Hyundai 250D-7E User manual

CONTENTS
CONTENTS
SECTION 1 GENERAL
SECTION 1 GENERAL
Group 1 Safety hints --------------------------------------------------------------------------------------------------------
Group 2 Specifications
----------------------------------------------------------------------------------------------------
Group 3 Operational checkout record sheet
-----------------------------------------------------------------
SECTION 2 REMOVAL AND INSTALLATION OF UNIT
SECTION 2 REMOVAL AND INSTALLATION OF UNIT
Group 1 Structure ------------------------------------------------------------------------------------------------------------
Group 2 Removal and Installation of Unit
----------------------------------------------------------------------
SECTION 3 POWER TRAIN SYSTEM
SECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and operation ------------------------------------------------------------------------------------
Group 2 Operation and maintenance ----------------------------------------------------------------------------
Group 3 Disassembly and assembly -----------------------------------------------------------------------------
Group 4 Adjustment
---------------------------------------------------------------------------------------------------------
SECTION 4 BRAKE SYSTEM
SECTION 4 BRAKE SYSTEM
Group 1 Structure and function --------------------------------------------------------------------------------------
Group 2 Operational checks and troubleshooting --------------------------------------------------------
Group 3 Tests and adjustments
--------------------------------------------------------------------------------------
Group 4 Disassembly and assembly -----------------------------------------------------------------------------
SECTION 5 STEERING SYSTEM
SECTION 5 STEERING SYSTEM
Group 1 Structure and function --------------------------------------------------------------------------------------
Group 2 Operational checks and troubleshooting --------------------------------------------------------
Group 3 Tests and adjustments
--------------------------------------------------------------------------------------
Group 4 Disassembly and assembly -----------------------------------------------------------------------------
SECTION 6 HYDRAULIC SYSTEM
SECTION 6 HYDRAULIC SYSTEM
Group 1 Structure and function --------------------------------------------------------------------------------------
Group 2 Operational checks and troubleshooting --------------------------------------------------------
Group 3 Disassembly and assembly
-----------------------------------------------------------------------------
1-1
1-5
1-13
2-1
2-2
3-1
3-46
3-57
3-185
4-1
4-32
4-40
4-43
5-1
5-9
5-17
5-21
6-1
6-28
6-33

SECTION 7 ELECTRICAL SYSTEM
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component location -----------------------------------------------------------------------------------------
Group 2 Electrical circuit -------------------------------------------------------------------------------------------------
Group 3 Cluster ---------------------------------------------------------------------------------------------------------------
Group 4 Transmission message indicator ---------------------------------------------------------------------
Group 5 Switches ------------------------------------------------------------------------------------------------------------
Group 6 Electrical component specification
------------------------------------------------------------------
Group 7 Connectors --------------------------------------------------------------------------------------------------------
Group 8 Troubleshooting
-------------------------------------------------------------------------------------------------
SECTION 8 MAST
SECTION 8 MAST
Group 1 Structure ------------------------------------------------------------------------------------------------------------
Group 2 Operational checks and troubleshooting
--------------------------------------------------------
Group 3 Adjustment --------------------------------------------------------------------------------------------------------
Group 4 Removal and installation
----------------------------------------------------------------------------------
7-1
7-3
7-14
7-23
7-27
7-32
7-42
7-59
8-1
8-3
8-6
8-8

0-1
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
This section gives the general information of the machine and explains the safety hints for
maintenance.
SECTION 2 REMOVAL & INSTALLATION OF UNIT
This section explains the procedures and techniques of removal and installation of each component.
SECTION 3 POWER TRAIN SYSTEM
This section explains the structure of the transmission as well as control valve and drive axle.
SECTION 4 BRAKE SYSTEM
This section explains the brake piping, each component and operation.
SECTION 5 STEERING SYSTEM
This section explains the structure of the steering unit, priority valve, trail axle as well as steering
circuit and operation.
SECTION 6 HYDRAULIC SYSTEM
This section explains the structure of the gear pump, main control valve as well as work equipment
circuit, each component and operation.
SECTION 7 ELECTRICAL SYSTEM
This section explains the electrical circuit and each component.
It serves not only to give an understanding electrical system, but also serves as reference material for
troubleshooting.
SECTION 8 MAST
This section explains the structure of mast, carriage, backrest and forks.
The specifications contained in this service manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.

0-2
Revised edition mark(ΗΘΙÄ)
When a manual is revised, an edition mark is
recorded on the bottom outside corner of the
pages.
R
Revisions
Revised pages are shown at the list of revised
pages on the between the contents page and
section 1 page.
Symbols
So that the shop manual can be of ample
practical use, important places for safety and
quality are marked with the following symbols.
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating
Any additions, amendments or other changes
will be sent to HYUNDAI distributors.
Get the most up-to-date information before you
start any work.
Filing method
See the page number on the bottom of the
page.
File the pages in correct order.
Following examples shows how to read the
page number.
Example 1
2 - 3
Item number(2. Structure and
Function)
Consecutive page number for
each item.
Additional pages : Additional pages are
indicated by a hyphen(-) and number after the
page number. File as in the example.
1.
2.
3.
Symbol Item Remarks
Special safety precautions are
necessary when performing the
work.
Extra special safety precautions
are necessary when performing
the work because it is under
internal pressure.
Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.
Safety
Caution
ö
10 - 4
10 - 4 - 1
10 - 4 - 2
10 - 5
Added pages

0-3
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
Method of using the Conversion Table to convert from millimeters to inches
Convert 55
mm
into inches.
Locate the number 50
in the vertical column at the left side, take this as ͽ, then draw a
horizontal line from ͽ.
Locate the number 5
in the row across the top, take this as ;, then draw a perpendicular line
down from ;.
Take the point where the two lines cross as Ϳ. This point Ϳgives the value when converting
from millimeters to inches. Therefore, 55
mm = 2.165 inches.
Convert 550
mm into inches.
The number 550 does not appear in the table, so divide by 10(Move the decimal point one place
to the left) to convert it to 55
mm .
Carry out the same procedure as above to convert 55mm to 2.165 inches.
The original value(550
mm ) was divided by 10, so multiply 2.165 inches by 10(Move the decimal
point one place to the right) to return to the original value.
This gives 550
mm = 21.65 inches.
1.
2.
(1)
(2)
(3)
(1)
(2)
(3)
Millimeters to inches 1
mm = 0.03937 in
;
ͽ
01 2 345 678 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Ϳ