Covering all four capacity variants in Utilev's UT20P to UT35P forklift range, this 110-page Utilev UT30P service manual PDF (OEM ID 76007600) fits your truck whichever gasoline or diesel engine sits behind the counterweight. Hydraulic schematics route the main oil circuit from pump through spool valve, main relief and tilt auto-lock valves to the lift and tilt cylinders, while electrical schematics trace the OPS and park brake alarm wiring. Torque converter, inching valve, king pins, wheel brakes and mast each get teardown or adjustment procedures, plus troubleshooting for steering, brakes, hydraulics and electrics. Change the engine oil filter every 600 hours or 3 months, and refill a Nissan K25 UT30P with 3.5 liters (3.7 qt). Setting a wheel brake clearance regulator from memory rarely ends well. Print the brake and hydraulic chapters, let them soak up grease on your bench, and keep the bookmarked, searchable file clean on the laptop.
What's Inside This Utilev UT20P, UT25P, UT30P, UT35P Manual
| System | Pages | Key Topics |
|---|---|---|
| Forklift Truck Main Parts | 7 | Power System, Drive Axle, Control System, Electrical System |
| Forklift Main Technical Parameters | 8-16 | Main Technical Parameters |
| Power System | 17-31 | Engine System (Engine Overview, Inspection, Engine Adjustment) |
| Hydraulic Transmission Case and Torque Converter | 32-39 | Overview, Torque Converter, Hydraulic Clutch, Control Valve, Safety Valve, And Inching Valve, Transmission Case, Hydraulic Oil Pump |
| Drive Axle | 40 | Overview, Maintenance of Drive Axle |
| Steering System | 41-46 | Overview, Hydraulic Steering Gear Assembly, Steering Cylinder, Reassembly of Steering System |
| Brake System | 47-59 | Overview, Master Cylinder, Wheel Brake, Automatic Clearance Regulator, Parking Brake, Brake Pedal |
| Hydraulic System | 60-80 | Main Pump, Control Valve and Bypass Valve (Operation of Spool Valve, Neutral Position, Spool Valve, Main Relief Valve and Bypass Valve, Tilt Auto-Lock Valve) |
| Lifting System | 81-84 | Safety Procedures When Working Near Mast (Inside and Outside Masts, Bracket, Adjust) |
| Electrical System | 85-100 | Overview, Electrical Box, Battery, Electrical Schematics, Troubleshoot Electrical System (Troubleshoot Truck Safety System) |
| Drive, Operation, and Routine Maintenance of Forklift Truck | 101-104 | Transporting the Forklift Truck, Towing, Long-Term Storage of Forklift Truck, Maintenance Procedures Prior to Operation, Cooling System |
| Display | 105-110 | Overview, Remove, Install |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| UT30P, UT35P | ||
| Lubricating Oil Capacity (Nissan K25) | 3.5 liter (3.7 qt) | p. 19 |
| Lubricating Oil Capacity (PSI 4G64-2.4L) | 4 liter (4.2 qt) | p. 19 |
| Fuel Tank Capacity (3-3.5T) | 60 liter | p. 26 |
| All Models | ||
| Air Filter replacement interval | every 1200 hours or 6 months | p. 105 |
| Wheel hub flat washer and slot nut torque | 206-235 N•m (151.9-173.3 lbf ft) | p. 46 |
| Wheel hub slot nut tightening torque (after loosening) | 9.8 N•m (7.2 lbf ft) | p. 40 |
| Inner Diameter of bearing | 19.12 mm (0.75 in.) | p. 75 |
| Total Length of bearing | 26.41 mm (1.04 in.) | p. 75 |
| Nissan K21/Nissan K25/Mitsubishi S4S-455 | ||
| Fuel Filter (Nissan/Mitsubishi) replacement interval | every 2400 hours or 12 months | p. 105 |
| 2-2.5T | ||
| Distance A between combined roller and inner mast (2-2.5T) | 24-29 mm (.94-1.14 in.) | p. 83 |
| 3-3.5T | ||
| Distance A between combined roller and inner mast (3-3.5T) | 19-24 mm (.75-.94 in.) | p. 83 |
| UT20P, UT25P | ||
| Fuel Tank Capacity (2-2.5T) | 52 liter | p. 26 |
Utilev UT20P, UT25P, UT30P, UT35P Common Problems This Manual Covers
Utilev UT20P UT25P UT30P UT35P steering operation hard to move and steering wheel feels heavy
Check bypass valve pressure first and adjust it if low, following the steering chart on page 46. Remove air from the oil circuit, then inspect the steering gear reset and replace the positioning leaf spring if it is broken. If steering stays heavy, inspect the steering cylinder piston sealing for excessive internal leak.
