Hyundai HDF20-5 HDF25-5 HDF30-5 Forklift Truck Service Repair Workshop Manual
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PARKING BRAKE(DRY TYPE)
Operating force of parking lever is 20 - 30
kgf(44 - 66lbf).
Check that parking brake can hold
machine in position when loaded on 15%
slope. If there is no slope available, travel
at low speed and check braking effect of
parking brake.
4-6
BRAKE PIPING
Check pipes, hoses and joints for damage, oil leakage or interference.
Operate brake pedal and check operating force when pedal is depressed. Check also change in
operating force, and change in position of pedal when pedal is kept depressed.
WHEEL BRAKE
Compact wheel base chassis
Measure lining at point with most wear, and check that lining thickness is at least 2.0mm(0.08in).
Hold lining surface with screwdriver to prevent piston from coming out, depress brake pedal and
check movement of shoe.
Remove brake shoe from anchor pin, and check for rust or wear.
When assembling, coat sliding parts with special brake grease.
BRAKE DRUM
Measure inside diameter of drum, and check that it is within 310mm(12.2in).
BACKING PLATE
Check visually for deformation or cracks.
Check particularly for deformation at outside circumference of plate and at mounting bolt.
Coat mounting bolt with loctite and tighten : 15~20kgf·m(108~145lbf·ft).
BRAKING FORCE
Select a dry, flat, paved surface and drive truck at maximum speed. When signal is given, stop
truck immediately and measure distance from point where signal was given to point where truck
stopped. (unloaded)
·Stopping distance : Within 5m(197in)
Check that there is no pulling of steering wheel, pulling by brakes to one side or abnormal noise
when making emergency stops.
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. OPERATIONAL CHECKS
1)
(1)
(2)
2)
(1)
(2)
(3)
3)
(1)
4)
(1)
(2)
5)
(1)
(2)
6)
(1)
(2)
2
1
L15C3BS05
4-7
Problem
Insufficient braking force
Brake acting unevenly.
(Machine is turned to one
side during braking.)
·Hydraulic system leaks oil.
·Hydraulic system leaks air.
·Lining surface soiled with water or oil.
·Lining surface roughened or in poor
contact with drum.
·Lining worn.
·Brake valve or wheel cylinder mal-
functioning.
·Hydraulic system clogged.
·Tires unequally inflated.
·Brake out of adjustment.
·Lining surface soiled with water or oil.
·Earth intruding into brake drum.
·Lining surface roughened.
·Lining in poor contact with drum.
·Lining worn.
·Brake drum worn or damaged
(distortion or rusting).
·Wheel cylinder malfunctioning.
·Brake shoe poorly sliding.
·Back plate mounting bolt loose.
·Back plate deformed.
·Wheel bearing out of adjustment.
·Hydraulic system clogged.
·Adjust tire pressure.
·Adjust.
·Clean or replace.
·Clean.
·Repair by polishing or replace.
·Repair by polishing.
·Replace.
·Repair or replace.
·Repair or replace.
·Adjust.
·Retighten or replace.
·Replace.
·Adjust or replace.
·Clean.
·Repair and add oil.
·Bleed air.
·Clean or replace.
·Repair by polishing or replace.
·Replace.
·Repair or replace.
·Clean.
cause Remedy
Brake trailing. ·Pedal has no play.
·Brake shoe poorly sliding.
·Wheel cylinder mal-functioning.
·Piston cup faulty.
·Return spring fatigued or bent.
·Parking brake fails to return or out of
adjustment.
·Brake valve return port clogged.
·Hydraulic system clogged.
·Wheel bearing out of adjustment.
·Adjust.
·Adjust.
·Repair or replace.
·Replace.
·Replace.
·Repair or adjust.
·Clean.
·Clean.
·Adjust or replace.
2. TROUBLESHOOTING
Brake chirps ·Brake trailing.
·Piston fails to return.
·Lining worn.
·Lining surface roughened.
·See above. Brake trailing.
·Replace.
·Replace.
·Repair by polishing or replace.
4-8
Problem
Brake rapping ·Drum sliding surface roughened.
·Drum eccentric or excessively distort-
ed.
