Hyundai 25DE-7 User manual

1 / 189
CONTENTS
FOREWORD ....................................................................................................................................... 2
SECTION 1 GENERAL ................................................................................................................. 11
GROUP1 SAFETY HINTS ...................................................................................................... 12
GROUP2 SPECIFICATIONS ................................................................................................... 16
GROUP3 PERIODIC REPLACEMENT .................................................................................... 24
SECTION2 REMOVAL AND INSTALLATION OF UNIT .................................................................. 25
GROUP1 STRUCTURE ......................................................................................................... 26
GROUP2 REMOVAL AND INSTALLATION OF UNIT .............................................................. 27
SECTION3 POWER TRAIN SYSTEM ............................................................................................ 42
GROUP1 STRUCTURE AND OPERATION ............................................................................. 43
GROUP2 DISASSEMBLY AND ASSEMBLY AND TROUBLESHOOTING ................................... 46
SECTION4 BRAKE SYSTEM ........................................................................................................ 68
GROUP1 STRUCTURE AND FUNCTION ............................................................................... 69
GROUP2 OPERATIONAL CHECKS AND TROUBLESHOOTING ............................................... 79
GROUP3 TESTS AND ADJUSTMENTS .................................................................................. 81
SECTION5 STEERING SYSTEM ................................................................................................... 83
GROUP1 STRUCTURE AND FUNCTION ............................................................................... 84
GROUP2 OPERATIONAL CHECKS AND TROUBLESHOOTING ............................................... 93
GROUP3 DISASSEMBLY AND ASSEMBLY ............................................................................. 96
SECTION6 HYDRAULIC SYSTEM .............................................................................................. 121
GROUP1 STRUCTURE AND FUNCTION ............................................................................. 122
GROUP2 OPERATIONAL CHECKS AND TROUBLESHOOTING ............................................. 134
GROUP3 DISASSEMBLY AND ASSEMBLY ........................................................................... 138
SECTION7 ELECTRICAL SYSTEM .............................................................................................. 152
GROUP1 COMPONENT LOCATION ................................................................................... 153
GROUP2 ELECTRICAL CIRCUIT .......................................................................................... 154
GROUP3 COMPONENT SPECIFICATION ............................................................................ 161
GROUP4 CONNECTOR DESTINATION ............................................................................... 162
GROUP5 TROUBLESHOOTING .......................................................................................... 165
SECTION8 MAST ..................................................................................................................... 166
GROUP1 STRUCTURE ....................................................................................................... 167
GROUP2 OPERATIONALCHECKS AND TROUBLESHOOTING .............................................. 171
GROUP3 ADJUSTMENT .................................................................................................... 174
GROUP4 REMOVAL AND INSTALLATION ........................................................................... 177

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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.

3 / 189
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.
1) Filing method
See the page number on the bottom of the page.
File the pages in correct order.
2) Revised edition mark(①②③…)
When a manual is revised, an edition mark is recorded on the bottom outside
corner of the pages.
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.
Symbol Item Remarks
Safety
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.
※ Caution
Special technical precautions or other precautions for
preserving standards are necessary when performing the
work.

4 / 189
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
1) Method of using the Conversion Table to convert from millimeters to inches
Convert 55mm into inches.
① Locate the number 50in the vertical column at the left side, take this as ○a,
then draw a horizontal line from ○a.
② Locate the number 5in the row across the top, take this as ○b , then draw a
perpendicular line down from ○b.
③ Take the point where the two lines cross as ○c . This point ○c gives the
value when converting from millimeters to inches. Therefore, 55mm
= 2.165 inches.
2) Convert 550mm into inches.
① 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 55mm.
② Carry out the same procedure as above to convert 55mm to 2.165 inches.
③ The original value(550mm) 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 550mm = 21.65 inches.
Millimeters to inches ○
b 1mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
0.394
0.787
1.181
1.575
1.969
2.362
2.756
3.150
3.543
0.039
0.433
0.827
1.220
1.614
2.008
2.402
2.795
3.189
3.583
0.079
0.472
0.866
1.260
1.654
2.047
2.441
2.835
3.228
3.622
0.118
0.512
0.906
1.299
1.693
2.087
2.480
2.874
3.268
3.661
0.157
0.551
0.945
1.339
1.732
2.126
2.520
2.913
3.307
3.701
0.197
0.591
0.984
1.378
1.772
2.165○
c
2.559
2.953
3.346
3.740
0.236
0.630
1.024
1.417
1.811
2.205
2.598
2.992
3.386
3.780
0.276
0.669
1.063
1.457
1.850
2.244
2.638
3.032
3.425
3.819
0.315
0.709
1.102
1.496
1.890
2.283
2.677
3.071
3.465
3.858
0.354
0.748
1.142
1.536
1.929
2.323
2.717
3.110
3.504
3.898

