Utilev operator manual 76001648 puts six internal combustion counterbalanced forklift trucks from the UT P and C series through their paces across 149 pages, from start-up and stacking to long-term storage and LPG fuel handling. Wiring diagrams in this Utilev UT20P, UT25P, UT30P, UT35P, UT25C, UT30C operator manual PDF trace the operator presence sensing system, showing how the seat belt, park brake and hydraulic function interlocks gate starting and forward or reverse travel. Your preventive maintenance schedule runs from daily through annual checks, backed by chain and hydraulic part replacement intervals, a fluid use chart, a lubrication drawing and load capability charts tied to load center distance. Fill the hydraulic tank with 45-50 L of HM32 on 2.0 to 3.5 t trucks, then torque front hub nuts to 441-588 N·m. A lift truck stuck on a tripped interlock can eat a shift you never get back. Bookmarked and text-searchable, the PDF is bought once and stays yours for this truck.
What's Inside This Utilev UT20P to UT35P Series Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| General Rules | 7-9 | Control Devices, Alarm Devices, Load Limits, Fork Usage, Fuel Handling, Parking Brake |
| Name of Main Parts or Component | 10-30 | Instruments, Switches, Controls, Body and Miscellaneous |
| Operating Instructions | 31-39 | Periodic Inspection, Engine Inspection, Fire Extinguisher, Control Operation, Load Backrest, Side Shift Mechanism |
| Operator Protection Equipment | 40 | Load Backrest Extension, Overhead Guard, Seat Belt, Hip Restraint |
| Maintenance | 41-61 | Daily Maintenance, Weekly Maintenance, Monthly Maintenance, Semi-Annual Maintenance, Annual Maintenance |
| Structure and Stability of Truck | 62-67 | Mast, Body, Center of Gravity, Stability Zone, Load Center Distance, Load Capability Chart |
| Operation | 68-71 | Start-Up, Traveling, Pick Up, Stacking Load, Remove Load |
| Parking | 72-74 | Parking Daily, Long Term Storage, Forklift Operation After Long-Term Storage |
| Periodic Maintenance | 75-84 | Preventive Maintenance Schedule, Torque Specifications, Periodic Replacement of Chain and Hydraulic Parts, Forklift Fluid Use Chart, Lubrication System Drawing, Environmental Protection |
| Labels | 85-103 | Danger Label, Mast Warning Label, Nameplate Label, Parking Brake Label, Hydraulic Oil Label, Emergency Stop Label |
| Truck Transporting, Lifting, Towing | 104-105 | Hoist, Steel Wire Ropes, Lifting Device, Towing Rod |
| Performance Parameters of IC Forklift | 106-117 | Rated Capacity, Load Center, Lifting Height, Traveling Speed, Grade Ability, Engine Type |
| Operation, Disassembly and Installation of Cab | 118-120 | Left Door, Right Door, Rear Door, Fastening Bolts, Wiring, Cab Support Legs |
| Operator Presence Sensing System | 121-126 | Starting Protection, Forward and Reverse Protection, Seat Belt Protection, Hydraulic Function Protection, Park Brake Protection |
| Operation and Notice About LPG Forklift | 127-139 | LPG Cylinder, Dual-Fuel Toggle Switch, Pressure-Reducing Regulator, Mixer, Fuel System |
| Operational Method of Lead Acid Battery | 140-144 | Storage, Maintenance, Battery Check, Recharging, Electrolyte |
| Use Installation and Safety Rules of Attachment | 145-146 | Attachment Nameplate, Attachment Operation, Attachment Maintenance, Attachment Assembly, Hydraulic Pressure Loop |
| Related Safety Instruction and Standard | 147-149 | Sound Pressure Level, Sound Power Level, Vibration Parameters, Electromagnetism Compatibility, Engine Emission |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| 2.0T-3.5T | ||
| Front wheel hub nut torque | 441-588 N·m | p. 49 |
| 2-3.5T | ||
| Front Wheel Hub Nut Torque | 441-588 N·m | p. 49 |
| 2T-3.5T | ||
| Rear wheel hub nut torque | 157-176 N·m | p. 49 |
| All Models | ||
| Engine oil drain plug tightening torque | 29 N·m-39 N·m | p. 51 |
| Engine Coolant Temperature Normal Range | 60°C - 115°C | p. 12 |
| Oil Pressure Alert Threshold | 0.05Mpa | p. 13 |
| Oil Temperature Normal Range | 60°C - 120°C | p. 14 |
| Brake Pedal Free Clearance | 1-3 mm | p. 50 |
| Inching Pedal Free Clearance | 0 mm | p. 50 |
| Cab Support Leg to Truck Body Fastening Torque | 137-167 N·m | p. 120 |
| Cab Head Frame to Support Leg Fastening Torque | 110-140 N·m | p. 120 |
| 2.0t-3.5T | ||
| Hydraulic oil capacity | 45-50 L | p. 82 |
Utilev UT20P to UT35P Series Common Problems This Manual Covers
Utilev UT25P forklift coolant temperature gauge needle climbing into the red zone during operation
Reduce engine speed and stop the truck immediately, but do not shut the engine off at once (page 61). Open the engine cover for ventilation and stop the engine once water temperature drops. Check coolant level and inspect the fan belt with the engine off (page 46). Never open the radiator cap above 70°C (page 27). Normal gauge range is the green zone, 60°C to 115°C.
