Chassis & Mast
GC35K
AT87-00001-up
AT87A-00001-10230
AT87A-10231-20230
AT87A-20231-up
GC40K AT87-00001-up
AT87A-00001-10230
AT87A-10231-20230
AT87A-20231-up
GC40K STR AT87-00001-up
AT87A-00001-10230
AT87A-10231-20230
AT87A-20231-up
GC45K SWB AT87-00001-up
AT87A-00001-10230
AT87A-10231-20230
AT87A-20231-up
GC45K STR AT87A-20231-up
GC45K AT88-00001-up
AT88A-00001-10230
AT88A-10231-20230
GC55K AT88-00001-up
AT88A-00001-10230
AT88A-10231-20230
AT88A-20231-up
GC55K STR AT88-00001-up
AT88A-00001-10230
AT88A-10231-20230
AT88A-20231-up
GC60K
AT89-00001-up
AT89A-00001-10230
AT89A-10231-20230
AT89A-20231-up
GC70K AT89-00001-up
AT89A-00001-10230
AT89A-10231-20230
AT89A-20231-up
GC70K STR AT89-00001-up
AT89A-00001-10230
AT89A-10231-20230
AT89A-20231-up
For use with GM4.3L, G6 Engine Service Manual and Fuel System Supplements
99739-82100
Lift Trucks ®
GroupItems
GENERALINFORMATIONVehicleExterior,Models,SerialNumberLocations,Dimensions,TechnicalData.
COOLINGSYSTEMDescription,RemovalandInstallation,InspectionandAdjustment,FanBelt Inspection,FanBeltAdjustment.
ELECTRICALSYSTEMDescription,DisassemblyandRe-assembly,MajorElectricalComponents, BatteryMaintenance,TypicalOpenCircuitVoltage,LampBulbSpecifications, ElectricalSystemSchematics.
POWERTRAINSpecifications,Structure,ReductionRatio,ProceduresandKeyPointsfor RemovalandInstallation.
POWERSHIFTTRANSMISSION1-SpeedTransmission(GC35K-GC55KSTR),Specifications,Structure, RemovalandInstallation,TorqueConverter,Transmission,ControlValve, Adjustment,Automatic2-speedTransmission(GC60K-GC70KSTR), Specifications,Structure,Transmission,SolenoidValve,Adjustment, Troubleshooting,ServiceData.
FRONTAXLESpecifications,Structure,ProceduresandKeyPointsforRemovaland Installation,AxleShaftandHub,ReductionDifferential,Troubleshooting, ServiceData.
REARAXLESpecifications,Structure,ProceduresandKeyPointsforRemovaland Installation,RearAxleAssembly,SteeringCylinder,Adjustment, Troubleshooting,ServiceData.
BRAKESYSTEMSpecifications,Structure,MasterCylinder,WheelCylinder,WheelBrake, ParkingBrakeLever,AdjustmentandTests,Troubleshooting,ServiceData.
STEERINGSYSTEMSpecifications,Structure,ProceduresandKeyPointsforRemovaland Installation,SteeringControlValve,Troubleshooting,ServiceData.
HYDRAULICSYSTEMSpecifications,Description,RemovalandInstallation,Disassemblyand Re-assembly,InspectionandAdjustment,HydraulicCircuitDiagram, Troubleshooting,ServiceData.
MASTSANDFORKSSpecifications,Description,DisassemblyandRe-assembly,Inspectionand Adjustment,Troubleshooting,ServiceData.
SERVICEDATAInspectionStandards,PeriodicReplacementofParts,SpecialToolTable.
1 2 3 4 5 6 7 8 9 10 11 12
GROUP INDEX
GENERAL INFORMATION VehicleExterior..........................................................................................................................1-1 Models........................................................................................................................................1-1 SerialNumberLocations............................................................................................................1-2 Dimensions..................................................................................................................................1-4 TechnicalData............................................................................................................................1-5 1
VehicleExterior
•ThisServiceManualdealswithallcomponentsorsystemsofCatlifttrucks;exceptfortheengine andattachment,whicharecoveredintherespectivemanuals.
102530A
Models
Thismanualappliestothefollowingvehiclemodels(names).
