Caterpillar DP135NZ Forklift Service Manual (99799-41000)

This Cat DP135NZ is a diesel counterbalanced truck for moving palletised loads around the warehouse, loading areas, and yard. When a second-shift breakdown pulls a truck out of the aisle, this is the manual a maintenance tech uses to find the fault and get it working again. It is written for workshop repair, adjustment, testing, and component replacement rather than daily driving instructions.

What this manual helps you do

• Trace electrical faults through the truck wiring and control circuits.
• Check hydraulic, brake, steering, cooling, and power-train systems.
• Follow removal and refitting procedures for truck and drive components.
• Diagnose operating faults using service data and troubleshooting guidance.
• Adjust and verify mast, axle, transmission, and hydraulic assemblies.

Who this is for

This suits a warehouse maintenance tech, plant maintenance team, dealer technician, independent forklift shop, or rental fleet mechanic working on Cat diesel counterbalanced trucks. The matching engine service manual handles engine internals, while the operator handbook is the companion volume for driving and routine checks.

FAQ

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

A: You receive 16 PDF files split by section, with 552 pages total. The set has a real text layer, so you can search and copy text, then zoom or print the relevant repair information.

Q: Which trucks and serials does it cover?

A: It covers DP100NZ, DP120NZ, DP135NZ, and DP150NZ. For the DP135NZ, the stated serial coverage is T38AE-10011-up, giving you a clear fit check before opening the book.

Q: How does it fit the job I'm doing?

A: Use it for in-house fault finding, planned repairs, teardown, reassembly, adjustments, and service checks on the truck chassis and systems. That makes it a practical shop reference when the next wave is due and the truck needs to return to work.

With this manual, you can work from a defined Cat model and serial range, test the truck methodically, and carry out repairs with the service procedures in front of you.

Models covered by this manual

Caterpillar publication 99799-41000 is the factory service manual for the DP135NZ, serial range T38AE-10011-up. The same publication covers 2 further forklift models: DP100NZ, DP120NZ. The cover also lists DP150NZ. Check the model and serial number on your data plate before ordering.

Table of Contents:

• 99799-41000 – Chassis & Mast Service Manual
  • Foreword
  • General Information
  • Cooling System
  • Electrical System
  • Controllers
  • Tiltable System
  • Power Train
  • Speed Powershift Transmission
  • Front Axle And Reduction Differential
  • Rear Axle
  • Brake System
  • Steering System
  • Hydraulic System
  • Masts And Forks
  • Fork Positioner
  • Service Data

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