Manual Section: Engine Coolant Temperature Troubleshooting p. 12Oil pressure alert lamp stays lit or comes on during operation after the engine starts
Check the lamp first. It should come on at key ON and go out once the engine starts and the accelerator is pressed (page 13). If it stays lit, pressure is below 0.05Mpa and must be checked immediately. Check the engine oil level with the truck on level ground, the parking brake set and the forks lowered (page 41). Milky oil means coolant has entered the oil (page 51).
Manual Section: Oil Pressure Alert Troubleshooting p. 13Diesel oil-water separator indicator light stays on or flashes while the engine is running
Drain the water from the oil-water separator. Shut the engine down first whenever the light stays on or flashes while running, following page 14. Afterward, verify the light behaves normally: it comes on with the key in start and goes out once the engine fires. If it lights again during operation, shut down and drain again.
Manual Section: Oil-Water Separator Troubleshooting p. 14Oil temperature warning lamp comes on during operation with the engine running
Reduce engine speed and stop the truck immediately so it can cool (page 14). Wait until the lamp goes out, then check the oil level in the torque converter transmission box. Hot oil and parts can cause injury, so do not touch them (page 52). Normal range is 60°C to 120°C. Avoid riding the inching pedal. It raises transmission oil temperature and slips the clutch (page 21).
Manual Section: Oil Temperature Troubleshooting p. 14Hydraulic oil level low in the tank or leaks at pipelines after an oil change
Check the hydraulic oil level with the engine off and all mast cylinder rods fully retracted, then top up to the fill mark following page 55. The level should sit between the two marks. Inspect each hydraulic component and pipeline for leaks. Hot hydraulic oil and parts can burn you, so do not touch them. Refill capacity is 45 to 50 L of L-HM32 (page 82).
Manual Section: Hydraulic System Troubleshooting p. 55Brake fluid level low in the reservoir or air bubbles present in the brake lines
Check that the fluid level sits between the two seams of the brake reservoir, and keep dirt and water out when topping up (page 43). To bleed, park on level ground with the forks down, the parking brake set, the transmission in neutral and the engine off. Have a helper pump the pedal while you crack the drain screw. Repeat until no bubbles remain. Verify brake pedal free clearance at 1 to 3 mm (page 50).
Manual Section: Brake System Troubleshooting p. 43Frequently Asked Questions
What are the bolt torque specifications for the Utilev UT20P to UT35P Series forklift?
The torque specifications depend on the bolt diameter and the bolt strength grade. For example, a 6mm bolt with a strength grade of 8.8 requires 9-12 N·m of torque, while a 39mm bolt with a strength grade of 8.8 requires 2923-3898 N·m. p. 80
What are the engine oil and oil filter replacement specifications for the Utilev UT20P to UT35P Series forklift?
Engine oil and the oil filter should be changed during monthly maintenance (166 hours). The drain plug tightening torque is 29 N·m to 39 N·m, and the new oil filter should be hand-tightened only. p. 51
How do you drain water from the fuel separator on a diesel truck?
To drain water from the separator, place a container under the fuel filter, loosen the drain bolt (W15A), and then loosen the drain plug by turning it 4 to 5 turns. Once the water is drained, fasten the drain bolt (W15A) and the plug. p. 53
What is the procedure for checking the fan belt tension?
Stop the engine and use your finger to press the belt at the midway point between the water pump pulley and the generator pulley with 10kg of pressure. The drop distance for a MAZDA 2.2L or PSI 2.4L engine should be 11-13mm. For 4TNE92/4TNE98 engines, the drop distance is 8-12mm for new belts (<5min) and 10-14mm for old belts (≥5min). p. 46
What is the required tire pressure for the Utilev UT20P to UT35P Series forklift?
For 2.0T-2.5T trucks, the front and rear tire pressure is 860kPa. For 3.0T-3.5T trucks, the front tire pressure is 830kPa and the rear tire pressure is 790kPa. p. 45
Will this Utilev UT20P to UT35P Series Operator Manual download right away?
One searchable PDF covering 149 pages, delivered instantly. No disc, no shipping, no waiting on the post.
Does this Utilev UT20P to UT35P Series manual allow printing?
Yes. Print the sections you need to take out to the shop for your own use. Standard letter or A4 paper works.
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