Manual Section: Steering System Troubleshooting p. 46Wheel brakes feel too weak and braking pressure stays low when the pedal is applied
Inspect the brake system for fluid leaks and repair them, then bleed air from the brake system. Adjust the adjuster gear to correct brake shoe clearance, per the chart on page 60. Measure pedal setup following page 53: 113 mm from front floor to brake pedal with a 20 mm stroke. Readjust the pedal (inching valve) if it is off.
Manual Section: Wheel Brake Troubleshooting p. 60Brake pulls to one side when the pedal is applied at travel speed
Inspect each brake shoe for fluid stains and repair or replace any stained shoe. Adjust the adjuster gear to correct brake shoe clearance, as the chart on page 60 directs. Check that the wheel cylinder operates, inspect the brake shoe return springs for damage and check the brake drum for deflection. Repair or replace whichever part is at fault.
Manual Section: Wheel Brake Troubleshooting p. 60Hydraulic gear pump noise loud with air bubbles showing in the hydraulic fluid
Check the fluid suction hose for twists and clean the filter if it is blocking the cavity, following the chart on page 80. Tighten each suction side joint to stop air being pulled in. Verify fluid viscosity is correct, and do not operate until fluid temperature is normal. Track down the source of any air bubbles.
Manual Section: Hydraulic System Troubleshooting p. 80Truck will not start and starting motor does not turn the engine over
Check that the gear is in neutral and, with OPS installed, that seat, seat belt and hand brake are in place, per page 100. Verify the seat switch and handbrake switch are closed and grounded. Inspect the electric box for a blown fuse or burned-smelling time relay. Turn off the key switch and battery grounding wire before examining wires (page 100), then check the negative connection, key switch and starting motor.
Manual Section: Truck Safety System (OPS/Park Brake Alarm) Troubleshooting p. 100Lift, lowering and tilt functions not working while engine runs and operator is seated
Check that the seat switch is closed and grounded; with it closed there should be 12V at the electrical box output and 12V input to the solenoid valve, per page 100. Shut off the key switch and battery grounding wire before examining wiring, then check plugs and insert pieces for looseness. If voltage reaches the valve but it does not work, check the solenoid valve spool.
Manual Section: Truck Safety System (OPS/Park Brake Alarm) Troubleshooting p. 100Frequently Asked Questions
What are the engine oil and oil filter replacement specifications for the Utilev UT20P, UT25P, UT30P, UT35P forklift?
For gasoline engines (Nissan K21/K25/Mitsubishi S4S-455), the engine oil should be replaced after 200 hours or 1 month of use. The engine oil filter should be replaced every 600 hours or 3 months, using a Nissan/Mitsubishi approved filter. p. 25
What are the replacement specifications for the fuel filter and air filter on the Utilev UT20P, UT25P, UT30P, UT35P?
For gasoline engines, the fuel filter should be replaced every 2400 hours or 12 months, and the air filter every 1200 hours or 6 months. Use Nissan/Mitsubishi approved filters for both. p. 25
What is the torque specification for the drive axle wheel mounting nut on the Utilev UT20P, UT25P, UT30P, UT35P?
The torque specification for the drive axle wheel mounting nut is 470-550 N•m (346.7-405.7 lbf ft). p. 40
What is the specified valve clearance for the Nissan K25 gasoline engine in the Utilev UT20P, UT25P, UT30P, UT35P?
The valve clearance for both the inlet and exhaust valves on the Nissan K25 engine (heat engine) is 0.38 mm (0.02 in.). p. 18
What is the fuel tank capacity of the Utilev UT20P, UT25P, UT30P, UT35P 2-2.5T and 3-3.5T forklift trucks?
The fuel tank capacity for 2-2.5T forklift trucks is 52 liters (13.7 gal), and for 3-3.5T forklift trucks, it is 60 liters (15.6 gal). p. 26
How will I receive this Utilev UT20P–UT35P Series Service Manual?
One searchable PDF covering 110 pages, delivered instantly. No disc, no shipping, no waiting on the post.
Is printing allowed for this Utilev UT20P–UT35P Series Service Manual?
Yes. Print a chapter or just the pages for the job at hand, for use in your own shop. Any home or office printer works.
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