter change, engine will not run
Remove air following page 16. Loosen the air vent screw, work the priming pump until no air comes out, tighten the screw, then pump until resistance rises sharply. If it still will not run, loosen the injection pipe nut and crank until fuel flows, then retighten. Disconnect the return hose and pump; no fuel flow means replace the priming pump.
Manual Section: 4TNE92/94L/98 Diesel Maintenance p. 16Transmission main oil pressure or torque converter inlet pressure reading outside normal range
Measure pressures following page 22. Park on level ground, set the parking brake, select neutral, lower the forks and shut the engine off, then remove the front floor plate. Connect a gauge rated for 2.5 MPa at each drain plug port and switch the key on. Verify main pressure at 1.1-1.4 MPa, torque converter inlet at 0.5-0.7 MPa and clutch pressure at 0.3 MPa.
Manual Section: Transmission Oil Pressure Measurement p. 22Drive axle abnormal noises, unstable driving, or oil leakage at the front drive wheels
Check the drive axle to body connecting bolts and wheel nuts and tighten any that are loose, per page 33. Adjust or replace the wheel hub bearing, replace a worn axle shaft spline or deformed wheel, and lubricate. Set tire pressure to (7±0.2) x 10^5 Pa. For leaks, replace a worn axle shaft oil seal, reseat the final drive gasket and tighten the drain plug.
Manual Section: Drive Axle Trouble Diagnoses p. 33Rear steering axle on the counterbalanced truck shows unstable driving or noises while traveling
Check and tighten loose wheel nuts, bolts and nuts, per page 39. Apply calcium based grease, adjust the axle end shaft shims and replace a damaged joint bearing at either rod end. Before adjusting wheel bearings, raise the truck and support it on wooden blocks (page 41). Tighten the spindle nut until the hub stops turning by hand, then back off 1/8 to 1/6 turn. Set tires to 0.7 MPa.
Manual Section: Steering Axle Trouble Diagnoses p. 39Frequently Asked Questions
What are the hydraulic, mast, and transmission troubleshooting procedures for a UTILEV P-series forklift?
Troubleshooting procedures are provided in the manual for each system. For the hydraulic system, refer to page 57 for the 'Trouble diagnoses and corrections' table. For the lifting system, refer to page 68. For the transmission, refer to the 'Principles of Operation' on page 20 and the disassembly process on page 23. p. 57
What are the replacement specs for engine oil and fuel filters on the Utilev UT15P to UT35P Series?
For the K21/K25 engines, the engine oil capacity is 3.6 L. For the 4TNE92/94L/98 diesel engines, the oil volume is 7.2/9.2 L. Always use the proper tool to remove the oil filter and hand-tighten the new filter only, as specified on page 8 for gasoline engines and page 15 for diesel engines. p. 8
What are the replacement specifications for the air filter on the Utilev UT15P to UT35P Series forklift?
The air cleaner uses a dry paper element. It should be cleaned or replaced according to the maintenance schedule, and more frequently when operating under dusty conditions. Refer to page 10 for K21/K25 engines and page 15 for 4TNE92/94L/98 diesel engines. p. 10
What is the specified cylinder head bolt torque for the K21/K25 engine in the Utilev UT15P to UT35P Series?
The cylinder head bolts on the K21/K25 engine must be tightened to a torque of 68.6 N·m. This should be done in two steps when the engine is cold, following the sequence shown in the manual. p. 8
What is the intake and exhaust valve clearance for the K21/K25 engine in the Utilev UT15P to UT35P Series?
The valve clearance for both intake and exhaust valves on the K21/K25 engine, when hot, is 0.38 mm. Ensure the engine is warm before performing this adjustment. p. 8
How is this Utilev UT15P Service Manual delivered?
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