Caterpillar Cat GC40K STR Forklift Lift Trucks Service Repair Manual SN AT87A-00001-10230

Service Manual Chassis & Mast GC35K

GC40K

GC40K STR

GC45K SWB

GC45K

AT87-00001-up

GC55K

AT88-00001-up

AT87A-00001-10230

AT88A-00001-10230

AT87A-10231-up

AT88A-10231-up

AT87-00001-up

GC55K STR

AT88-00001-up

AT87A-00001-10230

AT88A-00001-10230

AT87A-10231-up

AT88A-10231-up

AT87-00001-up

GC60K

AT89-00001-up

AT87A-00001-10230

AT89A-00001-10230

AT87A-10231-up

AT89A-10231-up

AT87-00001-up

GC70K

AT89-00001-up

AT87A-00001-10230

AT89A-00001-10230

AT87A-10231-up

AT89A-10231-up

AT88-00001-up

GC70K STR

AT89-00001-up

AT88A-00001-10230

AT89A-00001-10230

AT88A-10231-up

AT89A-10231-up

For use with GM4.3L, G6 Engine Service Manual and Fuel System Supplement

99739-80130

FOREWORD This service manual is a guide to servicing of Cat Lift Trucks for 3.5 thru 7.0 ton models. The instructions are grouped by systems to serve the convenience of your ready reference.

Long productive life of your lift trucks depends to a great extent on correct servicing — the servicing consistent with what you will learn from this service manual. We hope you read the respective sections of this manual carefully and know all the components you will work on before attempting to start a test, repair or rebuild job.

The descriptions, illustrations and specifications contained in this manual were of the trucks of serial numbers in effect at the time it was approved for printing. Cat Lift Trucks reserves the right to change specifications or design without notice and without incurring obligation.

The GM4.3 Liter engine’s fuel system was changed to comply with the EPA guidelines in 2004 and again at the beginning of 2007. This manual has minimal information on the fuel systems. Please see the Fuel System Supplement for information regarding the Multi Port Fuel Injection System (MPFI). Also see the engine service manual for general engine repair or rebuild. For the items pertaining to the engine, refer to the following service manuals: • GM4.3L (G6) Engine Service Manual • GM4.3L 2004~2006 Fuel System Supplement • GM4.3L 2007~2009 Fuel System Supplement

SAFETY RELATED SIGNS The following safety related signs are used in this service manual to emphasize important and critical instructions: WARNING

Indicates a specific potential hazard resulting in serious bodily injury or death.

CAUTION

Indicates a specific potential hazard resulting in bodily injury, or damage to, or destruction of the machine.

NOTE

Indicates a condition that can cause damage to, or shorten service life of the machine.

Pub. No. 99739-80130

WARNING

SAFETY WARNING

WARNING

The proper and safe lubrication and maintenance for this lift truck, recommended by Cat Lift Trucks, are outlined in the OPERATION & MAINTENANCE MANUAL for these trucks.

Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance.

Do not operate this truck unless you have read and understood the instructions in the OPERATION & MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death.

4.

Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly.

5.

Use steps and grab handles (if applicable) when mounting or dismounting a truck. Clean any mud or debris from steps, walkways or work platforms before using. Always face truck when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

6.

To avoid back injury, use a hoist when lifting components which weighs 23 kg (50 lb.) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

7.

To avoid burns, be alert for hot parts on trucks which have just been stopped and hot fluids in lines, tubes and compartments.

8.

Be careful when removing cover plates.

Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely.

9.

Be careful when removing filler caps, breathers and plugs on the truck. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquid under pressure. The danger is even greater if the truck has just been stopped because fluids can be hot.

The serviceman or mechanic may be unfamiliar with many of the systems on this truck. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component.

Because of the size of some of the truck components, the serviceman or mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components.

Following is a list of basic precautions that should always be observed.

1.

Read and understand all warning plates and decals on the truck before operating, lubricating or repairing the product.

2.

Always wear productive glasses and protective shoes when working around trucks. In particular, wear protective glasses when pounding on any part of the truck or its attachments with a hammer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery.

3.

Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the truck before performing any disassembly.

10. Always use tools that are in good condition and be sure you understand how to use them before performing any service work.

11. Reinstall all fasteners with same part number.

Do not use lesser quality fastener if replacements are necessary. Do not mix metric fastener with standard nuts and bolts.

