CAT DP100N–DP160N Lift Truck Service Manual – PDF DOWNLOAD
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Official CAT Lift Trucks DP100N, DP120N, DP135N, DP150N, and DP160N Service Manual PDF covering chassis, mast, and option systems. Includes full repair instructions, torque data, hydraulic diagrams, electrical schematics, and troubleshooting procedures. Designed for professional forklift technicians servicing Mitsubishi Caterpillar DP series with the 6M60-TL diesel engine.
Description
CAT DP100N–DP160N Lift Truck Service Manual Chassis, Mast & Options (6M60-TL Engine) – PDF DOWNLOAD
Description
📘 Overview
This CAT Lift Trucks DP100N–DP160N Service Manual (Publication No. 99799-63100) provides complete maintenance, disassembly, and troubleshooting details for chassis, mast, and options. Intended for use with the 6M60-TL Engine Service Manual, it enables precise servicing of Caterpillar forklift trucks built by Mitsubishi Caterpillar Forklift Europe (MCFE).
📑 Table of Contents
1. General Information
• Vehicle identification, model coding, and serial number ranges
• Service precautions and torque specification tables
• Special tools and standard tightening torques
2. Chassis Systems
• Frame construction and inspection procedures
• Counterweight removal and installation
• Axle mounting and alignment checks
3. Powertrain
• Transmission assembly, disassembly, and oil pressure checks
• Drive axle repair and differential backlash adjustment
• Propeller shaft alignment procedures
4. Steering & Brake System
• Hydraulic steering circuit schematic and flow chart
• Steering column and orbitrol valve repair
• Hydraulic brake system, master cylinder, and accumulator servicing
5. Hydraulic System
• Hydraulic circuit layout and flow control operation
• Lift and tilt cylinder overhaul procedures
• Valve bank disassembly and pressure adjustment
6. Mast & Fork Assembly
• 2-stage and 3-stage mast description
• Lift chain, roller, and carriage servicing
• Load backrest, fork, and safety latch adjustments
7. Electrical System
• Full wiring diagrams for lighting, control, and instrumentation circuits
• Alternator, starter, and relay testing procedures
• Troubleshooting voltage drops and fuse circuit issues
8. Troubleshooting & Maintenance
• Hydraulic and mechanical fault diagnosis tables
• Periodic service intervals and lubrication chart
• Preventive inspection checklists
9. Appendices
• Specifications for chassis and mast assemblies
• Recommended hydraulic oils and coolant data
• Metric conversion tables
🔧 Key Features
Covers DP100N, DP120N, DP135N, DP150N, DP160N forklifts
Chassis, mast, and hydraulic option coverage
Hydraulic schematics and wiring diagrams included
Torque data, service tools, and troubleshooting charts
For use with the 6M60-TL Engine Manual
📂 File Details
| Detail | Specification |
|---|---|
| Manual Name | CAT Lift Trucks DP100N–DP160N Service Manual |
| Models Covered | DP100N, DP120N, DP135N, DP150N, DP160N |
| Chassis Numbers | T36A–T40A (10011-up) |
| Engine Type | 6M60-TL Diesel Engine |
| Publisher | Mitsubishi Caterpillar Forklift Europe B.V. |
| Year | 2007 |
| PDF Quality | High-resolution factory scan with bookmarks |
| Pages | 523 pages |
| Part Number | 99799-63100 |