TruckModelsTransmissionSerialNumberEngineMounted
GC35K
AT87-00001-up
GC40KAT87A-00001~10230
AT87A-10231-20230
GC40KSTRAT87A-20231-up
GC45KSWB1-Speed
GC45KSTR
GC45KAT88-00001-up
AT88A-00001~10230
GC55KAT88A-10231-20230
GC55KSTR
GC60K
AT88A-20231-up
AutomaticAT89-00001-up
GC70K2-SpeedAT89A-0000~10230
AT89A-10231-20230
GC70KSTRAT89A-20231-up
GM4.3LGasolineEngine
INFORMATION 1
GENERAL
1-2
NumberLocations Name Plate Chassis Serial Number (FormerModels) Gasoline Engine Serial Number Mast NumberTransmission Serial NumberChassis Serial Number (New Models)
GENERAL INFORMATION
Serial
Chassis and Mast Model Identification
[Chassis]
GC 55 K
Generation designator
Maximum capacity 55 :5500kg (12000lb)
Engine type
GC: gasoline engine type
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
[Mast] A 55 A 33 GENERAL INFORMATION 1-3
Dimensions F J K G H E N M C D A B I L 206999 GENERAL INFORMATION 1-4
Technical Data
Unit:mm(in.)
Ref.TruckModelsGC35KGC40KGC40KGC45K No.STRSWB
Items
AMaximumliftSimplexmast3050(120)2900(114)
Simplexmast150(5.9)160(6.3)
Freelift920(36.2)895(35.2)
B(FloortoDuplexmast3.0m(118in.)mast2.8m(112in.)mast forktop)800(31.5)920(36.2)
Triplexmast4.0m(157in.)mast4.3m(169in.)mast
CForklength1220(48)
DTiltangle5/10Simplex,Duplexmast (forward–backward)deg.6/5Triplexmast
EOveralllength(OLH)2510(98.5)2550(100)2360(93)2620(103)
FOverallwidthStandard1180(46.5) (outside)Widetread(option)1270(50.0)
GOverallheight2155(85.0) (totopofmastlowered)
HOverallheight2155(85.0) (totopofoverheadguard)
Simplex4250(167)4125(162) mast
IOverallheight4250(167)4080(160.6) (mastextended)Duplexmast3.0m(118in.)mast2.8m(112in.)mast
Triplex5250(206.7)5560(218.9) mast4.0m(157in.)mast4.3m(169in.)mast
JTread(front) Standard940(37.0)
Widetread(option)1040(41.0)
KTread(rear)980(38.5)
LWheelbase1575(62.0)
MRearoverhang485(18.8)525(20.3)335(13.3)565(22.1)
NUnderclearance(atframe)150(5.9)
GENERAL INFORMATION 1-5
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Unit:mm(in.)
2900(114)2350(93)
160(6.3)165(6.5)
895(35.2)
2.8m(112in.)mast
895(35.2)900(35.4)
4.0m(157in.)mast3.5m(138in.)mast
1220(48)
5/10Simplex,Duplexmast6/10Simplexmast
6/5Triplexmast6/5Triplexmast
2730(107)2910(115)2640(104)2950(116)2730(107)
1320(52.0)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)
2.8m(112in.)mast
5560(218.9)4785(188.3)
4.0m(157in.)mast3.5m(138in.)mast
1015(40.0)1130(44.5)
1120(44)
965(38.0)1160(45.5)
1780(70.0)1830(72.0)
470(18.1)650(26.1)380(15.1)590(23.1)340(13.1)
150(5.9)200(7.9)
GENERAL INFORMATION 1-6
GC45KSTRGC45KGC55KGC55KGC60KGC70KGC70K STRSTR
GC35KGC40KGC40KGC45K TruckSTRSWB Models
Capacity/loadcenterkg/mm3500/5004000/5004500/600 (lb/in.)(7000/24)(8000/24)(10000/24)
MaximumliftheightSimplexmm(in.)3050(120)2900(114)
Liftspeed(loaded)mm/sec.540(105)390(78.0)
Loweringspeed(loaded)(fpm)550(108)440(86.5)
Masttilt(forward-backward)degree5/10
Freeliftmm(in.)150(6.0)160(6.5)
TravelPowershiftLoadedkm/h19(12.0)18.5(11.5) speedtransmissionNoload(mph)19.5(12.5) models
Minimumturningradius2235(88.0)2285(90)2090(82.5)2340(92.0)
MinimumStandardmm(in.)2245(88.5)2295(90.5)2100(82.5)2350(92.5) intersectingisle
Gradeabilityat1mphLoaded37333227 (1.6km/h)Noloaded%23.821.121.517.7
GradeabilityatstallLoaded42373630 Noloaded23.821.121.517.7
Overalllengthtoforkface2510(98.5)2550(100)2360(93)2620(103)
OverallStandard1180(46.5)
widthWidetread(optional)1270(50.0)
Totopofmast2200(86.5)2350(92.5) (lowered)
OverallTotopofmast4250(167.5)4130(162.5) height(extended)
Totopof2155(85.0) overheadguardmm(in.)
