Hyundai 250D-7E Maintenance & Inspection Checklist
Daily pre-start checks · hour-based service schedule · warning actions · fluids and capacities.
Daily Pre-Start Inspection
Park level, lower the forks and stop the engine before checking fluid levels.
Engine oil & walk-around
After a 15-minute shutdown, verify the 20 L engine-oil level between H and L. Inspect beneath and around the truck for oil, coolant, fuel or hydraulic leaks and visible structural damage.
Act if: oil is below L, contaminated or diluted, or any leak/crack is found. Do not overfill.
Cooling system & fan belt
Check the 30.6 L cooling system at the reservoir and inspect the belt tensioner, pulley and belt for cracks, damage or dirt buildup.
Act if: coolant is below the normal band or a tensioner stop touches its boss. Never open a hot radiator cap.
Fuel & water separator
Check the 540 L fuel tank gauge and the water-in-fuel lamp. Drain the separator when its float reaches the red drain line.
Act if: fuel is low or the warning remains on after draining; investigate before operating.
Hydraulic, transmission & axle oils
Check hydraulic-tank level for the fitted mast, transmission level, axle/differential gear oil and brake-cooling oil.
Act if: any level is low, oil is milky/foaming or leakage is visible. Investigate contamination before topping up.
Tyres, rims & pressure
From a position facing the tread, check all tyres and rims. Front and rear pressure: 10.9 ± 2 kgf/cm² (156 psi / 10.6 bar).
Act if: pressure is low or damage is present. Do not add air yourself; use a trained high-pressure tyre technician.
Battery & electrical connections
Inspect battery terminals, master connection and cables for corrosion, looseness, heat damage or abrasion.
Act if: connections are loose or corroded. Isolate power before service and keep sparks or flames away.
Service, inching & parking brakes
Check pedal movement for catching or abnormal heaviness; function-test service brake, inching response and parking-brake holding force.
Act if: a pedal binds, braking is weak or the parking brake does not hold. Do not operate until adjusted.
Steering, accelerator & drive controls
Test steering through full lock, accelerator/idle response, forward/reverse operation and speed-range selection.
Act if: steering binds or has excess play, engine response is erratic, or a direction/range fails to engage.
Mast, chain, carriage & forks
Inspect lift chains and fasteners, mast rollers/pins, carriage, attachments and forks for damage, wear or looseness.
Act if: a chain or fork is damaged, a fastener is loose or wear is excessive. Remove the truck from service.
Horn, lamps & instruments
Test horn, work/road lamps, turn signals, gauges and warning lamps during start-up.
Act if: any safety lamp, gauge or warning indicator fails. Daily inspection is still required when the monitor shows normal.
Wiper, washer & safety plates
Test wiper/washer operation, check the 1 L washer tank, and confirm capacity, warning and safety plates are attached and legible.
Act if: visibility equipment fails or a required plate is missing or unreadable.
Noise, vibration & guards
During function tests, listen and feel for abnormal noise or vibration; inspect guards, cabin, backrest and mounting points.
Act if: abnormal noise/vibration, a loose guard or structural damage is present.
Hour-Based Service Schedule
Perform daily checks at every interval and complete each task when its hour limit is reached.
Air-cleaner element
Inspect and clean; replace if damaged or restricted.
Transmission oil level
Check and top up using the correct oil-level procedure.
Steering-axle linkage
Inspect and lubricate all specified points.
Engine oil & filter
Change 20 L engine oil and replace the oil filter.
Transmission oil & filter
Change 32 L transmission oil and replace the filter; verify final level by the correct level procedure.
Differential and hub gear oil
Initial change: 27.5 L differential plus 3.2 L in each hub.
Brake-cooling oil
Initial change 33 + 2 L; subsequently inspect the level and condition.
Fuel filter
Replace the filter and bleed the system as required.
Air cleaner & hydraulic breather
Replace air element; inspect and replace the breather when needed.
Lift chain, mast rollers and tilt pins
Check chain tension, inspect forks and lubricate mast points.
Cylinder ends, wheel bearing & pedal pivot
Lubricate lift, tilt, steering and attachment cylinder ends plus chassis points.
