This manual covers the CAT DP100, DP115, DP135, and DP150 Diesel Forklift Trucks, specifically models from the indicated production generations. These robust machines are engineered for demanding industrial applications, built with Caterpillar's renowned quality and reliability. The DP-Series forklifts are designed to provide efficient material handling solutions, featuring powerful diesel engines and advanced hydraulic systems. Notable features include versatile transmission options, sophisticated mast and fork systems, and integrated safety mechanisms, all contributing to their operational effectiveness and durability in challenging environments.
This comprehensive workshop service repair manual provides essential information for the efficient operation, maintenance, and repair of your CAT Diesel Forklift Truck. It details maintenance procedures, including charts, lubrication instructions, and periodic replacement parts. The manual offers in-depth coverage of all major systems, such as the chassis, cooling, electrical, powertrain, axles, brakes, steering, and hydraulics, along with specific guidance for the 6D16 diesel engine and powershift transmissions. Extensive troubleshooting sections, diagnostic information, and detailed schematics are included to assist technicians and owners in identifying and resolving issues, ensuring the longevity and optimal performance of the equipment.
Original Illustrated Factory Workshop Service Manual for CAT Diesel Forklift Truck DP-Series.
Original factory manuals for CAT Lift Trucks contains high quality images, circuit diagrams and instructions to help you to operate, maintenance and repair your truck. All Manuals Printable, without restrictions, contains Searchable Text and bookmarks
Covered models:
DP100 (3DP-10011-up)
DP115 (4DP-10011-up)
DP135 (5DP-10011-up)
DP150 (6DP-10011-up)
Language: English
Format: ZIP, Contained Set of PDF Manuals:
1. Chassis and Frame Service Manual, PDF, 478 Pages
Contents:
GENERAL INFORMATION
Model View, Truck Models Covered, Serial Number Locations, Technical Data, Dimensions
COOLING SYSTEM
Removal and Installation, Fan Belt Adjustment
ELECTRICAL SYSTEM
Console Box, Major Components, Lamp Bulb Specifications, Batteries, Electrical System Schematic
POWER TRAIN
2-speed Transmission, 3-speed Transmission, Gear Ratios, Removal and Installation, Engine and Transmission Unit
2-SPEED POWERSHIFT TRANSMISSION
Torque Converter, Transmission, Power Flow, Control Valve, Main Regulator Valve,
Hydraulic Controls, Speed Selector System, Control System
3-SPEED POWERSHIFT TRANSMISSION
Torque Converter, Transmission, Power Flow, Control Valve, Main Regulator Valve,
Hydraulic Controls, Speed Selector System, Control System
FRONT AXLE AND REDUCTION DIFFERENTIAL
Front Wheels (Tires), Front Axle and Reduction Differential
REAR AXLE
Rear Axle, Power Cylinder, Minimum Turning Radius
BRAKE SYSTEM
Wheel Brake System, Brake Control Valve, Air Master, Air Governor, Air Dryer, Parking Brake, Testing and Adjusting
STEERING SYSTEM
Steering Control Valve, Tilt Steering Assembly
HYDRAULIC SYSTEM
Hydraulic System, Hydraulic Tank, Gear Pump, Priority Valve, Control Valve, Flow Regulator Valve,
Down Safety Valve, Lift and Tilt Cylinders
MASTS AND FORKS
Simplex Mast
HYDRAULIC FORK POSITIONER
Applicable Attachment Models, Specifications, Structure, Removal and Installation, Removal,
Installation, Fork Positioner Assembly, Fork Positioner Cylinder, Inspection and Adjustment, Troubleshooting, etc.
HYDRAULIC SIDE SHIFTERS
Side Shifter Assembly, Hydraulic Cylinder
SERVICE DATA
Maintenance Chart, Tightening Torque for Standard Bolts and Nuts, Periodic Replacement Parts,
Lubrication Instructions, Weight of Major Components, Special Tools
2. 6D16 Diesel Engine Service Manual, PDF, 305 Pages
Contents:
HOW TO READ THIS MANUAL
GENERAL
ENGINE
LUBRICATION
FUEL AND ENGINE CONTROL
COOLING
INTAKE AND EXHAUST
ELECTRICAL SYSTEM
SPECIAL EQUIPMENT .
Original Illustrated Factory Workshop Service Manual for CAT Diesel Forklift Truck DP-Series.
Original factory manuals for CAT Lift Trucks contains high quality images, circuit diagrams and instructions to help you to operate, maintenance and repair your truck. All Manuals Printable, without restrictions, contains Searchable Text and bookmarks
Covered models:
DP100 (3DP-10011-up)
DP115 (4DP-10011-up)
DP135 (5DP-10011-up)
DP150 (6DP-10011-up)
Language: English
Format: ZIP, Contained Set of PDF Manuals:
1. Chassis and Frame Service Manual, PDF, 478 Pages
Contents:
GENERAL INFORMATION
Model View, Truck Models Covered, Serial Number Locations, Technical Data, Dimensions
COOLING SYSTEM
Removal and Installation, Fan Belt Adjustment
ELECTRICAL SYSTEM
Console Box, Major Components, Lamp Bulb Specifications, Batteries, Electrical System Schematic
POWER TRAIN
2-speed Transmission, 3-speed Transmission, Gear Ratios, Removal and Installation, Engine and Transmission Unit
2-SPEED POWERSHIFT TRANSMISSION
Torque Converter, Transmission, Power Flow, Control Valve, Main Regulator Valve,
Hydraulic Controls, Speed Selector System, Control System
3-SPEED POWERSHIFT TRANSMISSION
Torque Converter, Transmission, Power Flow, Control Valve, Main Regulator Valve,
Hydraulic Controls, Speed Selector System, Control System
FRONT AXLE AND REDUCTION DIFFERENTIAL
Front Wheels (Tires), Front Axle and Reduction Differential
REAR AXLE
Rear Axle, Power Cylinder, Minimum Turning Radius
BRAKE SYSTEM
Wheel Brake System, Brake Control Valve, Air Master, Air Governor, Air Dryer, Parking Brake, Testing and Adjusting
STEERING SYSTEM
Steering Control Valve, Tilt Steering Assembly
HYDRAULIC SYSTEM
Hydraulic System, Hydraulic Tank, Gear Pump, Priority Valve, Control Valve, Flow Regulator Valve,
Down Safety Valve, Lift and Tilt Cylinders
MASTS AND FORKS
Simplex Mast
HYDRAULIC FORK POSITIONER
Applicable Attachment Models, Specifications, Structure, Removal and Installation, Removal,
Installation, Fork Positioner Assembly, Fork Positioner Cylinder, Inspection and Adjustment, Troubleshooting, etc.
HYDRAULIC SIDE SHIFTERS
Side Shifter Assembly, Hydraulic Cylinder
SERVICE DATA
Maintenance Chart, Tightening Torque for Standard Bolts and Nuts, Periodic Replacement Parts,
Lubrication Instructions, Weight of Major Components, Special Tools
2. 6D16 Diesel Engine Service Manual, PDF, 305 Pages
Contents:
HOW TO READ THIS MANUAL
GENERAL
ENGINE
LUBRICATION
FUEL AND ENGINE CONTROL
COOLING
INTAKE AND EXHAUST
ELECTRICAL SYSTEM
SPECIAL EQUIPMENT .
