Hyundai HDF 20-5 User Manual

215 pages

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CONTENTS

SECTION 1 GENERAL

Group 1 Safety Hints 1-1

Group 2 Specifications 1-5

Group 3 Periodic Replacement 1-13

SECTION 2 REMOVAL AND INSTALLATION OF UNIT

Group 1 Structure 2-1

Group 2 Removal and Installation of Unit 2-2

SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and Operation 3-1

Group 2 Troubleshooting 3-15

Group 3 Tests and Adjustments 3-19

Group 4 Disassembly and Assembly 3-23

SECTION 4 BRAKE SYSTEM

Group 1 Structure and Function 4-1

Group 2 Operational Checks and Troubleshooting 4-6

Group 3 Tests and Adjustments 4-9

SECTION 5 STEERING SYSTEM

Group 1 Structure and Function 5-1

Group 2 Operational Checks and Troubleshooting 5-10

Group 3 Disassembly and Assembly 5-12

SECTION 6 HYDRAULIC SYSTEM

Group 1 Structure and Function 6-1

Group 2 Operational Checks and Troubleshooting 6-17

Group 3 Disassembly and Assembly 6-21

SECTION 7 ELECTRICAL SYSTEM

Group 1 Component Location 7-1

Group 2 Electrical Circuit 7-2

Group 3 Component Specification 7-9

Group 4 Troubleshooting 7-12

Table of Contents

Questions and Answers:

P
Peter LeonAug 7, 2025
Why is my Hyundai HDF 20-5 oil temperature rising excessively?
- R
  robertcarrAug 7, 2025
  An excessive oil temperature rise in your Hyundai Forklifts can be addressed by several checks. Start by verifying the oil level and adjusting it as needed. If the issue persists, drain the oil from both the oil tank and transmission, then inspect and replace any parts that are interfering. Also, check the engine stalling speed and replace if necessary. Examine the inlet side joint or pipe, retightening the joint or replacing the gasket if required. Additionally, inspect the drained oil and change it if needed. Other solutions include disassembling, inspecting, repairing, or replacing components, checking and replacing parts, verifying if the machine moves in neutral (and replacing the clutch plate if it does), and disassembling, checking, and replacing parts.
D
douglastorresAug 18, 2025
What to do if my Hyundai HDF 20-5 has unusual oil pressure?
- R
  Robert LawrenceAug 19, 2025
  If your Hyundai Forklifts is experiencing unusual oil pressure, start by checking the spool operation and replace the valve if necessary. Also, check for any clogging in the small hole of the valve body; clean or repair it if needed. If the atmospheric temperature is below freezing and normal oil pressure returns when heated, change the oil. Other solutions include checking and changing the oil, disassembling, checking, and replacing parts, checking spring tension and replacing if necessary, and checking joints and pipes, retightening or replacing the packing if needed. Furthermore, check the oil level and add oil if needed, and disassemble and inspect the piston ring and O-ring for wear and other defects, replacing them as necessary.
L
Laura BrownAug 25, 2025
Why is my Hyundai HDF 20-5 making noise during operation?
- J
  Jennifer CombsAug 26, 2025
  If your Hyundai Forklifts is making unusual noises during operation, several steps can be taken to address this. Begin by changing the oil and replacing any parts that are leaking air. Listen for rotating sounds during low-speed operation; if necessary, replace the flexible plate. Other solutions include disassembling, checking, and replacing components, checking the impeller or drained oil for foreign matter, and changing the oil if needed. Also, disassemble and check parts, retightening or replacing them as needed. Check to see whether or not the machine moves even when transmission is in neutral position. If so, replace clutch plate. Disassemble, check and retighten or replace parts.
L
Lisa RoseAug 31, 2025
What to do if power is not transmitted in my Hyundai HDF 20-5?
- V
  vwilliamsAug 31, 2025
  If power is not being transmitted in your Hyundai Forklifts, begin by listening for abnormal sounds at a low converter speed to check for damage, and replace parts if necessary. Also, check the oil level and add oil if needed. Other solutions include disassembling and checking for wear on the pump gear, shaft, and spline, replacing defective parts, and checking the oil pump gear for wear and oil suction force, replacing the pump if necessary. Check, measure and adjust components. Also, ensure the machine does not move when in neutral; if it does, replace parts. Disassemble, check main shaft, etc., and replace.

Hyundai HDF 20-5 Specifications

General

Model	HDF 20-5
Power Source	Diesel
Rated Capacity	2000 kg
Load Capacity	2000 kg
Lift Height	3000 mm
Mast Type	Duplex
Category	Forklift

Summary

Section 1 General

Group 1 Safety Hints

Provides essential safety guidelines and precautions for handling the machine and its components.

Group 2 Specifications

Details the technical specifications and dimensions of various machine components and systems.

Group 3 Periodic Replacement

Outlines the recommended replacement intervals for consumable and wear-prone parts.

Section 2 Removal and Installation of Unit

Group 1 Structure

Illustrates the components and overall structure of the machine's main units.

Group 2 Removal and Installation of Unit

Provides step-by-step procedures for removing and installing various machine components.

Section 3 Power Train System

Group 1 Structure and Operation

Explains the structure and operational principles of the power train system.

Group 2 Troubleshooting

Identifies common problems in the power train system and provides solutions.

Group 3 Test and Adjustments

Details procedures for testing and adjusting the power train system components.

Group 4 Disassembly and Assembly

Provides instructions for the disassembly and assembly of power train system parts.

Section 4 Brake System

Group 1 Structure and Function

Describes the structure and functional principles of the brake system.

Group 2 Operational Checks and Troubleshooting

Covers operational checks and troubleshooting for brake system issues.

Group 3 Tests and Adjustments

Details procedures for testing and adjusting the brake system.

Section 5 Steering System

Group 1 Structure and Function

Explains the structure and functional principles of the steering system.

Group 2 Operational Checks and Troubleshooting

Covers operational checks and troubleshooting for steering system issues.

Group 3 Disassembly and Assembly

Provides instructions for the disassembly and assembly of steering system components.

Section 6 Hydraulic System

Group 1 Structure and Function

Describes the structure and functional principles of the hydraulic system.

Group 2 Operational Checks and Troubleshooting

Covers operational checks and troubleshooting for hydraulic system issues.

Group 3 Disassembly and Assembly

Provides instructions for the disassembly and assembly of hydraulic system components.

Section 7 Electrical System

Group 1 Component Location

Identifies the locations of various electrical system components on the machine.

Group 2 Electrical Circuit

Presents the wiring diagrams and electrical circuit layouts for the machine.

Group 3 Component Specification

Lists the specifications for electrical system components.

Group 4 Troubleshooting

Diagnoses common electrical system problems and provides remedies.

Section 8 Mast

Group 1 Structure

Details the structural components of the mast assembly.

Group 2 Operational Checks and Troubleshooting

Covers operational checks and troubleshooting for mast system issues.

Group 3 Adjustment

Provides procedures for adjusting mast components and clearances.

Group 4 Removal and Installation

Outlines the steps for removing and installing mast assemblies.

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