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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


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


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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

Kingpin inclination

1-13

GC45K SWB

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Caterpillar Cat GC70K Forklift Lift Trucks Service Repair Manual SNAT89-00001 and up  

Caterpillar Cat GC70K Forklift Lift Trucks Service Repair Manual SNAT89-00001 and up  

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