Hyundai 25DE-7U 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

2/ 189
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.
①Locate the number 50in the vertical column at the left side, take this as ○a,
then draw a horizontal line from ○a .
②Locate the number 5in the row across the top, take this as ○b, then draw a
perpendicular line down from ○b .
③Take 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.
①The 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.
②Carry out the same procedure as above to convert 55mm to 2.165 inches.
③The 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 ○
b1mm = 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