12. If possible, make all repairs with the truck parked on a level, hard surface. Block truck so it does not roll while working on or under truck.

13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck. Hang “Do not Operate� tag in the Operator’s Compartment.

14. Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures.

Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal.

15. Do not damage wiring during removal operation. Reinstall the wiring so it is not damaged nor it will be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid.

16. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution.

17. Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is performed, which requires the mast in the raised position.

18. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury.

Use cardboard or paper to locate pin hole leaks.

19. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibrations or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure, must be installed correctly.

20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

21. Do not operate a truck if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

HOW TO READ THIS MANUAL Disassembly diagram (example)

2

1 4

Each disassembly diagram is followed

by Disassembly sequence and Suggestions disassembly.

3

▲

1 Cover, Bolt, Washer (part name) 2 Output shaft (part name)

▲

Disassembly sequence

▲

Suggestion for disassembly (1) Output shaft removal Unit: mm (in.)

Clearance between cylinder and piston

A

0.020 to 0.105 (0.00079 to 0.00413)

B

0.15 (0.0059)

A: Assembly standard B: Repair or service limit

Symbols or abbreviations OP..........................Option R1/4 ......................Taper pipe thread (external) 1/4 inch (formerly PT1/4) Rc1/8 ....................Taper pipe thread (internal) 1/8 inch (formerly PT1/8) G1/4A ....................Straight pipe thread (external) 1/4 inch (formerly PF1/4-A) Rp1/8 ....................Straight pipe thread (internal) 1/8 inch (formerly PS1/8)

GROUP INDEX

Group

Items

GENERAL INFORMATION Serial number locations, Dimensions, Technical data

1

COOLING SYSTEM

Fan Belt Removal, Fan Belt Inspection, Fan Belt Inspection

2

Console box, Combination Meter, Lamp bulb specifications,

3

ELECTRICAL SYSTEM

POWER TRAIN

Electrical system schematic Engine and Transmission

4

POWERSHIFT TRANSMISSION Transmission, Control valve

5

FRONT AXLE

Front wheels, Front axle, Reduction differential

6

REAR AXLE

Rear axle, Rear wheels

7

BRAKE SYSTEM

Caliper, Brake pedal, Master cylinder

8

STEERING SYSTEM

Steering control valve

9

HYDRAULIC SYSTEM

MASTS AND FORKS

Tank, Pump, Control valve, Lift and tilt cylinders, Flow regulator valve, Down safety valve Simplex Mast, Duplex Mast, Triplex Mast

10 11

Inspection standards, Periodic replacement of parts, Lubrication standards, SERVICE DATA

Main component weight, Tightening torque for standard bolts and nuts, Special tools

12

GENERAL INFORMATION

Vehicle Exterior .......................................................................................................................... 1 - 1 Models ........................................................................................................................................ 1 - 1 Serial Number Locations ............................................................................................................ 1 - 2 Dimensions.................................................................................................................................. 1 - 5 Technical Data ............................................................................................................................ 1 - 6

1

GENERAL INFORMATION

Vehicle Exterior • This Service Manual deals with all components or systems of the 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 GC40K

AT87-00001-up AT87A-00001~10230 AT87A-10231-up

GC40K STR GC45K SWB

1-Speed

GC45K

GM4.3L Gasoline Engine AT88-00001-up AT88A-00001~10230 AT88A-10231-up

GC55K GC55K STR GC60K GC70K GC70K STR

Automatic 2-Speed

AT89-00001-up AT89A-00001~10230 AT89A-10231-up 1

GENERAL INFORMATION

Serial Number Locations

Name Plate

Chassis Serial Number

Mast Number

Transmission Serial Number

Gasoline Engine Serial Number

207831

1-2

GENERAL INFORMATION

[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

1-5

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)

1-6

565 (22.1)

GENERAL INFORMATION

Unit: mm (in.)

GC45K

GC55K STR

GC55K

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)

1-7

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

Tread

150 (6.0)

Standard

To top of overhead guard

Front

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 (mph) No load 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)

1-8

GENERAL INFORMATION

GC45K

GC55K STR

GC55K

4500/600 (10000/24)

GC60K

5500/600 (12000/24)

GC70K STR

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)

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

650 (26.1)

1160 (45.5) 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)

1-9

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

1-10

GENERAL INFORMATION

MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems.

