service repair manual

1. Service Manual
99739-80130
For use with GM4.3L, G6 Engine Service Manual and
Fuel System Supplement
GC35K AT87-00001-up
AT87A-00001-10230
AT87A-10231-up
GC40K AT87-00001-up
AT87A-00001-10230
AT87A-10231-up
GC40K STR AT87-00001-up
AT87A-00001-10230
AT87A-10231-up
GC45K SWB AT87-00001-up
AT87A-00001-10230
AT87A-10231-up
GC45K AT88-00001-up
AT88A-00001-10230
AT88A-10231-up
GC55K AT88-00001-up
AT88A-00001-10230
AT88A-10231-up
GC55K STR AT88-00001-up
AT88A-00001-10230
AT88A-10231-up
GC60K AT89-00001-up
AT89A-00001-10230
AT89A-10231-up
GC70K AT89-00001-up
AT89A-00001-10230
AT89A-10231-up
GC70K STR AT89-00001-up
AT89A-00001-10230
AT89A-10231-up
Chassis & Mast

2. 1
2
3
4
5
6
7
8
9
10
11
12
GROUP INDEX
Group Items
GENERAL INFORMATION Serial number locations, Dimensions, Technical data
COOLING SYSTEM Fan Belt Removal, Fan Belt Inspection, Fan Belt Inspection
ELECTRICAL SYSTEM
Console box, Combination Meter, Lamp bulb specifications,
Electrical system schematic
POWER TRAIN Engine and Transmission
POWERSHIFTTRANSMISSION Transmission, Control valve
FRONT AXLE Front wheels, Front axle, Reduction differential
REAR AXLE Rear axle, Rear wheels
BRAKE SYSTEM Caliper, Brake pedal, Master cylinder
STEERING SYSTEM Steering control valve
HYDRAULIC SYSTEM
Tank, Pump, Control valve, Lift and tilt cylinders, Flow regulator valve,
Down safety valve
MASTS AND FORKS Simplex Mast, Duplex Mast, Triplex Mast
Inspection standards, Periodic replacement of parts, Lubrication standards,
SERVICE DATA Main component weight, Tightening torque for standard bolts and nuts,
Special tools

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

4. AT88-00001-up
AT88A-00001~10230
AT88A-10231-up
AT89-00001-up
AT89A-00001~10230
AT89A-10231-up
AT87-00001-up
AT87A-00001~10230
AT87A-10231-up
GENERAL INFORMATION
1
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.
Models
This manual applies to the following vehicle models (names).
Truck Models Transmission Serial number Engine mounted
GC35K
GC40K
GC40K
STR
GC45K 1-Speed
SWB
GC45K
GM4.3L Gasoline Engine
GC55K
GC55K
STR
GC60K
GC70K Automatic
GC70K
2-Speed
STR
102530A

5. GENERAL INFORMATION
1-2
Serial Number Locations
Name Plate Chassis Serial Number Gasoline Engine Serial Number
Mast Number Transmission Serial Number
207831

6. [Chassis]
GC 55 K
Generation designator
Maximum capacity
55 :5500kg (12000lb)
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
Engine type
GC: gasoline engine type
[Mast]
A 55 A 33
GENERAL INFORMATION
1-3

7. GENERAL INFORMATION
1-5
Dimensions
F J K
G H
E
N
M
C
D
A
B
I
L
206999

8. GENERAL INFORMATION
1-6
Unit: mm (in.)
Truck Models
Ref.
GC35K GC40K
GC40K GC45K
No. STR SWB
Items
A Maximum lift Simplex mast 3050 (120) 2900 (114)
Simplex mast 150 (5.9) 160 (6.3)
Free lift 920 (36.2) 895 (35.2)
B (Floor to
Duplex mast
3.0 m (118 in.) mast 2.8m(112in.)mast
forktop) 800 (31.5) 920 (36.2)
Triplex mast
4.0 m (157 in.) mast 4.3m(169in.)mast
C Fork length 1220 (48)
D
Tilt angle 5/10 Simplex, Duplex mast
(forward – backward) deg. 6/5 Triplex mast
E Overall length (OLH) 2510 (98.5) 2550 (100) 2360 (93) 2620 (103)
F
Overall width Standard 1180 (46.5)
(outside) Wide tread (option) 1270 (50.0)
G
Overall height
2155 (85.0)
(to top of mast lowered)
H
Overall height
2155 (85.0)
(to top of overhead guard)
4250 (167) 4125 (162)
Simplex mast
I Overall height 4250 (167) 4080 (160.6)
(mast extended) Duplex mast 3.0 m (118 in.) mast 2.8m(112in.)mast
5250 (206.7) 5560 (218.9)
Triplex mast 4.0 m (157 in.) mast 4.3m(169in.)mast
J Tread (front)
Standard 940 (37.0)
Wide tread (option) 1040 (41.0)
K Tread (rear) 980 (38.5)
L Wheelbase 1575 (62.0)
M Rear overhang 485 (18.8) 525 (20.3) 335 (13.3) 565 (22.1)
N Underclearance (at frame) 150 (5.9)
Technical Data

9. GENERAL INFORMATION
1-7
GC45K GC55K
GC55K
GC60K GC70K
GC70K
STR STR
2900 (114) 2350 (93)
160 (6.3) 165 (6.5)
895 (35.2)
2.8 m (112 in.) mast
895 (35.2) 900 (35.4)
4.0 m (157 in.) mast 3.5 m (138 in.) mast
1220 (48)
5/10 Simplex, Duplex mast 6/10 Simplex mast
6/5 Triplex mast 6/5 Triplex mast
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)
2.8 m (112 in.) mast
5560 (218.9) 4785 (188.3)
4.0 m (157 in.) mast 3.5 m (138 in.) 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)
Unit: mm (in.)

