PDF Service Manuals Caterpillar DP55NM1 Lift Truck - 13 MB
This is the complete collection of service manuals for the Caterpillar DP55NM1 Lift Truck.
It provides technicians with everything they need to know to perform comprehensive repairs and maintenance.
The manuals cover the engine, transmission, chassis, mast, and hydraulic systems in great detail.
With step-by-step instructions and clear diagrams, this resource is indispensable for keeping your Caterpillar lift truck fleet in prime condition.
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--- Page 1 ---
Chapter 1 GENERAL INFORMATION
1. Model View............................................................................................... 1-1
2. Lift Truck Models Covered ..................................................................... 1-2
3. Serial Number Locations........................................................................ 1-3 1
4. Dimensions.............................................................................................. 1-4
5. Technical Data......................................................................................... 1-5
6. Performance ............................................................................................ 1-6
--- Page 3 ---
COOLING SYSTEM
Chapter 2 COOLING SYSTEM
1. Specifications
Item Specified value
Cooling method Water-cooled, forced circulation
Cooling Radiator Corrugated fin (pressure) type
system Water pump Centrifugal type
Thermostat Wax pellet type
2-1
--- Page 4 ---
CONTROLLERS
Chapter 4 CONTROLLERS
1. Outline
The controllers control both the lift truck body and the engine.
Each controller is located as shown below.
Input unit
Instrument panel (Only for FC model)
GSE connector
Consult DCM
connector Output unit (Diesel engine
(Only for FC model) control module)
Glow relay ECM
Glow timer (Gasoline engine
control module)
VCM-4 OCM
(Vehicle control module) (Optional control module)
(Only for wet disk brake model)
215314
4-1
--- Page 5 ---
CONTROLLERS
(4) Fault Status
Click the fault status button from the menu or toolbox
Fault status button
to display the fault status monitor screen in the main
window. The fault status monitor screen allows you to
monitor a current fault status. Pressing the trouble-
shooting manual button in the lower part of screen
brings up a list of error code and the troubleshooting
information.
Troubleshooting manual button 214890
4-11
--- Page 6 ---
CONTROLLERS
4.2 Mast Interlock System of VCM-4 Controller, Checking Procedure
Mast Interlock System
(a) Raise the forks high enough to see them from
the operator seat.
(b) Apply the parking brake and place the direction
lever to the neutral position. Then, with the
engine idling (without pressing the accelerator
pedal), half rise from the operator seat.
(c) Check that the mast interlock indicator lamp
blinks in a few seconds. Operate the lift lever to
check that the forks do not move up and down.
213489
(d) Operate the tilt lever to ensure the mast does
not tilt forward or backward.
Make sure that sufficient space is available for the lift
truck to move around and that no one or no obstacle is
around the lift truck.
Mast Interlock System of VCM-4 Controller,
Checking Procedure
(1) Connect the service tool to the VCM-4 controller.
(2) Turn the key switch to the ON position and start
the engine.
(3) Display the input monitor screen of the service
tool.
(4) While monitoring the input monitor screen, sit in
the operator seat and make sure that the seat
switch status and the seat switch timer are ON. 214155
Fig. 1-1 Input monitor screen
(5) Display the service tool output monitor screen.
When the status of the seat switch timer is ON,
the controller unlocks the mast interlock and turns
the unload output and the lift lock output ON. (Fig.
1-2)
You can operate the mast system under this con-
dition.
Operate the lift lever to check that the forks move
up and down, and operate the tilt lever to check
that the mast tilts forward and backward.
214156
Fig. 1-2 Output monitor screen
4-21
--- Page 7 ---
CONTROLLERS
(11)To unlock the interlock function, sit on the opera-
tor seat and return the direction lever to the neu-
tral position. At this time, make sure that the
driving interlock indicator lamp (N) changes from
blink to glow.
If the seat switch will not turn ON
Check the seat switch operation and wiring connec-
tions by referring to the "Harness codes of section 8",
the "VCM-4 controller of section 9.1", and the "Seat
switch/Seat belt switch of section 9.2."
When T/M (F)/(R) Solenoid error occurs
Check the solenoid output according to "Active test
inspection procedure" of section 5.3. If the solenoid
output does not turn ON even after the active test
inspection, refer to the "Error Codes and Trouble-
shooting of Section 10" and check for the possible
causes of the error code F-85, F-87 and F-89.
When a speed or speed sensor error occurs
Refer to "Error Codes and Troubleshooting of Section
10" and check for the possible causes of the error
code F-17 and F-34.
