Model:
100D-7, 120D-7, 135D-7, 160D-7
Product Type:
Forklift Truck Service Repair Workshop Manual
Vehicle Type:
Industrial Forklift Truck
Model Codes:
100D-7, 120D-7, 135D-7, 160D-7
Target Audience:
Maintenance and repair technicians, fleet managers, and owner-operators of Hyundai 100D-7, 120D-7, 135D-7, and 160D-7 forklift trucks.
Value Proposition:
Enables cost savings through DIY repairs and maintenance, enhances operational efficiency by providing accurate repair information, and builds user confidence in maintaining their equipment.
Competitor Manuals:
Competes with other OEM and aftermarket service manuals, but distinguished by its direct factory origin and comprehensive coverage of specific Hyundai models.
Key Features:
Original Factory Manual, Easy-to-read text, High-quality diagrams, Comprehensive system coverage, Troubleshooting guides.
Primary Coverage:
Comprehensive service, repair, and troubleshooting for Hyundai 100D-7, 120D-7, 135D-7, and 160D-7 forklift models.
System Coverage:
General Information, Unit Function (Structure, Removal/Installation), Power Train System, Brake System, Steering System, Hydraulic System, Electric System, Mast.
Estimated Page Count:
Information not explicitly stated, but typical for comprehensive service manuals covering multiple models and systems.
Type:
Service Repair Workshop Manual
General:
Safety Hints, Specifications, Operational Checkout Record Sheet.
Unit Function:
Structure, Removal and installation of units.
Power Train:
Structure and Operation, Operation and Maintenance, Disassembly and Assembly, Adjustment.
Brake System:
Structure and Function, Operational Checks and Troubleshooting, Test and Adjustment, Disassembly and Assembly.
Steering System:
Structure and Function, Operational Checks and Troubleshooting, Test and Adjustment, Disassembly and Assembly.
Hydraulic System:
Structure and Function, Operational Checks and Troubleshooting, Disassembly and Assembly.
Electric System:
Component Location, Electrical Circuit Diagrams, Monitoring System, Cluster Indication, Switches, Electrical Component Specifications, Connectors, Troubleshooting.
Mast:
Structure, Operational Checks and Troubleshooting, Adjustment, Removal and Installation.
Maintenance:
Scheduled maintenance, lubrication, fluid checks and changes.
Diagnostics Troubleshooting:
System-specific troubleshooting guides, fault code interpretation (if applicable), common issues and solutions.
Repair Rebuild:
Detailed disassembly and assembly procedures for all major components and systems.
Adjustment Calibration:
Procedures for adjusting brakes, steering, hydraulic systems, and other critical components.
Electrical Diagnostics:
Wiring diagrams, component testing, connector identification, and troubleshooting electrical faults.
Depth:
Comprehensive workshop-level detail, suitable for certified technicians and experienced DIY mechanics. Includes structural analysis, operational principles, detailed repair instructions, and diagnostic procedures.
Engine Type:
Diesel (specific engine model not provided in product info, but typically a Hyundai or Cummins diesel for this class of forklift).
Displacement:
Variable based on specific model (e.g., 100D-7 likely a smaller displacement than 160D-7). Typical for this class range from 2.5L to 4.5L.
Horsepower:
Variable based on specific model and engine tune. Likely in the 40-80 HP range for this class.
Torque:
Variable based on specific model and engine tune. Crucial for lifting capacity.
Oil Type:
Refer to specific engine model within the manual; typically API CJ-4 or higher for modern diesel engines.
Oil Capacity:
Refer to specific engine model within the manual.
Type:
Typically a hydrostatic or torque converter automatic transmission designed for heavy-duty forklift operation.
Control Type:
Lever or pedal operated for forward, reverse, and speed control.
Fluid Type:
Refer to manual; often specialized hydraulic transmission fluid (HTF) or ATF.
Lift Capacity:
Nominal lift capacities are indicated by the model numbers: 10000 lbs (100D-7), 12000 lbs (120D-7), 13500 lbs (135D-7), 16000 lbs (160D-7) at a standard load center (e.g., 24 inches).
Mast Height:
Variable depending on mast configuration (e.g., 2-stage, 3-stage) and lift height. Specifics available in the manual.
Operating Weight:
Significant weight, typically in the 10,000 - 20,000+ lbs range, depending on model and configuration.
Design Standards:
Likely designed and manufactured to meet relevant industrial safety standards (e.g., ANSI B56.1 in the US).
Braking System:
Hydraulic disc or drum brakes, serviced by the manual.
Warning Systems:
Audible alarms (backup alarm), visual indicators (lights, dashboard warnings) covered in the electric system section.
Operator Protection:
Operator overhead guard (OHG) is standard; details on its structure and maintenance may be included.
Infotainment System:
Not applicable for this type of industrial equipment; focus is on functional operation and diagnostics.
Driver Assistance Features:
Limited to operator feedback via dashboard indicators and controls. No advanced electronic driver assistance systems expected.
Telematics:
Basic models may not have telematics. Higher-spec industrial equipment might have basic hour meters and fault indicators, covered under the electric system.
System Monitoring:
Dashboard indicators for engine oil pressure, coolant temperature, battery charge, hydraulic oil level, and warning lights for system faults, detailed in Section 7.
Engine Oil Change:
Typically every 250-500 operating hours, or annually. Refer to manual for exact interval based on operating conditions.
Transmission Fluid Change:
Typically every 1000-2000 operating hours. Refer to manual for exact interval and fluid type.
Hydraulic Filter Change:
Typically every 500-1000 operating hours. Critical for system longevity.
Engine Coolant:
Ethylene glycol based, 50/50 mix with deionized water. Specific type and additive package detailed in manual.
Hydraulic Fluid:
ISO VG 32 or VG 46 hydraulic oil, or specific Hyundai specification. Crucial to match viscosity and additive package.
Common Wear Items:
Brake pads/shoes, hydraulic hoses and seals, mast rollers, steering components, filters (engine, hydraulic, transmission).
Troubleshooting Focus:
The manual's structure indicates a strong focus on diagnosing and resolving issues within the power train, brake, steering, and hydraulic systems, which are common areas for wear and malfunction in forklifts.
Manufacturer:
Hyundai Heavy Industries (HHI) - known for robust industrial equipment.
Series:
The 'D-7' designation typically signifies a specific generation or series of Hyundai diesel forklifts, indicating advancements in design, engine technology, and operator ergonomics over previous models.
Production Era:
Specific production years not provided, but this series likely covers models manufactured from the mid-2000s onwards. The manual would be for a specific range within that.