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

1-11

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

11 (2.9) 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

1-12

GENERAL INFORMATION

MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems.

GC45K

GC55K

GC55K STR

GC60K

GC70K

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

1-13

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°

1-14

GC45K SWB

GENERAL INFORMATION

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°

1-15

GC70K STR

GENERAL INFORMATION

Truck Models GC35K

GC40K STR

GC40K

Items

Brake system

Type Service brakes

Parking brake

Self-adjusting, duo-servo

Drum diameter, mm (in.)

317.5 (12.50)

Lining (length×width thick×number), mm (in.)

330×63×10-2 (13×2.48×0.39-2)

Master cylinder ID, mm (in.)

28.57 (1.125)

Wheel cylinder ID, mm (in.)

31.75 (1.250)

Type

Mechanical, mounted on wheels

Brake fluid cc (cu.in)

130 (7.9)

Brake booster

Mastervac (vacuum suspended)

Body

Assembled-frame type Type

Gear

Manufacturer’s type Gear pump

Control valve Hydraulic system

GC45K SWB

Flow regulator valve

KFP3240 AMBAS

Rated discharge, liter (U.S.gal)/rpm

98 (25.89)/2450

Drive line

Universal joint

Type

6000-C193

Relief pressure, MPa (kgf/cm2) [psi]

19.12

Type

+0.5 0

(195

+5 0

) [2773

+71 0 ]

Variable (Adjustable)

Regulated flow rate, liter (U.S.gal)/min

100 (26.4)

115 (30.38)

Simplex mast ID, mm (in.)

Lift cylinders Stroke, mm (in.)

60 (2.36)

70 (2.75)

Duplex mast ID, mm (in.)

First lift cylinders Stroke, mm (in.)

90 (3.54)

110 (4.33)

820 (32.28)

845 (33.27)

55 (2.17)

60 (2.36)

1590 (62.60)

1585 (62.40)

90 (3.54)

110 (4.33)

820 (32.28)

845 (33.27)

60 (2.36)

70 (2.75)

1480 (58.27)

1530 (60.24)

1650 (65)

Duplex mast ID, mm (in.)

Second lift cylinders Stroke, mm (in.)

Triplex mast ID, mm (in.)

First lift cylinders Stroke, mm (in.)

Triplex mast ID, mm (in.)

Second lift cylinders Stroke, mm (in.)

Tilt cylinders

ID, mm (in.)

100 (3.937)

Stroke, mm (in.)

120 (4.724)

Hydraulic tank capacity, liter (U.S.gal)

46 (12.1)

1-16

GENERAL INFORMATION

GC45K

GC55K

GC55K STR

GC60K

GC70K

Self-adjusting, duo-servo 317.5 (12.50) 330×63×10-2 (13×2.48×0.39-2) 28.57 (1.125) 31.75 (1.250) Mechanical, mounted on wheels 130 (7.9) Mastervac (vacuum suspended) Assembled-frame type Gear KFP3240 AMBAS

SPG2-48L194

98 (25.89)/2450

117.6 (31.07)/2450 Universal joint 6000-C193 19.12

+0.5 0

(195

+5 0

) [2773

+71 0 ]

Variable (Adjustable) 115 (30.38)

165 (43.56)

70 (2.75)

80 (3.15) 1650 (65)

110 (4.33) 845 (33.27) 60 (2.36) 1585 (62.40) 110 (4.33)

125 (4.92)

845 (33.27)

855 (33.66)

70 (2.75)

80 (3.15)

1530 (60.24)

1495 (58.86)

100 (3.937)

110 (4.33)

120 (4.724)

139 (5.472)

52 (13.6)

69 (18.2)

1-17

GC70K STR

GENERAL INFORMATION

Truck Models GC35K

GC40K

Items

Mast and forks

Mast model

GC40K STR

GC45K SWB

CJ type

Flange ID × flange Outer back thickness × flange front thickness × Inner, Middle web thickness Main rollers

Bearing

Side rollers

Bearing

118×28×24×13 (4.6×1.1×0.9×0.5)

130×30×26×15 (5.1×1.2×1.0×0.6)

118×24×24×12 (4.6×0.9×0.9×0.47)

130×26×26×13 (5.1×1.0×1.0×0.5)

Ball bearing

Diam × width, mm (in.)