·Lining surface roughened.
·Repair by polishing or replace.
·Replace.
·Repair by polishing or replace.
cause Remedy
Large pedal stroke
Pedal dragging.
Abnormal noise
·Brake out of adjustment.
·Hydraulic line sucking air.
·Oil leaks from hydraulic line, or lack
of oil.
·Lining worn.
·Shoe tilting or does not return compl-
etely.
·Lining in poor contact with brake
drum.
·Twisted push rod caused by improp-
erly fitted brake valve.
·Brake valve seal faulty.
·Flow control valve orifice clogged.
·Lining worn.
·Lining surface roughened.
·Poor shoe to lining contact.
·Excessively large friction between
shoe and back plate.
·Foreign matter on drum sliding sur-
face.
·Drum sliding surface damaged or
distorted.
·Brake shoe deformed or poorly in-
stalled.
·Back plate mounting bolt loosening.
·Worm anchor or other contact portion.
·Lining in poor contact with drum.
·Adjust.
·Bleed air.
·Check and repair or add oil.
·Replace.
·Repair.
·Repair.
·Adjust.
·Replace.
·Clean or replace.
·Replace
·Repair by polishing or replace.
·Replace.
·Clean and apply brake grease.
·Clean
·Replace
·Replace or repair.
·Retighten
·Replace
·Repair or replace.
Brake squeaks ·Lining surface roughened.
·Lining worn.
·Poor shoe to lining contact.
·Excessively large friction between
shoe and back plate.
·Foreign matter on drum sliding surfa-
ce.
·Drum sliding surface damaged or di-
storted.
·Brake shoe deformed or poorly insta-
lled.
·Back plate mounting bolt loosening.
·Worn anchor or other contact portion.
·Lining poor contact with drum.
·Anti-rattle spring poorly installed.
·Repair by polishing or replace.
·Replace.
·Replace.
·Clean and apply brake grease.
·Clean
·Replace.
·Replace or repair.
·Retighten.
·Replace.
·Repair or replace.
·Repair or replace.
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$41.99
The Hyundai HDF20-5 HDF25-5 HDF30-5 Forklift Truck Service Repair Manual is a comprehensive resource suitable for both professional mechanics and DIY enthusiasts. It contains easy-to-read text sections, high-quality diagrams, and clear instructions, making it an invaluable tool for anyone undertaking repair or maintenance tasks.
The manual covers a wide range of topics, including:
- SECTION 1 - GENERAL
- Group 1: Safety Hints
- Group 2: Specifications
- Group 3: Periodic replacement
- SECTION 2 - REMOVAL AND INSTALLATION OF UNIT
- Group 1: Major components
- Group 2: Removal and installation of unit
- SECTION 3 - POWER TRAIN SYSTEM
- Group 1: Structure and Operation
- Group 2: Troubleshooting
- Group 3: Test and adjustments
- Group 4: Disassembly and assembly
- SECTION 4 - BRAKE SYSTEM
- Group 1: Structure and function
- Group 2: Operational checks and troubleshooting
- Group 3: Test and adjustment
- SECTION 5 - STEERING SYSTEM
- Group 1: Structure and function
- Group 2: Operational checks and troubleshooting
- Group 3: Disassembly and assembly
- SECTION 6 - HYDRAULIC SYSTEM
- Group 1: Structure and function
- Group 2: Operational checks and troubleshooting
- Group 3: Disassembly and assembly
- SECTION 7 - ELECTRIC SYSTEM
- Group 1: Component location
- Group 2: Electrical circuit
- Group 3: Component specification
- Group 4: Troubleshooting
- SECTION 8 - MAST
- Group 1: Structure
- Group 2: Operational checks and troubleshooting
- Group 3: Adjustment
- Group 4: Removal and installation
The manual is available in PDF format, compatible with all versions of Windows and Mac. It is presented in English and requires Adobe Reader and Win for access. Investing in the Hyundai HDF20-5 HDF25-5 HDF30-5 Forklift Truck Service Repair Manual will not only save time and money but also enhance your understanding of your vehicle, ensuring efficient and effective maintenance and repair procedures in the long run.
