Issued by Utilev under factory document number 76500008, this 76-page Utilev UT40P, UT50PS, 4T-5TS service manual PDF is the real book for the 4T-5TS series of internal combustion counterbalanced forklift trucks, spanning six variants in dual-fuel, LPG and diesel builds. Electrical schematics trace the fuse box and lighting circuits wire by wire, while the hydraulic circuit diagram follows oil from the main pump through the control valve to the lift and tilt cylinders. Fault diagnosis tables open each system, from the torque converter and two-way clutch to the drive axle, steering axle, brakes and mast, and the lifting chapter walks you through dismantling, installing and adjusting the mast. Your transmission takes 12 L, and the fluid comes out every 1,000 hours on the meter. One missing figure can park a truck all shift. Chapter bookmarks and a searchable text layer put you on the brake master cylinder or steering control unit in seconds.
What's Inside This Utilev UT40P, UT50PS Manual
| System | Pages | Key Topics |
|---|---|---|
| Powertrain | 4-5 | Engine Configuration, Rated Power, Rated Engine Speed, Maximum Torque, Exhaust Emissions, Diagnostic Connector |
| Hydraulic Transmission and Torque Converter | 6-17 | Hydraulic Transmission Data, Fault Diagnosis and Correction, Transmission Overview |
| Drive Axle | 18-22 | Data, Fault Diagnosis and Elimination (Removing and Installing the Drive Axle Assembly, Half Axle and Wheel Hubs, Bearings) |
| Steering Axle | 23-26 | Fault Diagnosis and Elimination (Steering Axle, Steering King Pin and Steering Spindle, Wheel Bearings) |
| Steering System | 27-30 | Steering System Troubleshooting, Hydraulic Steering Control Unit, Steering Cylinder |
| Brake System | 31-37 | Fault Diagnosis and Correction, Brake Master Cylinder, Brake Booster |
| Hydraulic System | 38-44 | Data, Fault Diagnosis and Correction (Main Oil Pump, Hydraulic Control Valve, Hydraulic System Circuit) |
| Lifting System | 45-56 | Assembly Data |
| Electrical System | 57-76 | Fuse Box Assembly, Lighting System, Removal and Installation |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Transmission Fluid Volume | 12 L | p. 6 |
| Transmission Fluid Replacement Interval | 1,000 hours | p. 9 |
| Tightening torque for wheel nuts (Tire Nut) | 638-850 N·m | p. 19 |
| Steering cylinder screw rod torque | 100 N·m - 120 N·m | p. 30 |
| Brake master cylinder piston-to-cylinder gap | 0.15 mm | p. 26 |
| Lift Chain Lock Nuts Torque | 441 ~ 539 N·m | p. 45 |
| Main Relief Valve Adjusted Pressure | 19 ± 0.25 MPa | p. 38 |
| Hydraulic Transmission Fluid Volume | 12L | p. 6 |
| Hydraulic Transmission Set Pressure | 1.2 MPa - 1.5 MPa | p. 6 |
| Drive Axle Tire Inflation Pressure | 830Pa | p. 18 |
| Steering Axle Tire Inflation Pressure | 0.86 MPa | p. 23 |
| Steering Cylinder Stroke | 181 mm | p. 27 |
Utilev UT40P, UT50PS Common Problems This Manual Covers
Utilev UT40P UT50PS hydraulic transmission clutch pressure low and truck shows excessive rocking
Check fluid level and fill to the normal mark (12 L capacity, page 6). Verify set pressure reads 1.2 MPa – 1.5 MPa (page 9). Still low? Wash or replace the clogged filter mesh, then inspect the clutch shaft rotating seal rings and the oil pump for wear per page 7. Replace worn seal rings and seat them correctly at assembly.
Manual Section: Hydraulic Transmission Fault Diagnosis and Correction p. 7Power steering wheel takes excessive effort to turn and steering fails to return to center
Bleed air from the steering oil line, then check diverter valve pressure and adjust if low, following page 27. Replace a broken or weak positioning spring if the wheel will not center. Engine off, turn the wheel with 1 kg force; it should return to within roughly 10% of its original position. Check the steering cylinder piston seal for internal leakage.