5 / 189
Millimeters to inches 1mm = 0.03937in
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
0.394
0.787
1.181
1.575
1.969
2.362
2.756
3.150
3.543
0.039
0.433
0.827
1.220
1.614
2.008
2.402
2.795
3.189
3.583
0.079
0.472
0.866
1.260
1.654
2.047
2.441
2.835
3.228
3.622
0.118
0.512
0.906
1.299
1.693
2.087
2.480
2.874
3.268
3.661
0.157
0.551
0.945
1.339
1.732
2.126
2.520
2.913
3.307
3.701
0.197
0.591
0.984
1.378
1.772
2.165
2.559
2.953
3.346
3.740
0.236
0.630
1.024
1.417
1.811
2.205
2.598
2.992
3.386
3.780
0.276
0.669
1.063
1.457
1.850
2.244
2.638
3.032
3.425
3.819
0.315
0.709
1.102
1.496
1.890
2.283
2.677
3.071
3.465
3.858
0.354
0.748
1.142
1.536
1.929
2.323
2.717
3.110
3.504
3.898
Kilogram to Pound 1kg = 2.2046lb
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
22.05
44.09
66.14
88.18
110.23
132.28
154.32
176.37
198.42
2.20
24.25
46.30
68.34
90.39
112.44
134.48
156.53
178.57
200.62
4.41
26.46
48.50
70.55
92.59
114.64
136.69
158.73
180.78
202.83
6.61
28.66
50.71
72.75
94.80
116.85
138.89
160.94
182.98
205.03
8.82
30.86
51.91
74.96
97.00
119.05
141.10
163.14
185.19
207.24
11.02
33.07
55.12
77.16
99.21
121.25
143.30
165.35
187.39
209.44
13.23
35.27
57.32
79.37
101.41
123.46
145.51
167.55
189.60
211.64
15.43
37.48
59.5.
81.57
103.62
125.66
147.71
169.76
191.80
213.85
15.43
37.48
59.5.
81.57
103.62
125.66
147.71
169.76
191.80
213.85
19.84
41.89
63.93
85.98
108.03
130.07
152.12
174.17
196.21
218.26

6 / 189
Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
2.642
5.283
7.925
10.567
13.209
15.850
18.492
21.134
23.775
0.264
2.906
5.548
8.189
10.831
13.473
16.115
18.756
21.398
24.040
0.528
3.170
5.812
8.454
11.095
13.737
16.379
19.020
21.662
24.304
0.793
3.434
6.6076
8.718
11.359
14.001
16.643
19.285
21.926
24.568
1.057
3.698
6.340
8.982
11.624
14.265
16.907
19.549
22.190
24.832
1.321
3.963
6.604
9.246
11.888
14.529
17.171
19.813
22.455
25.096
1.585
4.227
6.869
9.510
12.152
14.795
17.435
20.077
22.719
25.631
1.849
4.491
7.133
9.774
12.416
15.058
17.700
20.341
22.983
25.625
2.113
4.755
7.397
10.039
12.680
15.322
17.964
20.605
23.247
25.889
2.378
5.019
7.661
10.303
12.944
15.586
18.228
20.870
23.511
26.153
Liter to U.K. Gallon 1ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
2.200
4.399
6.599
8.799
10.998
13.198
15.398
17.598
19.797
0.220
2.420
4.619
6.819
9.019
11.281
13.418
15.618
17.818
20.017
0.440
2.640
4.839
7.039
9.239
11.438
13.638
15.838
18.037
20.237
0.660
2.860
5.059
7.259
9.459
11.658
13.858
16.058
18.257
20.457
0.880
3.080
5.279
7.479
9.679
11.878
14.078
16.278
18.477
20.677
1.100
3.300
5.499
7.969
9.899
12.098
14.298
16.498
18.697
20.897
1.320
3.520
5.719
7.919
10.119
12.318
14.518
16.718
18.917
21.117
1.540
3.740
5.939
8.139
10.339
12.528
14.738
16.938
19.137
21.337
1.760
3.950
6.159
8.359
10.559
12.758
14.958
17.158
19.357
21.557
1.980
4.179
6.379
8.579
10.778
12.978
15.178
17.378
19.577
21.777

