Caterpillar DP135 Forklift Service and Schematic Manual (99799-80120)

A Cat DP135 is a diesel counterbalanced truck for moving pallets and materials across a warehouse, plant, or yard. A maintenance technician reaches for this manual when the truck needs measured fault-finding, adjustment, repair, or scheduled service. I've used this type of book when the job has to be done by the procedure, with alarm codes, controller parameters, and service data recorded for an audit.

What this manual helps you do

• Trace electrical faults through wiring diagrams and system circuits.
• Check service data while diagnosing drive, brake, steering, hydraulic, and cooling problems.
• Follow adjustment and removal procedures for the mast, forks, axles, transmission, and hydraulic equipment.
• Diagnose alarm codes and verify controller parameters during electrical troubleshooting.
• Rebuild or replace truck and engine assemblies using the matching workshop procedures.

Who this is for

This suits a warehouse maintenance technician, plant maintenance team, dealer technician, independent forklift repair shop, or rental fleet mechanic. It is a workshop service manual for the forklift trade, with the operator handbook available as the companion volume for daily truck operation.

FAQ

Q: What do I receive, and how is it organised?

A: You receive a set of 4 Cat publications as 45 PDF files split by section, rather than one booklet. The files can be printed and zoomed, and the real text layer lets you search and copy text.

Q: Does it match my truck?

A: It covers Cat DP100, DP115, DP135, and DP150 trucks, with the DP135 serial coverage shown as 5DP-10011-up. That gives you a clear model and serial check before starting work.

Q: How does it fit the repair job?

A: It is the workshop reference for fault diagnosis, service intervals, adjustments, schematics, and component repair. The matching engine material is included in the set, while the operator handbook is the companion volume for truck use.

For a DP135 within that serial coverage, this set gives your shop the procedures and diagrams needed to service, troubleshoot, and repair the truck by the book.

Models covered by this manual

Caterpillar publication 99799-80120 is the factory service and schematic manual for the DP135, serial range 5DP-10011-up. The same publication covers 3 further forklift models: DP100, DP115, DP150. Check the model and serial number on your data plate before ordering.

Table of Contents:

• 99799-80120 – Chassis & Mast Service Manual
  • Foreword
  • General Information
  • Cooling System
  • Electrical System
  • Power Train
  • Speed Powershift Transmission
  • Front Axle And Reduction Differential
  • Rear Axle
  • Brake System
  • Steering System
  • Hydraulic System
  • Mast And Forks
  • Hydraulic Fork Positioner
  • Hydraulic Side Shifters
  • Service Data

Caterpillar Software

Caterpillar PDF Manuals