Wheelbase1575(62.0)
Standard940(37.0)
Tread FrontWidetread1040(41.0) (optional)
Rear980(38.5)
OverhangRear485(18.8)525(20.3)335(13.3)565(22.1)
Underclearance(atframe)150(5.9)
FrontSingle22×9×16
Tiresizewheelsmm
Rear18×7×12.12
Serviceweight5200(11500)5600(12300)5700(12700)6500(14300)
Singlewheels-noload (withoutload)AxleFrontkg(lb)2050(4600)2025(4400)2150(4900)1925(4200)
loadingRear3150(6900)3575(7900)3550(7800)4575(10100)
GENERAL INFORMATION 1-7
Weight Work performance Traveling
Dimensions
Technical Data
performance
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)1160(45.5)
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)
GENERAL INFORMATION 1-8 GC45KSTRGC45KGC55KGC55KSTRGC60KGC70KGC70KSTR 4500/6005500/6006000/6007000/600 (10000/24)(12000/24)(13500/24)(15500/24) 2900(114)2360(93) 390(78.0)360(71.0) 440(86.5)540(106.0) 5/106/10 160(6.5)165(6.5) 18.5(11.5)18(11.5)21(13.0)20.5(12.5) 19.5(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) 2622.622.224.521.721.4 23.820.220.922.219.720.4 302625302726 23.820.220.922.219.720.4 2730(107)2910(115)2460(104)2950(116)2700(106) 1320(52.0)1440(56.5)
×12×1628×12×12 18×8×12.1218×8×12.1222×8×16
470(18.1)650(26.1)380(15.1)590(23.1)340(13.1) 150(5.9)200(7.9) 22
TruckModelsGC40KGC45K ItemsGC35KGC40KSTRSWB
EnginemodelGM4.3L
TypeGasoline
CoolingsystemWatercooled
No.ofcylinders-arrangement6-90°V
No.ofstrokes4
TypeofcombustionchamberSemi-spherical ValvearrangementOverhead
TypeofcylinderlinersIntegral Cylinderbore × stroke,mm(in.)101.6×88.39(4.00×3.48)
Displacement,cc(cuin.)4293(262)
Compressionratio9.2:1
Ratedoutput,PS/rpm94/2450
Ratedtorque,kgf·m/rpm31.0/1200
Min.rpm750-800, 650-700
Max.rpm2650-2700, 2600-2650
Dimensions(L×W×H),mm(in.)710×620×740(28.0×24.4×29.1)
Weight,kg(lb)260(573)
InstallationpositionRear
IgnitionSpark
Firingorder1-6-5-4-3-2
Initialignitiontiming,BTDCdeg0°Gasoline,8°L.P.G., ECU Controlled Fueltankcapacity,liter(U.S.gal)66(17.4)
IgnitioncoilTypeMold
TypePointless
Distributor
TypeofsparkadvanceInternalsolidstatecircuit, ECU Controlled control
ModelAC#41-932, R42LTS
SparkplugSize,mm(in.)14(0.55)
Gap,mm(in.)1.24(0.0488), .89 (.035)
CarburetorTypeSingleBarrel, MPFI
GovernorTypeElectronic
FuelpumpTypeElectromagnetic AircleanerType × NumberCyclonewithpaperelement × 1
GENERAL INFORMATION 1-9
Fuelsystem
Engine Ignition system
MPFIspecsin Bold.Ifnotindicatedinbold,specsareforCarburetedandMPFIsystems.
GM4.3L
Gasoline
Watercooled 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
Internalsolidstatecircuit
AC#41-932, R42LTS
14(0.55)
1.24(0.0488), .89 (.035)
SingleBarrel, MPFI
Electronic
Electromagnetic
Cyclonewithpaperelement × 1
GC45KSTRGC45KGC55KGC55KSTRGC60KGC70KGC70KSTR
MPFIspecsin Bold.Ifnotindicatedinbold,specsareforCarburetedandMPFIsystems. GENERAL INFORMATION 1-10