118×32 (4.65×1.26)

130×34 (5.12×1.34)

Lubricated type needle roller bearing

Diam × width, mm (in.)

52×36 (2.05×1.42)

Lift chains

BL834

Fork (length × width × thick), mm (in.)

1220×150×50 (48×6×2)

Fork spread (outer width), mm (in.)

1060 (41.5)

1-18

BL1034

GENERAL INFORMATION

GC45K

GC55K STR

GC55K

GC60K

GC70K

GC70K STR

CJ type 130×30×26×15 (5.1×1.2×1.0×0.6)

150×34×30×20 (5.9×1.3×1.2×0.8)

130×26×26×13 (5.1×1.0×1.0×0.5)

150×30×30×15 (5.9×1.2×1.2×0.6) Ball bearing

130×34 (5.12×1.34)

150×36 (5.91×1.42)

Lubricated type needle roller bearing 52×36 (2.05×1.42)

58×40 (2.3×1.6) BL1034

1220×150×60 (48×6×2.4)

1220×150×65 (48×6×2.56)

1060 (41.5)

1230 (48.5)

1-19

COOLING SYSTEM

Description .................................................................................................................................. 2 - 1 Removal and Installation ............................................................................................................ 2 - 2 Inspection and Adjustment.......................................................................................................... 2 - 4 Fan Belt Inspection .............................................................................................................. 2 - 4 Fan Belt Adjustment ............................................................................................................ 2 - 4

2

COOLING SYSTEM

Description

6 •

5 •

8 •

9 •

4 1 •

• 7

•

•

3

2

207009

1 2 3 4

5 6 7 8 9

Engine Universal joint Gear pump Fan belt

2-1

Cooling fan Upper hose Lower hose Radiator Transmission Oil Cooler

COOLING SYSTEM

Removal and Installation Fan Belt Removal 1. Method by removing radiator

3

2 1

207010

Removal sequence 1 Universal joint 2 Tension pulley bolt (loosening only) 3 Belt Start by: Remove the radiator cover.

2-2

COOLING SYSTEM

Suggestions for removal and installation (1) Loosen the tension pulley bolt until the fan tension becomes loose.

(2) Force the pulley all the way toward the fan and remove fan belt.

Installation To install, follow the reverse of removal procedure and do the following steps: (1) Turn the fan by hand to make sure it rotates smoothly. If its bearing is noisy, replace it.

(2) After putting the belt on the drive and driven pulleys, push it midway between the pulleys to make sure the tension pulley moves freely.

Then, tighten the pulley bolt.

2-3

COOLING SYSTEM

Inspection and Adjustment Fan Belt Inspection (1) Check to make sure the belt is free of oil, grease or other foreign matter. Replace the belt if necessary. A slightly dirty belt can be re-used by cleaning with cloth or paper. Do not attempt to clean the belt with gasoline or the like.

(2) At the time of overhauling the engine or adjusting the belt tension, closely check the belt and replace it if it is defective.

Fan Belt Adjustment (1) Loosen the tension pulley bolt by one to two full turns with ratchet wrench.

Tension pulley bolt 207011

(2) The belt will be properly tightened by the tension spring. Tighten the tension pulley bolt.

2-4

ELECTRICAL SYSTEM

Description .................................................................................................................................. 3 - 1 Console Box ........................................................................................................................ 3 - 1 Sub Panel .............................................................................................................................. 3 - 2 Disassembly and Reassembly ....................................................................................................

Console Box ........................................................................................................................

Components in Console Box................................................................................................

Combination Meter ..............................................................................................................

3-3 3-3 3-4 3-5

Major Electrical Components ....................................................................................................

Starter Switch (with Anti-restart Lock)................................................................................

Lighting Switch ...................................................................................................................

Fuse Box ..............................................................................................................................

Spare Terminals ....................................................................................................................

3-6 3-6 3-7 3-8 3-8

Battery Maintenance .................................................................................................................. 3 - 9 Typical Open Circuit Voltage...................................................................................................... 3 - 10 Lamp Bulb Specifications .......................................................................................................... 3 - 12 Electrical System Schematics ....................................................................................................

Chassis (2007-01~up) ..........................................................................................................

Engine (2007-01~up)............................................................................................................

Chassis w/ Neutral Safety Switch (2005-11~2006-12)........................................................

Chassis w/o Neutral Safety Switch (2004-01~2005-10)......................................................

