Model:
100D-7, 120D-7, 135D-7, 160D-7 Forklift Truck
Model Designation Breakdown:
100D-7 (10,000 lbs capacity), 120D-7 (12,000 lbs capacity), 135D-7 (13,500 lbs capacity), 160D-7 (16,000 lbs capacity)
Product Type:
Workshop Service Repair Manual
Market Segment:
Heavy-duty industrial forklifts for demanding material handling applications
Competitors:
Caterpillar, Komatsu, Toyota, Mitsubishi, Hyster-Yale
Robustness:
Designed for durability and reliability in harsh industrial environments
Power:
High lifting capacities and powerful diesel engines for efficient operation
Ease Of Use:
Easy-to-read format, suitable for both novice and expert users
Completeness:
Provides all necessary information for correct procedure execution
Primary Focus:
Comprehensive service, repair, maintenance, and troubleshooting
Target Audience:
Owner/Amateur, Professional Technician
Estimated Page Count:
Varies significantly based on specific forklift configuration and engine option. Typically 500-1500+ pages for comprehensive industrial forklift manuals.
Type:
Service and Repair Manual
Operating Systems:
All Versions of Windows & Mac
Software Requirements:
Adobe PDF Reader
Powertrain:
Engine, transmission, drive axle
Braking System:
Service brakes, parking brake, hydraulic brake system
Steering System:
Hydraulic steering, steering linkages, steering column
Hydraulic System:
Lift and tilt functions, hydraulic pump, valves, cylinders, hoses, filters
Electrical System:
Wiring diagrams, component locations, monitoring systems, cluster indicators, switches, connectors, troubleshooting
Mast Assembly:
Mast structure, lift chains, rollers, side thrust rollers, inspection, adjustment, removal, installation
Maintenance:
Routine checks, lubrication, fluid changes, filter replacement, preventive maintenance
Repair:
Component disassembly, assembly, and repair for all covered systems
Troubleshooting:
Diagnostic procedures, fault finding, error code interpretation
Installation:
Removal and installation of major units and components
Depth:
Detailed, from basic operational checks to complex component overhauls and system diagnostics
Quality:
High-resolution PDF, ensuring clear text and diagrams
Scalability:
Printable pages at full quality
Binding:
Digital (PDF), no physical binding
Paper Type:
Not applicable (digital format)
Engine Type:
Diesel Engine (Specific model varies by configuration, often industrial-grade Cummins, Isuzu, or Hyundai engines)
Power Output:
Engine power is commensurate with forklift capacity, typically ranging from 50 HP to over 100 HP depending on the specific model (100D-7 to 160D-7) and engine variant.
Torque Output:
Sufficient torque for heavy lifting and gradeability in industrial settings.
Injection System:
Likely a high-pressure common rail (HPCR) or direct injection system for efficient combustion.
Type:
Liquid-cooled, typically with a substantial radiator and fan assembly.
Controls:
May include exhaust gas recirculation (EGR), diesel particulate filters (DPF), or selective catalytic reduction (SCR) depending on emissions regulations applicable during the manufacturing period.
Type:
Automatic transmission, specifically a powershift transmission designed for heavy-duty industrial use.
Optional Types:
While powershift is standard, variations in gear ratios or torque converter specifications might exist depending on regional markets or specific application needs.
Features:
Robust design for frequent directional changes and load engagement, often with inching control for precise maneuvering.
Fluid Type:
Specific Automatic Transmission Fluid (ATF) or heavy-duty transmission oil as specified in the manual. Common specifications might include ZF TE-ML 03D/04D or equivalent.
Capacity:
Refer to the manual for exact fluid capacity, typically several gallons for heavy-duty transmissions.
Lift Capacity:
10,000 lbs (100D-7), 12,000 lbs (120D-7), 13,500 lbs (135D-7), 16,000 lbs (160D-7) at standard load center (e.g., 24 inches).
Overall Width:
Varies by mast configuration and tire type, but generally designed to operate in standard warehouse aisles. Approximate width might be in the range of 50-70 inches.
Overall Length:
Varies by mast configuration and load backrest. Includes forks, typically in the range of 100-150 inches without load.
Operating Weight:
Significant, reflecting the heavy-duty construction. Likely in the range of 10,000 lbs to 20,000+ lbs depending on the model and options.
Axle Load Distribution:
Front axle load will be significantly higher, especially under load. Rear axle provides steering and counterbalancing.
Safety Standards:
Designed to meet relevant ANSI/ITSDF B56.1 standards for industrial lift trucks, as well as other applicable regional safety regulations.
Braking System:
Powerful service brakes (likely hydraulic drum or wet disc) and a reliable parking brake system for secure stopping and parking.
Stability:
Designed with a stable chassis and counterweighting for safe operation across its lifting range.
Operator Protection:
Operator overhead guard (OHG) or cab for protection from falling objects. Seatbelt for operator restraint.
Visibility:
Designed for good operator visibility of the load and working environment, though mast design can impact this.
Infotainment System:
Not applicable in the traditional automotive sense. Focus is on operational displays and indicators.
Operator Aids:
May include features like load capacity indicators, tilt angle indicators, or basic warning lights for system faults. Modern units might have basic sensor systems for operational feedback.
Telematics:
Some industrial forklifts offer telematics for fleet management, usage monitoring, and diagnostics. Availability would depend on the specific model configuration and options selected.
Electrical System Features
Monitoring:
Includes engine oil pressure, coolant temperature, battery charging system, hydraulic system pressure warnings, and transmission status indicators.
Daily Checks:
Fluid levels (engine oil, hydraulic oil, transmission fluid, coolant, brake fluid), tire condition, forks, mast operation, safety devices, battery connections.
Hourly Checks:
Oil filter replacement, fuel filter replacement, air cleaner service, hydraulic filter replacement, lubrication of mast channels and linkages.
Preventive Maintenance Schedule:
Detailed schedules for every 250, 500, 1000, 2000, and 4000 operating hours will be outlined in the manual, covering component inspections, adjustments, and replacements.
Engine Oil:
Likely a heavy-duty diesel engine oil, such as API CK-4 or CJ-4, with viscosity grade like 15W-40 or 10W-30 depending on ambient temperature. Specific OEM specification is crucial.
Hydraulic Fluid:
Hydraulic oil with good anti-wear, anti-foam, and oxidation resistance properties. ISO VG 32 or VG 46 is common. Consult manual for exact OEM specification.
Coolant:
Ethylene glycol-based antifreeze/coolant mixture, typically 50/50 with deionized water, to protect against freezing and boiling. Ensure it meets heavy-duty diesel engine requirements.
Common Wear Items:
Fork wear, mast chain stretch, hydraulic hose wear/leaks, brake component wear, tire wear, cooling system component failure (radiator, fan belt).
Powertrain Considerations:
Proper cooling and lubrication are critical for engine and transmission longevity. Adherence to service intervals is paramount.
Hyundai Heavy Industries:
Hyundai Heavy Industries is a major global player in heavy equipment manufacturing, known for its robust and reliable machinery across various sectors, including construction and material handling.
Model Series:
The 'D-7' series represents a generation of Hyundai diesel forklifts, building upon previous designs with improvements in performance, durability, and operator comfort.
Manufacturing Locations:
Likely manufactured in Hyundai's dedicated forklift production facilities, potentially in South Korea or other global manufacturing hubs.
