Caterpillar DP160N Forklift Service Manual (99799-63100)

This is a diesel counterbalanced Cat truck used for heavy pallet work in warehouses, yards, and plant loading areas. Around my shop, technicians reach for this kind of manual when a DP-series truck needs more than routine servicing. It gives the repair procedures and service data needed to put an older truck back to work.

What this manual helps you do

• Trace electrical circuits, connectors, and starting or charging faults.
• Check and adjust the brake, steering, hydraulic, and power-train systems.
• Follow procedures for mast, fork, axle, transmission, and drive-unit service.
• Diagnose operating problems with testing steps, specifications, and fault information.
• Rebuild or replace major engine, cooling, hydraulic, and drivetrain components.

Who this is for

This suits a warehouse maintenance technician, plant maintenance team, dealer technician, rental fleet mechanic, or independent forklift repair shop. It is workshop documentation for the forklift trade, with the operator handbook and parts catalog available as companion volumes.

FAQ

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

A: You receive 28 PDF files containing two Cat publications, split by section, with 877 pages total. The set has a real text layer, so you can search it, copy text, print pages, and view them enlarged.

Q: Which trucks and serials does it cover?

A: It covers DP100N, DP120N, DP135N, DP150N, and DP160N models, with DP160N coverage beginning at serial T40A-10011-up. That makes it a direct fit for the listed DP160N truck range.

Q: How does it fit the repair job?

A: This is a service manual set for diagnosis, adjustment, teardown, repair, and service checks, with the engine publication included alongside the truck manual. It is the book to use when the truck is in the bay and the repair needs more than an operator handbook.

For the stated DP160N serial range, this set gives your shop the working repair reference for fault-finding and major service work.

Models covered by this manual

Caterpillar publication 99799-63100 is the factory service manual for the DP160N, serial range T40A-10011-up. The same publication covers 4 further forklift models: DP100N, DP120N, DP135N, DP150N. Check the model and serial number on your data plate before ordering.

Table of Contents:

• 99799-63100 – Chassis, Mast & Options Service Manual
  • Foreword
  • General Information
  • Cooling System
  • Electrical System
  • Controller
  • Tiltable System
  • Power Train
  • Speed Powershift Transmission
  • Front Axle And Reduction Differential
  • Rear Axle
  • Brake System
  • Steering System
  • Hydraulic System
  • Mast And Forks
  • Fork Positioner
  • Service Data

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