Caterpillar DP20 FC Forklift Service Manual (99719-60100)

A Cat DP20 FC is a diesel counterbalanced forklift for moving palletized loads around warehouses, yards, and plant floors. When one is out of warranty, a shop reaches for the service manual to diagnose faults, make adjustments, and tear into the truck safely. In my experience, this is the book for the mechanic doing the repair, not the operator running the truck.

What this manual helps you do

• Trace electrical circuits, switches, and wiring faults.
• Check hydraulic operation, steering, brakes, and cooling systems.
• Follow removal, inspection, adjustment, and reassembly procedures.
• Diagnose power-train, transmission, axle, and driveline problems.
• Rebuild or service mast, fork, hydraulic, and engine-related assemblies.

Who this is for

This suits an independent forklift repair shop, dealer technician, warehouse maintenance tech, plant mechanic, or rental fleet mechanic. The trade is forklift service and repair. An operator handbook and companion chassis or engine manuals are also available where that job calls for them.

FAQ

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

A: You receive 2 Cat publications in 32 PDF files, with 555 pages total, split by section. The set gives you the service material together, rather than one loose booklet.

Q: Which trucks does it fit?

A: The manual identifies GP15, GP18, GP20, GP25, GP30, GP35, DP15, DP18, DP20, DP25, DP30, and DP35, including the DP20 FC application. That puts your Cat diesel truck in the covered counterbalanced family.

Q: How does it fit the repair job?

A: Use it at the bench or on the truck for wiring, hydraulics, power train, transmission, axles, brakes, steering, mast, and engine service work. It is the workshop reference for getting a used or out-of-warranty truck back into working condition.

If your truck is a Cat DP20 FC, the answer is yes. This set gives a working mechanic the repair procedures and service information needed to diagnose, adjust, rebuild, and return the truck to service.

Models covered by this manual

Caterpillar publication 99719-60100 is the factory service manual for the DP20 FC. The same publication covers 11 further forklift models: DP15 FC, DP18 FC, DP25 FC, DP30 FC, DP35 FC, GP15 FC, GP18 FC, GP20 FC, GP25 FC, GP30 FC, GP35 FC. The cover also lists GP15, GP18, GP20, GP25, GP30, GP35, DP15, DP18, DP20, DP25, DP30, DP35. Check the model and serial number on your data plate before ordering.

Table of Contents:

The following is a general outline of the sections covered in a Cat service manual of this type. Actual chapter numbering and section names may vary by model.

• Foreword
• General Information
• Cooling System
• Electrical System
• Controllers
• Power Train
• Powershift Transmission
• Front Axle and Reduction Differential
• Rear Axle
• Brake System
• Steering System
• Hydraulic System
• Mast and Forks
• Troubleshooting
• Service Data

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