Manual Section: Steering System Troubleshooting p. 27Service brakes feel weak and forklift shows insufficient braking force when the pedal is applied
Inspect brake lines for leaks, repair them and top up fluid, then bleed air from the brake line following page 31. Check the friction linings: wipe off water or engine oil or replace contaminated linings, and replace linings with uneven contact or wear. Rectify or replace a malfunctioning master cylinder or brake cylinder, and flush a clogged oil channel.
Manual Section: Brake System Fault Diagnosis and Correction p. 31Main hydraulic oil pump noisy with low output pressure and air bubbles in the reservoir
Check the suction-side hose for kinks and clean the clogged filter, then re-tighten every suction connector to stop air entry following page 39. If fluid is too thick, replace it with the correct viscosity and do not operate until fluid temperature is normal. Use a pressure gauge to set the main relief valve to 19±0.25 MPa (page 38).
Manual Section: Main Oil Pump Fault Diagnosis and Correction p. 39Fork carriage creeps noticeably lower with lift control lever held in the neutral position
Verify the valve stem stays centered in neutral, then check the housing-to-stem wear gap and replace the stem to the required gap following page 40. Flush or replace a worn or dirt-stuck overload valve. If drift continues, repair the cylinder seals: shut off the engine, fully lower the pistons and keep your body clear (page 53), and never reuse the dust ring, O-ring or Y Seal Ring (page 54).
Manual Section: Hydraulic Control Valve Fault Diagnosis and Correction p. 40Forks lift unevenly and fork carriage movement is not smooth through the mast channel
Adjust the lift chains to the same tension, checking slack against 25 mm to 30 mm per page 45. Clear dirt from moving parts and grease the sliding guide rail contact surfaces. Set clearance between the inner mast channel and top carriage side rollers to 0.2 mm to 1.0 mm (page 51) with 0.5 mm or 1.0 mm shims. The fork, carriage and mast are heavy: keep hands and feet clear of the fork and carriage (page 49).
Manual Section: Lifting System Fault Diagnosis and Elimination Method p. 46Frequently Asked Questions
What are the hydraulic, transmission, wheel lug, and mast chain torque specifications for the Utilev UT40P, UT50PS?
The tightening torque for lift chain lock nuts is 441-539 N·m (M24x2). The torque for the bearing cover between the mast and drive axle is 245-314 N·m (M20x1.5), and lift cylinder bolts are 127-157 N·m (M16). For the drive axle, tightening torque for position E is 638-850 N·m. p. 45
What is the correct procedure for adjusting the lift chain tension?
Lower the lift cylinder until the fork contacts the ground. Adjust the chain regulating nuts (three nuts at each end) until the length 'C' is 25 mm to 30 mm when pressing down on the middle of the chain. p. 52
What is the normal operating fluid temperature for the hydraulic transmission?
The normal operating fluid temperature is 70°C to 95°C. The maximum temperature should not exceed 120°C for a period longer than 5 minutes. p. 9
What is the main relief valve pressure setting for the hydraulic control valve on the Utilev UT40P, UT50PS?
The main relief valve pressure is adjusted at the factory to 19±0.25 MPa. p. 38
How do you adjust the wheel bearings on the drive axle?
Tighten the nuts until the wheel hub cannot be turned by hand, then turn back 60 degrees. After seating the bearings by turning the hub 2-3 times, tighten again until firm, then turn back 60 degrees. The rotation starting pull force should be 10-29 N. p. 22
Will this Utilev UT40P Service Manual download right away?
Delivery is instant: a 76-page searchable PDF is yours the second checkout clears. Laptop, tablet, or phone, all fine.
Am I free to print this Utilev UT40P Service Manual?
Yes. Print the pages you need for the job in your own shop, and bin them when they get greasy.
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