7 / 189
kgf•m to lbf•ft 1kgf•m = 7.233lbf•ft
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
72.3
144.7
217.0
289.3
361.7
434.0
506.3
578.6
651.0
723.3
795.6
868.0
940.3
1012.6
1084.9
1157.3
1129.6
1301.9
1374.3
7.2
79.6
151.9
224.2
396.6
368.9
441.2
513.5
585.9
658.2
730.5
802.9
875.2
947.5
1019.9
1092.2
1164.5
1236.8
1309.2
1381.5
14.5
86.8
159.1
231.5
303.8
376.1
448.5
520.8
593.1
665.4
737.8
810.1
882.4
954.8
1027.1
1099.4
1171.7
1244.1
1316.4
1388.7
21.7
94.0
166.4
238.7
311.0
383.4
455.7
528.0
600.3
672.7
745.0
817.3
889.7
962.0
1034.3
1106.6
1179.0
1251.3
1323.6
1396.0
28.9
101.3
173.6
245.9
318.3
390.6
462.9
535.2
607.6
679.9
752.2
824.6
896.9
969.2
1041.5
1113.9
1186.2
1258.5
1330.9
1403.2
36.2
108.5
180.8
253.2
325.5
397.8
470.2
542.5
614.8
687.1
759.5
831.8
904.1
976.5
1048.8
1121.1
1193.4
1265.8
1338.1
1410.4
43.4
115.7
188.1
260.4
332.7
405.1
477.4
549.7
622.0
694.4
766.7
839.0
911.4
983.7
1056.0
1128.3
1200.7
1273.0
1345.3
1417.7
50.6
123.0
195.3
267.6
340.0
412.3
484.6
556.9
629.3
701.6
773.9
846.3
918.6
990.9
1063.2
1135.6
1207.9
1280.1
1352.6
1424.9
57.9
130.2
202.5
274.9
347.2
419.5
491.8
564.2
636.5
708.8
781.2
853.5
925.8
998.2
1070.5
1142.8
1215.1
1287.5
1359.8
1432.1
65.1
137.4
209.8
282.1
354.4
426.8
499.1
571.4
643.7
716.1
788.4
860.7
933.1
10005.4
1077.7
1150.0
1222.4
1294.7
1367.0
1439.4

8 / 189
kgf/cm2 to lbf/in2 1kgf / cm2 = 14.2233lbf / in2
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
200
210
220
230
240
142.2
284.5
426.7
568.9
711.2
853.4
995.6
1138
1280
1422
1565
1707
1849
1991
2134
2276
2418
2560
2845
2987
3129
3271
3414
14.2
156.5
298.7
440.9
583.2
725.4
867.6
1010
1152
1294
1437
1579
1721
2863
2005
2148
2290
2432
2574
2859
3001
3143
3286
3428
28.4
170.7
312.9
455.1
597.4
739.6
881.8
1024
1166
1309
1451
1593
1735
1877
2020
2162
2304
2446
2589
2873
3015
3158
3300
3442
42.7
184.9
327.1
469.4
611.6
753.8
896.1
1038
1181
1323
1465
1607
1749
1892
2034
2176
2318
2460
5603
2887
3030
3172
3314
3456
56.9
199.1
341.4
483.6
625.8
768.1
910.3
1053
1195
1337
1479
1621
1764
1906
2048
2190
2333
2475
2617
2901
3044
3186
3328
3470
71.1
213.4
355.6
497.8
640.1
782.3
924.5
1067
1209
1351
1493
1636
1778
1920
2062
2205
2347
2489
2631
2916
3058
3200
3343
3485
85.3
227.6
369.8
512.0
654.3
796.5
938.7
1081
1223
1365
1508
1650
1792
1934
2077
2219
2361
2503
2646
2930
3072
3214
3357
3499
99.6
241.8
384.0
526.3
668.5
810.7
953.0
1095
1237
1380
1522
1664
1806
1949
2091
2233
2375
2518
2660
2944
3086
3229
3371
3513
113.8
256.0
398.3
540.5
682.7
825.0
967.2
1109
1252
1394
1536
1678
1821
1963
2105
2247
2389
2532
2674
2958
3101
3243
3385
3527
128.0
270.2
412.5
554.7
696.9
839.2
981.4
1124
1266
1408
1550
1693
1835
1977
2119
2262
2404
2546
2688
2973
3115
3257
3399
3542

