Six Utilev 4-wheel electric counterbalanced forklift trucks, rated 1.5 to 3.5 tonne, are covered by this 56-page Utilev UT15PFE to UT35PFE service manual PDF (OEM ID 76502794). Electrical principle diagrams trace the controller, encoder, parking brake switch, directional switch, temperature sensor and serial port circuits, while hydraulic schematics map the main pump and control valve feeding the lift and tilt cylinders. Drive, steering and brake chapters cover the AC motor, reduction gearbox, drive axle, steer axle and parking brake; the mast section finishes with lift and tilt cylinder rebuilds, and controller fault codes round out the electrical chapter. Set main relief pressure to 15.5 MPa on 1.5 T trucks or 17.4 MPa on 1.8 T, and run M16 lift chain lock nuts to 127-157 N·m. A mast job stalls on one missing torque figure. Your copy is searchable and bookmarked, and the exploded views help you match the right component before you order, so the replacement fits first time.
What's Inside This Utilev UT15PFE to UT35PFE Series Manual
| System | Pages | Key Topics |
|---|---|---|
| Drive System | 5-12 | AC Motor, Reduction Gearbox, Drive Axle |
| Steering System | 13-17 | Steering Column, Steering Axle |
| Brake System | 18-22 | Brake Master Cylinder, Foot Brake, Parking Brake |
| Hydraulic System | 23-27 | Main Pump, Control Valve |
| Lifting System | 28-39 | Assembly Data, Fault, Mast, Lifting Cylinder, Tilting Cylinder, Removal and Adjustment, Disassembly and Assembly of Lifting Cylinder, Disassembly and Installation of Tilt Cylinder |
| Electrical System | 40-47 | Controller, OPS System |
| Electrical Principle Diagram | 48-56 | Controller, Encoder, Parking Brake Switch, Directional Switch, Temperature Sensor, Serial Port |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| UT15PFE | ||
| Bolt #7 Torque | 137-186 Nm or 101-137 lbf-ft | p. 15 |
| Nut #22 Torque | 78-98 Nm or 58-72 lbf-ft | p. 15 |
| All Models | ||
| Main Relief Valve Pressure (1.5 T) | 15.5 MPa | p. 27 |
| Main Relief Valve Pressure (1.8 T) | 17.4 MPa | p. 27 |
| Traction and hydraulic fuse ratings | 10A, 225A, 250A, 350A, 425A | p. 48 |
| 1.5T | ||
| Main Relief Valve Pressure | 15.5 MPa | p. 27 |
| 1.8T | ||
| Main Relief Valve Pressure | 17.4 MPa | p. 27 |
| 2.0T | ||
| Main Relief Valve Pressure | 17.5 MPa | p. 27 |
| 2.5T | ||
| Main Relief Valve Pressure | 17.6 MPa | p. 27 |
| 3.0T | ||
| Main Relief Valve Pressure | 17.7 MPa | p. 27 |
| 3.5T | ||
| Main Relief Valve Pressure | 17.8 MPa | p. 27 |
| 1.5t-1.8t | ||
| Tire inflation pressure | 0.79 MPa | p. 7 |
Utilev UT15PFE to UT35PFE Series Common Problems This Manual Covers
Utilev UT15PFE through UT35PFE lift cylinder and hydraulic pump showing insufficient lift power or no lift movement
Check that the load is within rated capacity, then check hydraulic oil temperature and viscosity; stop work and let hot oil cool, or change wrong oil. Tighten joint nuts on leaking hydraulic pipes and inspect the seals. Test for worn pump body and gears, a worn lift piston Yx-ring, or inoperative control valve and relief valve springs per page 29. Fit new seals; page 37 says never reuse the dust gasket ring, O-ring or Y-ring.