Engine oil & filter
Change 20 L engine oil and replace the filter.
Ignition/timing and air cleaner
Inspect engine timing components; replace air element if the restriction warning is active.
Coolant concentration & filter
Test coolant inhibitor concentration and replace the coolant filter.
Battery and mast mounting bolts
Clean battery connections; inspect and tighten mast mounting hardware.
Transmission oil & filter
Change 32 L oil and replace the transmission filter; verify final level by the correct level procedure.
Axle and brake-cooling oils
Renew differential/hub gear oil and brake-cooling oil; brake-cooling capacity 33 + 2 L.
Brake-pressure filter element
Replace the filter element.
Fan belt and tensioner
Inspect belt damage and tensioner condition; replace as necessary.
Radiator coolant
Drain, flush and refill the 30.6 L system with the specified coolant mixture.
Conventional hydraulic oil
Change oil at 2,000 h; fill by mast-specific level and the correct checking procedure.
Suction strainer
Remove, inspect and clean.
Hydraulic oil
Change at 5,000 h. Do not extend conventional-oil service to this interval.
Return filter and breather
Inspect filtration and replace components due by condition or interval.
Fuel tank, separator and filter
Drain/clean water or contamination and replace the filter when required.
Engine oil, coolant and radiator
Refill or replace fluids and clean the radiator according to condition.
Air-cleaner element
Replace for damage, restriction or an active warning.
Hydraulic oil, strainer and filters
Refill/replace oil; clean suction strainer; replace return filter and breather as required.
Warning Alerts & Immediate Actions
Stop for red conditions; correct amber conditions before continuing work.
Low or damaged high-pressure tyre
Action: do not operate or add air yourself. Isolate the truck and use a trained tyre technician to inspect the tyre and rim.
Hot pressurized cooling system
Action: allow the radiator to cool until touch-safe, then loosen the cap slowly to release pressure. Never remove it while hot.
Battery gas near sparks or flames
Action: eliminate ignition sources, ventilate the area and wear eye protection before battery work.
Welding with electronics connected
Action: switch off, remove the key, isolate battery ground and disconnect ECU, TCU and cluster connectors. Attach the welding earth close to the work.
Milky, foaming or contaminated oil
Action: stop the machine and investigate water, air or fuel contamination before restarting.
Normal monitor display
Action: still perform the complete daily inspection; the monitor alone does not confirm machine condition.
Bubbles after hydraulic service
Action: inspect suction hoses, clamps and seals for air entry before placing the system under load.
Mixed fluid brands or types
Action: do not mix incompatible engine oil, coolant or hydraulic oil. Identify the installed product before topping up.
Fluids, Lubricants & Capacities
Capacities are approximate system values; fill by the specified level procedure and do not mix incompatible products.
Fuel tank
Clean diesel meeting ASTM D975 No. 1 or No. 2 for ambient conditions.
Engine oil
SAE 10W-30 or 15W-40; API CH-4 or better. Select viscosity for starting temperature.
Cooling system
ASTM D6210 coolant with DCA4; standard 50/50 ethylene-glycol antifreeze and clean water.
Transmission
SAE 10W-30, API CF-4 or better; check warm, level and in neutral. Use 32 L service value and verify by level procedure.
Drive axle
SAE 80W-90, API GL-5: differential plus two hubs.
Brake-cooling system
Shell Donax TD or equivalent specification; do not use ordinary brake fluid.
Hydraulic tank
ISO VG 32/46/68 anti-wear hydraulic oil selected for ambient temperature.
Cab tilt hand pump
Hydraulic oil; inspect and refill by condition.
Washer-fluid tank
Clean windscreen washer fluid suitable for ambient temperature.
Grease points
Lithium-base multipurpose grease, NLGI No. 2; use No. 1 for low-temperature selection.
Tyre pressure — front and rear
10.9 ± 2 kgf/cm² (156 psi / 10.6 bar).
Hub-nut torque
Front 35 ± 2 kgf·m; rear 83.5 ± 12.5 kgf·m.