Caterpillar CAT Lift Truck Service Manual

Product Overview

This comprehensive service manual is designed for Caterpillar lift truck models: DP100, DP115, DP135, and DP150. The manual is provided in PDF format and offers detailed instructions and information essential for the maintenance and repair of these lift trucks. This guide also includes a specific manual for the 6D16 Diesel Engine.

Key Features

• Comprehensive 395-page service manual for DP series forklifts
• Includes a detailed 270-page manual for the 6D16 Diesel Engine
• Available in English
• PDF format for easy access and reference

Benefits

• Ease of Use: The PDF format allows for quick searching and convenient handling.
• Comprehensive Coverage: Extensive content covering all aspects of maintenance and repair.
• Detailed Diagrams and Instructions: Facilitates better understanding and execution of repair processes.

Usage Recommendations

• Refer to this manual regularly to ensure proper maintenance and extended lifespan of your equipment.
• Use this manual to aid in troubleshooting and resolving any operational issues.

Forklift Manual Table of Contents

• General Information
• Cooling System
• Electrical System
• Power Train
• Powershift Transmissions
• Front Axle
• Rear Axle
• Brake System
• Steering System
• Hydraulic System
• Masts and Forks
• Fork Positioner
• Hydraulic Side Shifter
• Service Data

Gear Pump Assembly

Precautions for Disassembly and Assembly:

1. Avoid using a hammer or similar tools to force out any part of the pump.
2. Ensure all parts are clean and apply hydraulic oil to the internal surfaces of the body before reassembly.
3. Apply a thin layer of grease to the oil seal for optimal performance.
4. Ensure proper gear alignment by matching the original gear teeth engagement when installing the drive and driven gears.
5. Tighten the cover bolts to the specified torque of 11.1 to 12.5 kgf.m (80-90 lbf-ft) .
6. Confirm satisfactory gear fit by checking that the pump shaft rotates smoothly with a 10 mm (0.4 in.) adjustable wrench.
7. If necessary, replace the entire pump assembly if the cover, drive gear, or driven gear is replaced.

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