Manual Section: Lifting System Faults p. 29Hydraulic main pump not pumping out fluid or running noisy with air bubbles in the tank
Check the reservoir and top up to the specified level. Flush the lines and reservoir if the suction hose or strainer is clogged, replace a kinked suction hose, clean or replace the filter, and retighten every suction-side fitting. Change dirty fluid or fluid with the wrong viscosity. Per page 25, do not run the pump until tank bubbles disappear and fluid temperature is normal.
Manual Section: Main Pump Troubleshooting p. 25Mast tilts forward when the control lever is moved with the truck switched off
Inspect the tilt lock valve first. If it is worn or damaged, replace the valve core and tilt lock valve together as an assembly. Check for a broken tilting lock spring and a damaged tilt valve plunger O-ring, and replace either following page 26. If the mast is erratic when tilting forward, replace the tilt relief valve assembly.
Manual Section: Control Valve Troubleshooting p. 26Foot brake and parking brake have insufficient braking force when stopping or parking
Inspect brake lines for fluid leaks, correct them and refill oil, then bleed air from the lines. Clean any blocked lines, and correct or replace a malfunctioning master cylinder or wheel cylinder. A good, adjusted parking brake holds full capacity on a 15% grade per page 22; if it needs adjustment, notify trained service personnel.
Manual Section: Parking Brake Troubleshooting p. 22Drive axle front wheel wobble with abnormal noise from the hub while travelling
Tighten loose wheel nuts and the bolts between the drive axle and truck frame. Check inner hub bearing adjustment against the page 7 axial clearance of less than 0.08 mm, and replace a worn or damaged bearing, worn axle shaft spline or damaged wheel. Set tire pressure to the page 7 value for your capacity, and grease the hub if lubrication is inadequate.
Manual Section: Drive Axle Troubleshooting p. 8Controller displays code 1,7 Severe Under voltage or 3,9 Main Contactor Did Not Close
Check for a blown B+ fuse first, then inspect the main contactor tips for oxidized or burned faces making poor contact. Check battery resistance, non-controller drains on the battery and Battery Menu parameters, and confirm the battery was not disconnected while driving. Read 1311 menu Monitor » Battery: Capacitor Voltage, following the codes on pages 43 and 44.
Manual Section: Controller Failure Codes p. 43Frequently Asked Questions
How do I reset an error code on the UTILEV UT15PFE, UT18PFE, UT20PFE, UT30PFE, or UT35PFE?
Whenever a fault is encountered, first shut off the KSI (Key Switch) and turn it back on to see if the fault clears. If the fault persists, shut off the KSI, remove the 35-pin connector, check for corrosion or damage, ensure pins are engaged, clean if necessary, and re-insert it. p. 42
What is the required gear oil capacity for the drive axle on a 1.5t to 1.8t Utilev UT15PFE to UT35PFE Series?
The drive axle for the 1.5t to 1.8t forklift models requires 4.5 liters of GL-5 85W/90 gear oil. Always ensure the vent plug is cleaned frequently to prevent pressure buildup in the axle housing. p. 10
What is the wheel nut tightening torque on a 2t-3.5t Utilev UT15PFE to UT35PFE Series forklift?
The tightening torque for the wheel nuts (Item E) on a 2t-3.5t forklift is 363-490 N.m. p. 9
What is the specified rotation starting tension for the hub at the hub bolt?
The rotation starting tension for the hub at the hub bolt should be between 10N and 29N. p. 12
What is the procedure for adjusting the main relief valve pressure on a 3t Utilev UT15PFE to UT35PFE Series truck?
Place 125% of the rated load (3750 kg) on the forks. With the brake pedal fully pressed, operate the lift lever; the pressure is correct if the load lifts to a 300 mm range. If it cannot be lifted, remove the front base plate, loosen the lock nut, and turn the adjusting screw clockwise to increase pressure. p. 27
What exactly do I receive with this Utilev UT15PFE Service Manual?
A 56-page Service Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Can I print this Utilev UT15PFE manual?
Yes. It prints from any PDF reader, so run off the pages you need for your own repair work.
Reviews
There are no reviews yet.