4-31
--- Page 8 ---
CONTROLLERS
9. Controller Output Details
9.1 VCM-4 Controller
VCM-4
Controller
CN1
(White connector)
(Left side) CN2
(Gray connector)
Name plate
215240
Fig. 7-1 Controller location
(1) VCM-4 Controller pin location
1 611 615 616 617 618 619 9 1 651 652 653 654 655 656 657 658 659 9
10 620 621 622 623 624 625 627 17 10 660 661 665 666 667 17
18 600 960 25 18 671 675 25
26 601 637 638 639 640 641 642 643 961 34 26 676 677 678 679 680 580 590 683 684 34
VCM-4 CN1 VCM-4 CN2
FC
1 611 616 617 618 619 9 1 651 652 653 655 656 657 658 659 9
10 620 621 622 623 624 625 627 17 10 660 661 665 666 667 17
18 600 960 25 18 671 675 25
26 601 640 641 642 643 961 34 26 676 677 678 679 680 580 590 683 684 34
VCM-4 CN1 VCM-4 CN2
MC
216943
Fig. 7-2 Controller pin allocation (VCM-4)
4-41
--- Page 9 ---
CONTROLLERS
For diesel model
1 13
294 962 973 326 330 300
302 301304306 303327 328 590580
14 26
METER PANEL
CAN H
CAN L
TEMP
ALT L
FUEL
GND
GND
OPS
PKB
BFS
BAT
RL1
RL2
IGN
SP
590
973
306
301
303
304
302
580
300
330
962
326
327
328
294
3
0.5 G/OR
0.5 PU/W
0.5 GY/B
0.5 L/OR
0.5 PU/R
0.5 GY/L
0.5 G/W
0.5 G/W
0.5 W/B
0.5 G/R
0.5 G/Y
Y
0.5 Y/G
0.85G
0.85B
0.5 B
215253
Fig. 7-18 Instrument panel circuit (diesel-engine model only)
Parking brake switch solenoid
0.5 G
683
0.5 G/B
684
683 684
(Black)
215336
Fig 7-19 Parking brake switch solenoid
4-51
--- Page 10 ---
CONTROLLERS
Diagnosis Tilt angle sensor error (F38)
Logic conditions
· Input signal is 0.1 V or less
· Input signal is 4.9 V or more F38
(400-millisecond continuity)
Recovery Turn on power again.
Control action · No tilt action with the tilt auto-stop ON.
LED blink pattern D
Diagnosis Steering error (F40)
Logic conditions
· Only wheel angle sensor has
2-second continuous change. F40
· Steering wheel angle sensor input error
Recovery Turn on power again.
Control action · No knob deviation correction control.
LED blink pattern D
Diagnosis RI01 error (F41)
Logic conditions
· CAN receiving abnormal flag from
F41
output unit.
Recovery Recovers automatically
Control action · Indication only
LED blink pattern B
Diagnosis RI01 PWM power error (F44)
Logic conditions
· CAN receiving abnormal flag from
F44
output unit.
Recovery Recovers automatically
Control action · Indication only
LED blink pattern B
Diagnosis RI01 communication error (F45)
Logic conditions
· CAN receiving from output unit is
impractical. F45
(100-millisecond continuity)
Recovery Recovers automatically
Control action · Activates with default values of output unit incoming data.
LED blink pattern B
Diagnosis RI02 error (F46)
Logic conditions
· CAN receiving abnormal flag from input
F46
unit.
Recovery Recovers automatically
Control action · Indication only
LED blink pattern B
4-61
--- Page 11 ---
CONTROLLERS
10.3 Error Codes and Troubleshooting
Error
Diagnosis Probable cause Check item
code
F-01
Memory check error 1. Controller bad
D-51
1. Connector contact bad 1. Connector connection check
F-02
Battery voltage fault 2. Harness bad 2. Harness connection check
D-52
3. Controller bad
1. Connector contact bad 1. Connector connection check
F-03
D-53 2. Harness bad 2. Harness connection check
VCM communication error
E-03 3. VCM Controller bad 3. Communication line check
L-03
4. Controller bad
1. Connector contact bad 1. Connector connection check
F-04
D-54 2. Harness bad 2. Harness connection check
ECM communication error
E-04 3. ECM Controller bad 3. Communication line check
L-04
4. Controller bad
1. Connector contact bad 1. Connector connection check
F-07
D-57 2. Harness bad 2. Harness connection check
MP communication error
E-07 3. Instrument panel bad 3. Communication line check
L-07
4. Controller bad
F-08 1. Connector contact bad 1. Connector connection check
D-58 2. Harness bad 2. Harness connection check
E-08 TMS communication error
P-08 3. TMS Controller bad 3. Communication line check
L-08 4. Controller bad
1. Controller bad 1. Setting check using service tool
F-09 Load type set error
2. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-10 Lift lever neutral error
3. Lift lever bad 3. Lever connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-11 Tilt lever neutral error
3. Tilt lever bad 3. Lever connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-12 Att1 lever neutral error
3. Att1 lever bad 3. Lever connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-13 Att2 lever neutral error
3. Att2 lever bad 3. Lever connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-14 Att3 lever neutral error
3. Att3 lever bad 3. Lever connection check
4. Controller bad
4-71
--- Page 12 ---
CONTROLLERS
11.Locations of Sensors and Switches
Fore-and-aft adjustment stopper knob
Selector switch between
fourth and fifth attachment
Emergency mast
stop button
Up-and-down adjustment
Attachment 2 stopper knob
lever Lift lever
Tilt lever
Attachment 1 lever
VCM-4
FC Lever box (for FC model)
VCM OCM
VCM-4
(frame left side)
Shift lever
Shift lever
connector
Oil temperature
sensor
Speed sensor
Shift lever Transmission (left side)
215254
4-81
--- Page 13 ---
POWER TRAIN
(5) Align the universal joint mounting bolts on the
transmission with the input flange threaded holes Universal joint
on reduction differential, and tighten the bolts.
Unit: N·m (kgf·m) [lbf·ft]
54.0 to 63.8
Tightening torque (5.51 to 6.51)
[39.85 to 47.08]
Tighten the mounting bolt
Input flange of
on the input flange side.
reduction differential
216941
(6) When installing the exhaust pipe, replace the gas-
ket with a new one.
(7) Check that all the harnesses on the engine and
the transmission are correctly connected.
(8) Check the battery cable for any missing connec-
tions or wrong connections, and then connect the
ground (negative) cable to battery.
216946
(9) Face the marking on the water inlet hose to the
upward of lift truck when installing the water inlet
hose to the vaporizer.
Face the marking on
the water inlet hose
to the upward of lift truck
217282
5-7
--- Page 14 ---
POWER TRAIN
3. Removal and Installation (Wet disc brake)
3.1 Removal of Engine and Transmission Assembly
This section only provides the information on the
removal and installation of the power line specific to
the wet disc brake. For the information common to
both wet disc brake and standard truck, refer to the
removal and installation for the standard truck.
Suggestions for Removal
Removal of Wet Disc Brake Hoses
2
1
5 3
4
217283
1 Suction hose 3 Return inlet hose 5 Rubber hose
2 Return outlet hose 4 Rubber hose
5-17
--- Page 15 ---
FRONT AXLE AND REDUCTION DIFFERENTIAL
3.2 Shoe and Lining (Standard Truck)
Note: Removal and installation of brake shoes and
linings can be done by removing the wheel
brake drum (the work can be done without re-
moving the axle shaft and wheel hub.) This sec-
tion describes the removal and installation
procedure of the shoes and linings. Refer to "9
BRAKE SYSTEM" for more details.
3.2.1 Preparation
Remove the front wheels. For removing front wheels,
refer to the previous section.
3.2.2 Removal
(1) Brake drums
Evenly tighten the two jack bolts into place as
shown in the illustration, and remove the brake
drum.
Unit: mm (in.)
M14 x 1.5 Nominal length:
Jack bolt
50 (1.97)
215696
(2) Brake shoe
Use the notch in the wheel hub to remove shoe
Return spring
and lining. Refer to "9 BRAKE SYSTEM" for more
installing
details. point
Concaved point
of wheel hub
Hold down spring
215909
3.2.3 Inspection and Adjustment
Brake drums
(a) Thoroughly clean and remove any dirt on the
friction surface with a clean rag.
(b) If oil or grease adheres to the lining or drum,
use a brake cleaner.
3.2.4 Installation
Brake drums
Evenly tap the wheel fitting surface to secure the brake
drum in place.
7-7
--- Page 16 ---
FRONT AXLE AND REDUCTION DIFFERENTIAL
3.6 Removal and Installation of Each Assembly (Standard Truck)
3.6.1 Preparation
(1) Remove the front axle assembly. For removing
the front axle assembly, refer to "Preparation" of
"Front Axle Assembly (Standard Truck)".
3.6.2 Removal
The numbers indicate the removal sequence.
