Every UT50, UT60 and UT70 internal combustion counterbalanced forklift truck, P variants included, is covered by this 80-page Utilev UT50P, UT60P, UT70P service manual PDF (OEM ID 76500014), so you know it matches your fleet before you buy. Wiring schematics trace the fuse box, combination switch and instrument cluster circuits, while the hydraulic system schematic maps oil from the pump through the multi-way directional valve and flow regulator to the lift and tilt cylinders. Troubleshooting tables cover the torque converter, drive axle, steering, brakes and mast, and the lifting section takes you through mast removal, adjustment and commissioning, plus Cummins and GM 4.3L engine diagnostics. On 5T to 7T trucks, set the main safety valve at 19±0.25 MPa and the steering safety valve at 9.8±0.25 MPa. One wrong relief setting can cost you a pump. The bookmarked, text-searchable PDF travels on a laptop or phone to wherever the truck sits, dock or yard.
What's Inside This Utilev UT50P, UT60P, UT70P Manual
| System | Pages | Key Topics |
|---|---|---|
| Powertrain | 5-7 | Power Configuration, Engine Parameters, Emission Values, Fault Diagnosis Connector |
| Hydrodynamic Transmission, Torque Converter | 8-11 | Overview, Main Technical Parameters, Troubleshooting Table, Drive Shaft |
| Drive Axle Assembly | 12-25 | Basic Structure and Working Principle of Drive Axle, Periodic Technical Services, Drive Axle Oil Adding/Draining Procedures and Oil Quantity, Lifting the Drive Axle |
| Steering Axle | 26-29 | General Specifications, Structural Diagram of Steering Axle |
| Steering System | 30-32 | Steering System Troubleshooting, Overview |
| Braking System | 33-42 | Specifications, Troubleshooting, Service Brake Pedal Height and Free Travel, Brake Master Cylinder, Hydraulic Booster, Brakes and Brake Wheel Cylinder, Parking Brake |
| Hydraulic System | 43-47 | Specifications, Troubleshooting, Oil Pump, Multi-Way Directional Valve, Flow Regulator Valve, Lift Cylinder, Tilt Cylinder, Schematic Diagram of Hydraulic System |
| Lifting System | 48-58 | Assembly and Commissioning Data, Fault Diagnosis and Troubleshooting, Overview, Mast Removal, Installation and Adjustment, Removal and Installation of Lift Cylinders |
| Engine Diagnostics | 59-61 | Cummins Engine Diagnostics, GM Engine Diagnostics |
| Electrical System | 62-80 | Inspection, Fuse Box Assembly, Combination Switch, Instrument Cluster Assembly |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Charging Pump Displacement | 21 ml/r | p. 8 |
| Rated Power | 74 kW | p. 5 |
| Transmission Oil Capacity | 25 L | p. 8 |
| Main Reduction Unit Oil Capacity | 10 L | p. 16 |
| Final Reduction Unit Oil Capacity | 1.5 L | p. 16 |
| Steering Tire Pressure | 0.83 MPa | p. 26 |
| 5T-7T | ||
| Main Safety Valve Pressure | 19±0.25 MPa | p. 43 |
| Mono-stable diverter valve flow | 18-22 L/min | p. 43 |
| Lift chain dimension C | 25–30 mm | p. 48 |
| 5T-6T | ||
| Inner/outer side rollers to mast flange clearance | 0.2~1 mm | p. 48 |
| UT50/60/70P (Diesel) | ||
| Rated Speed | 2200 rpm | p. 5 |
| UT60/70P (Dual Fuel) | ||
| Rated Speed | 2300 rpm | p. 5 |
Utilev UT50P, UT60P, UT70P Common Problems This Manual Covers
Utilev UT50 UT60 UT70 torque converter transmission losing drive efficiency with oil temperature running too high
Check oil level first: add working oil, run the engine in neutral for 5 minutes, and confirm the level sits between the dipstick marks per page 10. Check oil pump condition, clear any blocked lubricant line, and inspect friction discs and separator plates for sticking, uneven contact or warping. Replace a damaged bearing. A seized one-way clutch means replacing the torque converter. Never modify the transmission oil line system (page 10).