Engine (2004-01~2006-12) ..................................................................................................

Chassis (1998-01~2003-12) ................................................................................................

Engine, Gasoline (1998-01~2003-12) ..................................................................................

Engine, LPG (1998-01~2003-12) ........................................................................................

3 - 13 3 - 13 3 - 15 3 - 17 3 - 19 3 - 21 3 - 23 3 - 25 3 - 27

3

ELECTRICAL SYSTEM

Description Console Box

4

1 Engine coolant temperature gauge 2 Speed selector switch (Only for 6 & 7 ton models) (moved to head guard pillar in 2006) 3 Fuel gauge 4 Service hourmeter 5 OK monitor (Indicator Lights) 6 Starter switch 7 Light switch 8 Fuse box

5 3 1 7 6

2 8

102868

OK monitor 1

2

3

4

5

6

7

8

102869

Function No.

Indicator light

OFF

On or flickering

1

Powershift transmission oil temp. indicator light

Normal

Overheating

2

Air cleaner element indicator light

Normal

Clogged

3

Brake fluid level indicator light

Normal

Low

4

Engine oil pressure indicator light

Normal

Low

5

Alternator not charging indicator light

Normal

Abnormal

6

LPG residual pressure alarm lamp

Normal

Small

7

Malfunction indicator lamp (moved to head guard pillar in 2006)

Normal

Service engine

8

Engine coolant level warning light

Normal

Low

Remarks

Option Option

How to check indicator light bulbs The bulbs are normal if the indicator lights come ON when the starter switch key is turned to â?™ (ON) position. (The indicator lights will go OFF when the engine starts.)

3-1

ELECTRICAL SYSTEM

Sub Panel The sub panel is mounted at the right front pillar of the head guard.

104794

1st speed mode/automatic mode selector switch (For 6 and 7 Ton Models as standard and others as optional) Automatic mode (1st speed

2nd speed)

1st speed mode

Select the 1st speed mode for operating in the speed-limit area [14 km/h (8.7 mph) max.], climbing or traction.

104789

104575

Driving interlock indicator lamp Flickers if the operator leaves the seat with the direction lever in the forward or reverse position while the engine is running.

Neutral indicator lamp Glows when the direction lever is placed in Neutral (N) position.

ECM warning light (GASOLINE) (IF EQUIPPED) Glows when ECM (engine control module) is abnormal.

Consult your Cat lift truck dealer.

3-2

ELECTRICAL SYSTEM

Disassembly and Reassembly Console Box

2

4

⎧ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎨ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎩

3

1 207751

Disassembly 1. Disconnect the electrical wires at connectors 1.

2. Remove screws 2 (four) securing the cover.

3. Remove screws 3 (six) and separate the front and rear panels.

4. Remove screws 4 (four) securing the instrument panel.

Reassembly To reassemble the console box, follow the reverse of disassembly procedure.

NOTE To replace the instrument panel bulbs, remove screws 3 and 4.

3-3

ELECTRICAL SYSTEM

Components in Console Box

4

3 2 1

5

6

207752

4 Light switch 5 Starter switch 6 Fuses

1 Power relay 2 Power relay 3 Turn signal relay

3-4

ELECTRICAL SYSTEM

Combination Meter Disassembly

1

2 3 4 5

6

7 8 9 206480

Sequence 1 Instrument panel 2 Dial 3 Engine coolant temperature gauge 4 Service hour meter 5 Fuel gauge CAUTION Be careful not to damage the printed circuit when disassembling the combination meter.

6 7 8 9

Meter case Printed circuit Bulb Socket

Bulb replacement For bulb replacement, remove the socket from the printed circuit by turning it counterclockwise.

For configuration of the indicator lights, refer to “OK Monitor�.

Reassembly To reassemble the combination meter, follow the reverse of disassembly sequence.

3-5

ELECTRICAL SYSTEM

Major Electrical Components Starter Switch (with Anti-restart Lock) This switch has a built-in anti-restart lock, so the key cannot be turned from ❙ (ON) to (START) position while the engine is running.

(OFF) (ON)

B

(START)

203561A Connection Terminal

B

Component Fuse box, battery, Key alternator position ● (OFF) ❙ (ON) (START)

● ● ●

M Fuse box, fuel-cut solenoid

S Starter, neutral switch (powershift transmission)

● ●

●

3-6

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