This comprehensive service and repair manual provides in-depth information for maintaining, assembling, disassembling, and servicing your Caterpillar Cat DP80 and DP90 lift trucks. Covering all years, this manual is your essential resource for ensuring the optimal performance and longevity of your equipment.

The manual includes detailed information on a wide range of components and systems, enabling you to diagnose and resolve issues efficiently. It covers the following topics:

**Chassis and Mast:**

* General Information
* Cooling System
* Electrical System
* Power Train
* 2-Speed Powershift Transmission
* 3-Speed Powershift Transmission
* Front Axle and Reduction Differential
* Rear Axle
* Brake System
* Steering System
* Hydraulic System
* Masts and Forks
* Service Data

**6D16 Diesel Engine Service Manual:**

* How to Read This Manual
* General
* Engine
* Lubrication
* Fuel and Engine Control
* Cooling
* Intake and Exhaust
* Electrical System
* Special Equipment

This manual features detailed specifications, diagrams, and real-life photo illustrations to guide you through each repair or maintenance procedure. With step-by-step instructions and comprehensive troubleshooting guidance, this manual empowers you to perform repairs and maintenance confidently, saving you time and money. You can easily access the information you need thanks to the manual's convenient bookmarking and search functionality.

The Caterpillar Cat DP80 and DP90 lift trucks are robust and versatile machines designed to handle heavy loads in demanding industrial environments. These electric forklifts are built on a proven platform, boasting powerful motors, high lifting capacities, and a compact footprint that makes them ideal for navigating tight spaces. Both models feature a durable steel chassis and a heavy-duty mast system, ensuring reliable performance across various applications. The DP80 is equipped with a 48-volt AC motor, capable of lifting up to 8,000 pounds, while the DP90 boasts a 72-volt AC motor and a lifting capacity of 9,000 pounds. Both models offer a wide range of mast options, including triplex masts with free lift and a variety of carriage configurations. The DP80 and DP90 also feature an ergonomic operator compartment with adjustable seats, intuitive control systems, and excellent visibility for enhanced safety and operator comfort.

Caterpillar engineers have incorporated numerous innovative features into the DP80 and DP90, ensuring optimal efficiency and user experience. The AC drive system provides smooth and precise control, while regenerative braking technology helps to conserve energy and reduce operating costs. These lift trucks are also equipped with advanced safety systems, including an emergency stop switch, load-sensing hydraulics, and an optional weight indicator. The DP80 and DP90 are designed for demanding applications such as warehousing, distribution centers, manufacturing facilities, and construction sites. Their reliability, durability, and ease of maintenance make them a popular choice for businesses seeking to optimize productivity and minimize downtime. The detailed service repair manual provides comprehensive information on every aspect of these lift trucks, including maintenance procedures, troubleshooting guides, and parts diagrams, empowering operators and technicians to ensure optimal performance and longevity.