Manual Section: Hydrodynamic Transmission Troubleshooting p. 10Steering hydraulic flow problem, forklift zigzags or wobbles down the aisle when driving straight
Adjust the diverter valve flow, since the chart on page 30 traces zigzag and wobble to steering flow that is too high. Set mono-stable diverter valve flow within 18-22 L/min per the hydraulic specs on page 43. If the truck still wanders, check for loose wheel nuts, wheel bearing adjustment and incorrectly fitted axle end shaft shims at the steering axle, page 26.
Manual Section: Steering System Troubleshooting p. 30Service brakes keep dragging after the operator fully releases the brake pedal on the truck
Measure brake pedal free travel and adjust it to 5-7.5 mm per page 33. No free play is the first cause on the page 34 chart. Flush a clogged master cylinder return port or line, then check for a weak or broken return spring, a damaged piston cup, improper shoe sliding, wheel cylinder operation and the brake booster. Before pulling a drum, block the truck as page 40 describes and keep the wood blocks off the front tires.
Manual Section: Braking System Troubleshooting p. 34Fork carriage drifts noticeably lower with the lift control lever held in the neutral position
Check that the control valve stem is centered in neutral, then inspect the wear gap between valve housing and stem and replace the stem to the required gap, per page 44. Replace or flush an overload valve that is worn or stuck with dirt, and repair or replace defective cylinder seals. When servicing the lift cylinder, never stand under the fork carriage and never reuse dust rings, O-rings or Y-rings (page 57).
Manual Section: Hydraulic System Troubleshooting p. 44Mast has insufficient lift power or no lift movement at all with a load on the forks
Test pump pressure with a gauge and set the main safety valve to 19 ± 0.25 MPa per page 43. Inspect for worn pump gears and housing, a worn lift cylinder piston seal, a defective relief valve spring, and leaking control valve or lines, following page 49. Change overheated or diluted hydraulic fluid and keep loads within regulations. When replacing the lift cylinder seal, do not stand under the fork carriage (page 57).
Manual Section: Lifting System Troubleshooting p. 49Forks lift unevenly and the mast makes excessive noise when raising or lowering the carriage
Adjust both lifting chains to the same tension and set chain slack to 25-30 mm per page 48. Clean and lubricate rollers clogged with hardened grease or dirt, grease the sliding guide rail contact surfaces, and adjust the fork carriage side rollers and side adjusting shims so they stop striking the mast guide rail after the extended mast is lowered, following the page 49 chart.
Manual Section: Lifting System Troubleshooting p. 49Frequently Asked Questions
What are the fault codes and meanings for the Cummins engine?
The manual does not list specific fault codes. Instead, it directs the technician to connect diagnostic equipment to the connector shown in Figure 9-1 or use the diagnostic switch procedure on page 60 to obtain codes. The "Severe Warning" indicator flashes, followed by a 1-2 second pause to indicate the beginning of the sequence, and the "Engine Failure" indicator flashes the fault code number. p. 60
What are the replacement specifications for the transmission oil filter on the Utilev UT50P, UT60P, UT70P forklift?
The transmission oil filter should be cleaned or replaced if the clutch pressure is low and the swing is too large. The oil should be changed after every 1000 hours of use or long periods of disuse. p. 10
What are the Utilev UT50P, UT60P, UT70P hydraulic oil filter and suction screen replacement specifications?
If the oil pump is not pumping out fluid, the suction hose or filter may be clogged. The remedy is to flush the fluid circuit and fluid reservoir, and change the hydraulic fluid if it is dirty. p. 43
What is the tightening torque for the main reduction unit fixing bolts on the Utilev UT50P, UT60P, UT70P forklift?
The tightening torque for the main reduction unit fixing bolts is 100 N·m. These bolts must be coated with Loctite 262 during installation. p. 13
What is the correct oil capacity for the main reduction unit on the Utilev UT50P, UT60P, UT70P forklift?
The main reduction unit requires approximately 10 liters of GL-5 85W/90 gear oil. p. 16
What format is this Utilev UT50P manual in?
Straight to your device: 80 pages of searchable Service Manual, downloadable the moment payment goes through.
Is this Utilev UT50P manual print-friendly?
You can. Print the sections you want for your own use and keep the file as your backup.
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