10. GENERAL INFORMATION
1-8
GC40K GC45K
GC35K GC40K
STR SWB
Truck Models
Capacity/load center
kg/mm 3500/500 4000/500 4500/600
(lb/in.) (7000/24) (8000/24) (10000/24)
Maximum lift height Simplex mm (in.) 3050 (120) 2900 (114)
Lift speed (loaded) mm/sec. 540 (105) 390 (78.0)
Lowering speed (loaded) (fpm) 550 (108) 440 (86.5)
Mast tilt (forward-backward) degree 5/10
Free lift mm (in.) 150 (6.0) 160 (6.5)
Travel Powershift Loaded
km/h
19 (12.0) 18.5 (11.5)
speed transmission
No load (mph) 19.5 (12.5)
models
Minimum turning radius 2235 (88.0) 2285 (90) 2090 (82.5) 2340 (92.0)
Minimum
Standard
mm (in.)
2245 (88.5) 2295 (90.5) 2100 (82.5) 2350 (92.5)
intersecting isle
Gradeability at 1 mph Loaded 37 33 32 27
(1.6 km/h) No loaded
%
23.8 21.1 21.5 17.7
Gradeability at stall
Loaded 42 37 36 30
No loaded 23.8 21.1 21.5 17.7
Overall length to fork face 2510 (98.5) 2550 (100) 2360 (93) 2620 (103)
Overall Standard 1180 (46.5)
width Wide tread (optional) 1270 (50.0)
To top of mast
2200 (86.5) 2350 (92.5)
(lowered)
Overall To top of mast
4250 (167.5) 4130 (162.5)
height (extended)
To top of
2155 (85.0)
overhead guard mm (in.)
Wheelbase 1575 (62.0)
Standard 940 (37.0)
Tread
Front Wide tread
1040 (41.0)
(optional)
Rear 980 (38.5)
Overhang Rear 485 (18.8) 525 (20.3) 335 (13.3) 565 (22.1)
Underclearance (at frame) 150 (5.9)
Front
Single
22×9×16
Tire size wheels mm
Rear 18×7×12.12
Service weight
5200 (11500) 5600 (12300) 5700 (12700) 6500 (14300)
Single wheels -no load
(without load) Axle Front
kg (lb)
2050 (4600) 2025 (4400) 2150 (4900) 1925 (4200)
loading Rear 3150 (6900) 3575 (7900) 3550 (7800) 4575 (10100)
Technical Data
Weight
Work
performance
Traveling
performance
Dimensions

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12. GENERAL INFORMATION
1-9
GC45K GC55K
GC55K
GC60K GC70K
GC70K
STR STR
4500/600 5500/600 6000/600 7000/600
(10000/24) (12000/24) (13500/24) (15500/24)
2900 (114) 2360 (93)
390 (78.0) 360 (71.0)
440 (86.5) 540 (106.0)
5/10 6/10
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)
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) 2700 (106)
1320 (52.0) 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) 1160 (45.5)
470 (18.1) 650 (26.1) 380 (15.1) 590 (23.1) 340 (13.1)
150 (5.9) 200 (7.9)
22×12×16 28×12×12
18×8×12.12 18×8×12.12 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)

13. GENERAL INFORMATION
1-10
Truck Models
GC40K GC45K
GC35K GC40K
STR SWB
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)
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 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 Type Mold
Distributor
Type Pointless
Type of spark advance
Internal solid state circuit, ECU Controlled
control
Model AC #41-932, R42LTS
Spark plug 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
Fuel
system
Engine
Ignition
system
MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems.

14. GENERAL INFORMATION
1-11
GC45K GC55K
GC55K
GC60K GC70K
GC70K
STR STR
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
MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems.

15. GENERAL INFORMATION
1-12
Truck Models
GC40K GC45K
GC35K GC40K
STR SWB
Items
Type Pressure feed
Oil pump Gear pump
Oil filter Paper element
Oil cooler Oil to water type
Refill capacities,
Oil pan 4.2 (1.1)
liter (U.S.gal)
Oil filter & cooler 0.8 (0.2)
Total 5.0 (1.3)
Type Forced circulation
Radiator Plate fins with pressure cap
Refill capacity, liter (U.S.gal) 11 (2.9)
Water pump Centrifugal type, V-belt driven, Serpentine belt driven
Thermostat/ Opening Temp F° Wax type/ 180
Type × 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
Starter
Engine
lubrication
system
Battery
Cooling
system
Alternator
MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems.

16. GENERAL INFORMATION
1-13
GC45K GC55K
GC55K
GC60K GC70K
GC70K
STR STR
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
MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems.