®
Lift Trucks
Service Manual Chassis & Mast GC35K
GC40K
GC40K STR
GC45K SWB
GC45K STR GC45K
AT87-00001-up
GC55K
AT88-00001-up
AT87A-00001-10230
AT88A-00001-10230
AT87A-10231-20230
AT88A-10231-20230
AT87A-20231-up
AT88A-20231-up
AT87-00001-up
GC55K STR
AT88-00001-up
AT87A-00001-10230
AT88A-00001-10230
AT87A-10231-20230
AT88A-10231-20230
AT87A-20231-up
AT88A-20231-up
AT87-00001-up
GC60K
AT89-00001-up
AT87A-00001-10230
AT89A-00001-10230
AT87A-10231-20230
AT89A-10231-20230
AT87A-20231-up
AT89A-20231-up
AT87-00001-up
GC70K
AT89-00001-up
AT87A-00001-10230
AT89A-00001-10230
AT87A-10231-20230
AT89A-10231-20230
AT87A-20231-up
AT89A-20231-up
AT87A-20231-up
GC70K STR
AT89-00001-up
AT88-00001-up
AT89A-00001-10230
AT88A-00001-10230
AT89A-10231-20230
AT88A-10231-20230
AT89A-20231-up
For use with GM4.3L, G6 Engine Service Manual and Fuel System Supplements
99739-82100
GROUP INDEX Group
Items
GENERAL INFORMATION Vehicle Exterior, Models, Serial Number Locations, Dimensions, Technical Data.
1
COOLING SYSTEM
Description, Removal and Installation, Inspection and Adjustment, Fan Belt Inspection, Fan Belt Adjustment.
2
ELECTRICAL SYSTEM
Description, Disassembly and Re-assembly, Major Electrical Components, Battery Maintenance, Typical Open Circuit Voltage, Lamp Bulb Specifications, Electrical System Schematics.
3
POWER TRAIN
Specifications, Structure, Reduction Ratio, Procedures and Key Points for Removal and Installation.
4
POWERSHIFT TRANSMISSION 1-Speed Transmission (GC35K-GC55K STR), Specifications, Structure, Removal and Installation, Torque Converter, Transmission, Control Valve, Adjustment, Automatic 2-speed Transmission (GC60K-GC70K STR), Specifications, Structure, Transmission, Solenoid Valve, Adjustment, Troubleshooting, Service Data.
5
FRONT AXLE
Specifications, Structure, Procedures and Key Points for Removal and Installation, Axle Shaft and Hub, Reduction Differential, Troubleshooting, Service Data.
6
REAR AXLE
Specifications, Structure, Procedures and Key Points for Removal and Installation, Rear Axle Assembly, Steering Cylinder, Adjustment, Troubleshooting, Service Data.
7
BRAKE SYSTEM
Specifications, Structure, Master Cylinder, Wheel Cylinder, Wheel Brake, Parking Brake Lever, Adjustment and Tests, Troubleshooting, Service Data.
8
STEERING SYSTEM
Specifications, Structure, Procedures and Key Points for Removal and Installation, Steering Control Valve, Troubleshooting, Service Data.
9
HYDRAULIC SYSTEM
Specifications, Description, Removal and Installation, Disassembly and Re-assembly, Inspection and Adjustment, Hydraulic Circuit Diagram, Troubleshooting, Service Data.
10
MASTS AND FORKS
Specifications, Description, Disassembly and Re-assembly, Inspection and Adjustment,Troubleshooting, Service Data.
11
SERVICE DATA
Inspection Standards, Periodic Replacement of Parts, Special Tool Table.
12
GENERAL INFORMATION
Vehicle Exterior .......................................................................................................................... 1 - 1 Models ........................................................................................................................................ 1 - 1 Serial Number Locations ............................................................................................................ 1 - 2 Dimensions.................................................................................................................................. 1 - 4 Technical Data ............................................................................................................................ 1 - 5
1
GENERAL INFORMATION
Vehicle Exterior • This Service Manual deals with all components or systems of Cat lift trucks; except for the engine and attachment, which are covered in the respective manuals.
102530A
Models This manual applies to the following vehicle models (names). Truck Models
Transmission
Serial Number
Engine Mounted
GC35K AT87-00001-up AT87A-00001~10230 AT87A-10231-20230 AT87A-20231-up
GC40K GC40K STR GC45K SWB
1-Speed
GC45K STR GM4.3L Gasoline Engine GC45K
AT88-00001-up AT88A-00001~10230 AT88A-10231-20230 AT88A-20231-up
GC55K GC55K STR GC60K GC70K GC70K STR
Automatic 2-Speed
AT89-00001-up AT89A-0000~10230 AT89A-10231-20230 AT89A-20231-up 1
GENERAL INFORMATION
Serial Number Locations
Name Plate
Chassis Serial Number (Former Models)
Mast Number
Transmission Serial Number
1-2
Gasoline Engine Serial Number
Chassis Serial Number (New Models)
GENERAL INFORMATION
Chassis and Mast Model Identification [Chassis] GC 55 K
Generation designator
Maximum capacity 55 :5500kg (12000lb) Engine type GC: gasoline engine type
[Mast] A
55 A
33
Maximum lifting height (“33” stands for 3300mm.) Order of the minor change (“A” for the original, “B” for the first change, “C” for the second change, and so on) Applicable truck model designation 55:5.5 ton class
Kind of mast A: simplex mast B: duplex mast C: triplex mast
1-3
GENERAL INFORMATION
Dimensions
F
K
J
I
D A
G
H B
N C
L E
1-4
M 206999
GENERAL INFORMATION
Technical Data Ref. No. A
B
Unit: mm (in.) Truck Models GC35K
Items Maximum lift Simplex mast Free lift (Floor to forktop)
GC40K
GC40K STR
3050 (120)
2900 (114)
Simplex mast
150 (5.9)
160 (6.3)
Duplex mast
920 (36.2) 3.0 m (118 in.) mast
895 (35.2) 2.8 m (112 in.) mast
Triplex mast
800 (31.5) 4.0 m (157 in.) mast
920 (36.2) 4.3 m (169 in.) mast
C
Fork length
D
Tilt angle (forward – backward)
E
Overall length (OLH)
F
Overall width Standard (outside) Wide tread (option)
G
Overall height (to top of mast lowered)
2155 (85.0)
H
Overall height (to top of overhead guard)
2155 (85.0)
1220 (48) 5/10 Simplex, Duplex mast 6/5 Triplex mast
deg. 2510 (98.5)
2550 (100)
2360 (93)
2620 (103)
1180 (46.5) 1270 (50.0)
4250 (167)
4125 (162)
Overall height (mast extended) Duplex mast
4250 (167) 3.0 m (118 in.) mast
4080 (160.6) 2.8 m (112 in.) mast
Triplex mast
5250 (206.7) 4.0 m (157 in.) mast
5560 (218.9) 4.3 m (169 in.) mast
Simplex mast I
GC45K SWB
Standard
940 (37.0)
Wide tread (option)
1040 (41.0)
J
Tread (front)
K
Tread (rear)
980 (38.5)
L
Wheelbase
1575 (62.0)
M
Rear overhang
N
Underclearance (at frame)
485 (18.8)
525 (20.3)
335 (13.3)
150 (5.9)
1-5
565 (22.1)
GENERAL INFORMATION
Unit: mm (in.) GC45K STR
GC45K
GC55K
GC55K STR
GC60K
GC70K
2900 (114)
2350 (93)
160 (6.3)
165 (6.5)
GC70K STR
895 (35.2) 2.8 m (112 in.) mast 895 (35.2) 4.0 m (157 in.) mast
900 (35.4) 3.5 m (138 in.) mast 1220 (48)
5/10 Simplex, Duplex mast 6/5 Triplex mast 2730 (107)
2910 (115)
6/10 Simplex mast 6/5 Triplex mast 2640 (104)
2950 (116)
1320 (52.0)
2730 (107)
1440 (56.5)
1420 (56.0) 2155 (85.0)
2205 (87.0)
2155 (85.0)
2205 (87.0)
4125 (162)
3585 (141)
4080 (160.6) 2.8 m (112 in.) mast 5560 (218.9) 4.0 m (157 in.) mast
4785 (188.3) 3.5 m (138 in.) mast
1015 (40.0)
1130 (44.5)
1120 (44)
470 (18.1)
965 (38.0)
1160 (45.5)
1780 (70.0)
1830 (72.0)
650 (26.1)
380 (15.1)
590 (23.1)
150 (5.9)
200 (7.9)
1-6
340 (13.1)
GENERAL INFORMATION
Technical Data GC35K
GC40K STR
GC40K
Traveling performance
Work performance
Truck Models Capacity/load center
kg/mm (lb/in.)
Maximum lift height Simplex
mm (in.)
3050 (120)
2900 (114)
Lift speed (loaded)
540 (105)
390 (78.0)
Lowering speed (loaded)
mm/sec. (fpm)
550 (108)
440 (86.5)
Mast tilt (forward-backward)
degree
Free lift
mm (in.)
Gradeability at 1 mph (1.6 km/h)
mm (in.)
Loaded No loaded
%
Loaded No loaded
Overall length to fork face Overall width
Overall height
2340 (92.0)
2245 (88.5)
2295 (90.5)
2100 (82.5)
2350 (92.5)
37
33
32
27
23.8
21.1
21.5
17.7
42
37
36
30
23.8
21.1
21.5
17.7
2510 (98.5)
2550 (100)
2360 (93)
2620 (103)
1180 (46.5)
Wide tread (optional)
1270 (50.0)
To top of mast (lowered)
2200 (86.5)
2350 (92.5)
To top of mast (extended)
4250 (167.5)
4130 (162.5)
2155 (85.0)
mm (in.)
1575 (62.0) Standard
940 (37.0)
Wide tread (optional)
1040 (41.0) 980 (38.5)
Rear
485 (18.8)
Single Front wheels
Service weight -no load Single wheels (without load) Axle Front loading Rear
525 (20.3)
335 (13.3)
565 (22.1)
150 (5.9) 22×9×16
mm
Rear Weight
18.5 (11.5)
2090 (82.5)
Underclearance (at frame) Tire size
19 (12.0)
2285 (90)
Rear Overhang
160 (6.5)
2235 (88.0)
Wheelbase Front
150 (6.0)
Standard
To top of overhead guard
Tread
4500/600 (10000/24)
19.5 (12.5)
Minimum turning radius Minimum intersecting isle Standard
4000/500 (8000/24)
5/10
Loaded Travel Powershift km/h transmission speed No load (mph) models
Gradeability at stall
Dimensions
3500/500 (7000/24)
GC45K SWB
18×7×12.12
kg (lb)
5200 (11500)
5600 (12300)
5700 (12700)
6500 (14300)
2050 (4600)
2025 (4400)
2150 (4900)
1925 (4200)
3150 (6900)
3575 (7900)
3550 (7800)
4575 (10100)
1-7
GENERAL INFORMATION
GC45KSTR
GC45K
GC55K
4500/600 (10000/24)
GC55K STR
GC60K
5500/600 (12000/24)
GC70K
6000/600 (13500/24)
7000/600 (15500/24)
2900 (114)
2360 (93)
390 (78.0)
360 (71.0)
440 (86.5)
540 (106.0)
5/10
6/10
160 (6.5)
165 (6.5)
18.5 (11.5)
18 (11.5)
21 (13.0)
19.5 (12.5)
GC70K STR
20.5 (12.5) 23 (14.5)
22.5 (14.0)
2440 (96.0)
2550 (100)
2350 (92.5)
2570 (101.0)
2400 (94.5)
2345 (92.5)
2455 (96.5)
2255 (89)
2395 (94.5)
2220 (87.5)
26
22.6
22.2
24.5
21.7
21.4
23.8
20.2
20.9
22.2
19.7
20.4
30
26
25
30
27
26
23.8
20.2
20.9
22.2
19.7
20.4
2730 (107)
2910 (115)
2460 (104)
2950 (116)
1320 (52.0)
2700 (106)
1440 (56.5)
1420 (56.0) 2350 (92.5)
2530 (99.5)
4130 (162.5)
2370 (93.0)
2155 (85.0)
2205 (87.0)
1780 (70.0)
1830 (72.0)
1015 (40.0)
1135 (44.5)
1115 (44.0) 965 (38.0) 470 (18.1)
18×8×12.12
1160 (45.5)
650 (26.1)
380 (15.1)
590 (23.1)
150 (5.9)
200 (7.9)
22×12×16
28×12×12 18×8×12.12
340 (13.1)
22×8×16
6600 (14500)
7200 (15800) 7400 (16200)
8800 (19300)
9500 (20900)
9700 (21300)
2625 (5700)
2425 (5300)
2625 (5700)
3300 (7300)
3300 (7200)
3500 (7500)
3975 (8800)
4775 (10500) 4775 (10500)
5500 (12000)
6200 (13700)
6200 (13800)
1-8
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GENERAL INFORMATION
MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems. Truck Models GC35K
GC40K STR
GC40K
Items Engine model
GM4.3L
Type
Gasoline
Cooling system
Water cooled
No. of cylinders-arrangement
6-90°V
No. of strokes
4
Type of combustion chamber
Semi-spherical
Valve arrangement
Overhead
Type of cylinder liners
Integral
Cylinder bore × stroke, mm (in.)
101.6×88.39 (4.00×3.48)
Engine
Displacement, cc (cu in.)
4293 (262)
Compression ratio
9.2 : 1
Rated output, PS/rpm
94/2450
Rated torque, kgf·m/rpm
31.0/1200
Min. rpm
750-800, 650-700
Max. rpm
2650-2700, 2600-2650
Dimensions (L×W×H), mm (in.)
710×620×740 (28.0×24.4×29.1)
Weight, kg (lb)
260 (573)
Installation position
Rear
Ignition
Spark
Firing order
Ignition system
1-6-5-4-3-2
Initial ignition timing, BTDC deg
0° Gasoline, 8° L.P.G., ECU Controlled
Fuel tank capacity, liter (U.S.gal)
66 (17.4)
Ignition coil
Fuel system
GC45K SWB
Distributor
Type
Mold
Type
Pointless
Type of spark advance control
Internal solid state circuit, ECU Controlled
Model Spark plug
AC #41-932, R42LTS
Size, mm (in.)
14 (0.55)
Gap, mm (in.)
1.24 (0.0488), .89 (.035)
Carburetor
Type
Single Barrel, MPFI
Governor
Type
Electronic
Fuel pump
Type
Electromagnetic
Air cleaner
Type × Number
Cyclone with paper element × 1
1-9
GENERAL INFORMATION
MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems. GC45K STR
GC45K
GC55K
GC55K STR
GC60K
GC70K
GM4.3L Gasoline Water cooled 6-90°V 4 Semi-spherical Overhead Integral 101.6×88.39 (4.00×3.48) 4293 (262) 9.2 : 1 92.6/2450 31.0/1200 750-800, 650-700 2650-2700, 2600-2650 710×620×740 (28.0×24.4×29.1) 260 (573) Rear Spark 1-6-5-4-3-2 0° Gasoline, 8° L.P.G., ECU Controlled 80 (21.1)
128 (34.0) Mold Pointless Internal solid state circuit AC #41-932, R42LTS 14 (0.55) 1.24 (0.0488), .89 (.035) Single Barrel, MPFI Electronic Electromagnetic Cyclone with paper element × 1
1-10
GC70K STR
GENERAL INFORMATION
MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems. Truck Models GC35K
GC40K STR
GC40K
Engine lubrication system
Type
Starter
Alternator
Battery
Type
Cooling system
Items
Pressure feed
Oil pump
Gear pump
Oil filter
Paper element
Oil cooler
Oil to water type
Refill capacities, liter (U.S.gal)
GC45K SWB
Oil pan
4.2 (1.1)
Oil filter & cooler
0.8 (0.2)
Total
5.0 (1.3) Forced circulation
Radiator
Plate fins with pressure cap
Refill capacity, liter (U.S.gal) Water pump
18.2 (4.82) Centrifugal type, V-belt driven, Serpentine belt driven
Thermostat/ Opening Temp F°
Wax type/ 180
Type Ă— number
Group 24
Voltage, V
12
Capacity, AH (5Hr)
45
Type
3-Phase AC
Manufacturer
MANDO, AC Delco
Rated output, V-A
12-50, 12-70
Regulator
Built in IC type
Type
Electromagnetic
Manufacturer
Delco Remy
Voltage-output, V-kW
12 - 0.75
1-11
GENERAL INFORMATION
MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems. GC45K STR
GC45K
GC55K
GC55K STR
GC60K
Pressure feed Gear pump Paper element Oil to water type 4.2 (1.1) 0.8 (0.2) 5.0 (1.3) Forced circulation Plate fins with pressure cap 11 (2.9) Centrifugal type, V-belt driven, Serpentine belt driven Wax type/ 180 Group 24 12 45 3-Phase AC MANDO, AC Delco 12-50, 12-70 Built in IC type Electromagnetic Delco Remy 12 - 0.75
1-12
GC70K GC70K STR
GENERAL INFORMATION
Truck Models GC35K
GC40K STR
GC40K
Items Type Torque converter
3-element, 1-stage, 2-phase
Manufacturer’s model
Okamura M15
Stall torque ratio
3.2
Control and shift
Power train
Transmission Powershift Reduction gear
Ratios
Hydraulic and column shift
Forward
2.898
Reverse
2.907
Type of gear
Spiral bevel
Gear ratio
4.571
Housing
Banjo
Differential Type of gear and pinion number
Gear
Straight bevel-2
Pinion
Straight bevel-4
Transmission/ torque converter oil liter (U.S. gal)
14 (3.7)
Differential gear oil liter (U.S. gal)
9.1 (2.4)
Steering system
Type
Full Hydrostatic power steering
Steering wheel diameter, mm (in.)
330 (13)
Power cylinder ID × rod diam., mm (in.) Power steering
85×60 (3.3×2.4)
Effective stroke, mm (in.)
155 (6.1)
Relief pressure, kPa (kgf/cm2) [psi]
11768 (120) [1706]
Traveling system
Flow rate, liter (U.S.gal)/min
23 (6.07)
Front axle
Full-floating tubular type
Rear axle
Elliott type
Suspension system
Front
Fixed type
Rear
Center-pivot type
Toe-in, mm (in.) Wheel alignment
0
Camber
1.0°
Caster
0°
Kingpin inclination
0°
1-13
GC45K SWB
GENERAL INFORMATION
GC45K STR
GC45K
GC55K
GC55K STR
GC60K
GC70K
3-element, 1-stage, 2-phase Okamura M15 3.2 Hydraulic and column shift 2.898
(1st/2nd) 5.104/2.882
2.907
(1st/2nd) 5.104/2.882
Spiral bevel
Hypoid gear
4.571
4.857 Banjo Straight bevel-2 Straight bevel-4 Transmission/ Torque oil 15 (3.9) 9.1 (2.4) Full Hydrostatic power steering 328 (12.9) 85×60 (3.3×2.4)
155 (6.1)
180 (7.1)
11768 (120) [1706]
14710 (150) [2133] 23 (6.07) Full-floating tubular type Elliott type Fixed tpe Center-pivot type 0 1.0° 0° 0°
1-14
GC70K STR