4
3
5 2
1
215702
1 Axle shaft 4 Reduction differential assembly
2 Tube assembly and final reduction 5 Axle housing
3 Center shaft
7-17
--- Page 17 ---
FRONT AXLE AND REDUCTION DIFFERENTIAL
4.1.3 Reassembly
To reassemble, follow the disassembly sequence in
reverse.
(1) Axle support
(a) Apply liquid gasket to the mating surfaces
between the axle tube and the brake drum.
ThreeBond #1194
Liquid gasket
or equivalent
Brake drum side Axle tube side
215717
(b) Tighten the mounting bolts to the specified
torque.
Axle support
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque 214 (21.8) [157.9]
215919
(2) Wheel Brake assembly
Thoroughly wash the mounting bolt threads, and
apply sealing compound to the threads before
tightening the bolts to the specified torque. Wheel brake
LOCTITE #271
Sealing compound
or equivalent
Unit: N·m (kgf·m) [lbf·ft]
Truck model
Item
4.0, 4.5 ton class 5.0C, 5.0, 5.5 ton class
Tightening 215918
214(21.8)[157.9] 295(30.1)[217.7]
torque
7-27
--- Page 18 ---
FRONT AXLE AND REDUCTION DIFFERENTIAL
4.2.3 Reassembly
(1) Clean the installing bolt for the axle support fully,
apply the sealing compound/ Front axle tube
Sealing compound LOCTITE #271 or equivalent Axle support
(2) Install the axle support to the axle tube to the
specified torque.
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque 214 (21.8) [157.9]
217171
(3) Reassemble the wet disc brake assembly.
(a) Assemble the piston seal, piston ring, O-ring, Piston ring
ring seal to the brake piston as shown in the Brake piston
O-ring
right illustration.
Note: Apply oil (SAE 10W-30 Engine oil CD) to the
brake piston, piston seal, piston ring, O-ring,
ring seal and sliding surface.
Piston seal
Ring seal
217172
(b) Install the brake piston and O-ring to the piston
Brake piston assembly
housing.
O-ring
Piston housing
217173
(c) Insert the return spring and spring guide from
Snap ring
the piston housing, and install the return plate, Plain washer
Return plate
plain washer and snap spring. O-ring
(d) Install the O-ring to the piston housing.
Return
Note: Be sure to install the multiple O-rings. spring
Piston
Spring housing
guide
O-ring
217174
7-37
--- Page 19 ---
FRONT AXLE AND REDUCTION DIFFERENTIAL
Suggestions for Disassembly
Note: 1. Before disassembling the reduction differen-
tial, be sure to measure and record gear
backlash so that it will be used as a reference
during reassembly, except when replacing
the reduction gear set.
Unit: mm (in.)
Reduction gear-to-reduction 0.20 to 0.26
pinion backlash (0.008 to 0.010)
213700
2. Put alignment marks across the bearing cap,
adjusting screw, and the carrier for correct re-
fitting.
215924
(1) Removing tapered roller bearing from differential
case, use a bearing puller to remove the bearing
inner race.
213702
(2) Removing shims
After removing lock nut 11 and shims, measure
and record the total thickness of the shims. Tie all
of the shims to the locknut with a string to prevent
losing them.
Lock nut
Shims
215925
7-47
--- Page 20 ---
FRONT AXLE AND REDUCTION DIFFERENTIAL
Reassembling Suggestions for Reduction Differ-
ential Assembly Differential case
assembly
(1) Adjusting backlash
(a) Turn over the differential carrier, and place the Bearing cap
reduction differential assembly facing upward.
(b) Paying attention to the match mark made on
the bearing cap and adjusting screw, reinstall Adjusting screw
the differential case to the differential carrier.
(c) Tentatively tighten the bearing cap mounting
bolts. 215936
(d) Set a dial gauge on the reduction differential
assembly with its probe positioned at a right
angle to the tooth face of the reduction gear.
(e) Turn the gear back and forth, and read deflec-
tion on the dial gauge (backlash).
Unit: mm (in.)
0.20 to 0.26
Backlash
(0.008 to 0.010)
213700
(f) If the backlash value falls out of the specified
range, adjust backlash value by turning the Backlash
adjusting screw. Decrease Increase
Note: When turning the adjusting screws, turn the ad-
justing screws, right and left, by the same
amount in the same direction in order not to af-
fect the bearing preload.
Decrease Increase
Increase
Backlash Decrease
213714
(2) Checking and adjusting reduction gear tooth con-
tact.