9 / 189
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a Fahrenheit temperature reading into a centigrade
temperature reading or vice verse is to enter the accompanying table in the center or
boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center
column as a table of Fahrenheit temperatures and read the corresponding Centigrade
temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center
column as a table of Centigrade values, and read the corresponding Fahrenheit
temperature on the right.

10 / 189
℃ ℃/℉ ℉ ℃ ℃/℉ ℉ ℃ ℃/℉ ℉ ℃ ℃/℉ ℉
-40.4
-37.2
-34.4
-31.7
-28.9
-28.3
-27.8
-27.2
-26.7
-26.1
-25.6
-25.0
-24.4
-23.9
-23.3
-22.8
-22.2
-21.7
-21.1
-20.6
-20.0
-19.4
-18.9
-18.3
-17.8
-17.2
-16.7
-16.1
-15.6
-15.0
-14.4
-13.9
-13.3
-12.8
-12.2
-40
-35
-30
-25
-20
-19
-18
-17
-16
-15
-14
-13
-12
-11
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
9
10
-40.0
-31.0
-22.0
-13.0
-4.0
-2.2
-0.4
1.4
3.2
5.0
6.8
8.6
10.4
12.2
14.0
15.8
17.6
19.4
21.2
23.0
24.8
26.6
28.4
30.2
32.0
33.8
35.6
37.4
39.2
41.0
42.8
44.6
46.4
48.2
50.0
-11.7
-11.1
-10.6
-10.0
-9.4
-8.9
-8.3
-7.8
-6.7
-6.7
-6.1
-5.6
-5.0
-4.4
-3.9
-3.3
-2.8
-2.2
-1.7
-1.1
-0.6
0
0.6
1.1
1.7
2.2
2.8
3.3
3.9
4.4
5.0
5.6
6.1
6.7
7.2
11
12
13
14
15
16
17
18
20
20
21
22
23
24
25
26
27
28
29
35
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
51.8
53.6
55.4
57.2
59.0
60.8
62.6
64.4
68.0
68.0
69.8
71.6
73.4
75.2
77.0
78.8
80.6
82.4
84.2
95.0
87.8
89.6
91.4
93.2
95.0
96.8
98.6
100.4
102.2
104.0
105.8
107.6
109.4
111.2
113.0
7.8
8.3
8.9
9.4
10.0
10.6
11.1
11.7
12.8
12.8
13.3
13.9
14.4
15.0
15.6
16.1
16.7
17.2
17.8
21.1
18.9
19.4
20.0
20.6
21.1
21.7
22.2
22.8
23.3
23.9
24.4
25.0
25.6
26.1
26.7
46
47
48
49
50
51
52
53
55
55
56
57
58
59
60
61
62
63
64
70
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
114.8
116.6
118.4
120.2
122.0
123.8
125.6
127.4
131.0
131.0
132.8
134.6
136.4
138.2
140.0
141.8
143.6
145.4
147.2
158.0
150.8
152.6
154.4
156.2
158.0
159.8
161.6
163.4
165.2
167.0
168.8
170.6
172.4
174.2
176.0
27.2
27.8
28.3
28.9
29.4
30.0
30.6
31.1
32.2
32.2
32.8
33.3
33.9
34.4
35.0
35.6
36.1
36.7
37.2
51.7
40.6
43.3
46.1
48.9
51.7
54.4
57.2
60.0
62.7
65.6
68.3
71.1
73.9
76.7
79.4
81
82
83
84
85
86
87
88
90
90
91
92
93
94
95
96
97
98
99
125
105
110
115
120
125
130
135
140
145
150
155
160
165
170
172
117.8
179.6
181.4
183.2
185.0
186.8
188.6
190.4
194.0
194.0
195.8
197.6
199.4
201.2
203.0
204.8
206.6
208.4
210.2
257.0
221.0
230.0
239.0
248.0
257.0
266.0
275.0
284.0
293.0
302.0
311.0
320.0
329.0
338.0
347.0