This manual covers the DP-Series Diesel Forklift Trucks, including models DP100N, DP120N, DP135N, DP150N, and DP160N, with chassis codes T36A through T40A. These robust machines are engineered for demanding industrial applications, offering reliable performance and durability characteristic of the brand. The DP-Series forklifts are designed to handle significant lift capacities, ranging from 10,000 to 16,000 pounds, and are powered by efficient 6D16 diesel engines coupled with 3-speed powershift transmissions. Their construction emphasizes operational efficiency and long service life in challenging environments.
This comprehensive workshop service repair manual provides factory-original information essential for the maintenance and repair of your DP-Series forklift. It details procedures for all major systems, including the cooling, electrical, powertrain, brake, steering, and hydraulic systems, as well as masts and forks. The manual also thoroughly covers the 6D16 diesel engine, offering guidance on lubrication, fuel and engine control, cooling, intake and exhaust, and electrical systems. Included are detailed maintenance schedules, fluid specifications, troubleshooting guides, diagnostic procedures, and component overhaul instructions, ensuring that owners and technicians have the necessary resources to maintain optimal performance and longevity.
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:
DP100N (T36A-10011-up)
DP120N (T37A-10011-up)
DP135N (T38A-10011-up)
DP150N (T39A-10011-up)
DP160N (T40A-10011-up)
Language: English
Format: ZIP, Contained set of PDF Manuals
1. Chassis and Mast Service Manual, PDF, 530 Pages
Contents:
GENERAL INFORMATION
Model View, Truck Models Covered, Serial Number Locations, Main Specifications,
Chassis and Mast Model Identification, Dimensions, Technical Data
COOLING SYSTEM
Specifications, Structure, Suggestions for Removal and Installation, Troubleshooting
ELECTRICAL SYSTEM
Specifications, Location of Components, Structure, Disassembly and Reassembly,
Batteries and Charging, Troubleshooting, Electrical Wiring Diagram
CONTROLLER
Outline, Service Tool Functions, Error Code List, Troubleshooting
TILTABLE SYSTEM
Specifications, Structure, Oil supply, Hydraulic circuit diagram, Service Data
POWER TRAIN
Specifications, Structure, Reduction ratio, Removal and Installation of Engine and Transmission Unit
POWERSHIFT TRANSMISSIONS
3-Speed Powershift Transmission Specifications, Description, Suggestions for Removal and Installation,
Disassembly and Reassembly, Adjustment, Troubleshooting, Service Data
FRONT AXLE AND REDUCTION DIFFERENTIAL
Specifications, Structure, Suggestions for Removal and installation, Front Axle and Reduction Differential,
Disassembly and Reassembly, Troubleshooting, Service Data
REAR AXLE
Specifications, Structure, Suggestions for Removal and Installation, Disassembly and Reassembly,
Readjustment, Troubleshooting, Service Data
BRAKE SYSTEM
Specifications, Structure, Suggestions for Removal and Installation, Disassembly and Reassembly,
Adjustment and Testing, Troubleshooting, Service Data
STEERING SYSTEM
Specifications, Structure, Procedure and Suggestions for Removal and Installation, Troubleshooting, Service Data
HYDRAULIC SYSTEM
Specifications, Structure, Suggestions for Removal and Installation, Priority valve, Lift cylinder,
Tilt cylinder, Inspection and Adjustment, Tests, Troubleshooting, Service Data
MASTS AND FORKS
Specifications, Structure, Suggestions for Removal and Installation, Mast assembly, Troubleshooting, Service Data
FORK POSITIONER
Applicable Attachment Model, Specifications, Structure, Suggestions for Removal and installation,
Fork positioner cylinder, Inspection and Adjustment, Troubleshooting, Service Data
SERVICE DATA
Maintenance Chart. Tightening torque of standard bolts, Lubrication Standards
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:
DP100N (T36A-10011-up)
DP120N (T37A-10011-up)
DP135N (T38A-10011-up)
DP150N (T39A-10011-up)
DP160N (T40A-10011-up)
Language: English
Format: ZIP, Contained set of PDF Manuals
1. Chassis and Mast Service Manual, PDF, 530 Pages
Contents:
GENERAL INFORMATION
Model View, Truck Models Covered, Serial Number Locations, Main Specifications,
Chassis and Mast Model Identification, Dimensions, Technical Data
COOLING SYSTEM
Specifications, Structure, Suggestions for Removal and Installation, Troubleshooting
ELECTRICAL SYSTEM
Specifications, Location of Components, Structure, Disassembly and Reassembly,
Batteries and Charging, Troubleshooting, Electrical Wiring Diagram
CONTROLLER
Outline, Service Tool Functions, Error Code List, Troubleshooting
TILTABLE SYSTEM
Specifications, Structure, Oil supply, Hydraulic circuit diagram, Service Data
POWER TRAIN
Specifications, Structure, Reduction ratio, Removal and Installation of Engine and Transmission Unit
POWERSHIFT TRANSMISSIONS
3-Speed Powershift Transmission Specifications, Description, Suggestions for Removal and Installation,
Disassembly and Reassembly, Adjustment, Troubleshooting, Service Data
FRONT AXLE AND REDUCTION DIFFERENTIAL
Specifications, Structure, Suggestions for Removal and installation, Front Axle and Reduction Differential,
Disassembly and Reassembly, Troubleshooting, Service Data
REAR AXLE
Specifications, Structure, Suggestions for Removal and Installation, Disassembly and Reassembly,
Readjustment, Troubleshooting, Service Data
BRAKE SYSTEM
Specifications, Structure, Suggestions for Removal and Installation, Disassembly and Reassembly,
Adjustment and Testing, Troubleshooting, Service Data
STEERING SYSTEM
Specifications, Structure, Procedure and Suggestions for Removal and Installation, Troubleshooting, Service Data
HYDRAULIC SYSTEM
Specifications, Structure, Suggestions for Removal and Installation, Priority valve, Lift cylinder,
Tilt cylinder, Inspection and Adjustment, Tests, Troubleshooting, Service Data
MASTS AND FORKS
Specifications, Structure, Suggestions for Removal and Installation, Mast assembly, Troubleshooting, Service Data
FORK POSITIONER
Applicable Attachment Model, Specifications, Structure, Suggestions for Removal and installation,
Fork positioner cylinder, Inspection and Adjustment, Troubleshooting, Service Data
SERVICE DATA
Maintenance Chart. Tightening torque of standard bolts, Lubrication Standards
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 .
