This is the Highly Detailed factory service repair manual for theCATERPILLAR CAT GC40K FORKLIFT LIFT TRUCKS, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.CATERPILLAR CAT GC40K FORKLIFT LIFT TRUCKS Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: Chassis and Mast: Foreword Chassis and Mast: General Information Chassis and Mast: Cooling System Chassis and Mast: Electrical System Chassis and Mast: Power Train Chassis and Mast: Power shift Transmission Chassis and Mast: Front Axle and Reduction Differential Chassis and Mast: Rear Axle Chassis and Mast: Brake System Chassis and Mast: Steering System Chassis and Mast: Hydraulic System Chassis and Mast: Mast and Forks Chassis and Mast: Service Data Chassis and Mast: Schematics Options Supplement: Foreword Options Supplement: Safety Options Supplement: Rear Combination Kit Options Supplement: Warning Lamp Kit Options Supplement: Working Lamp Kit Options Supplement: Creeper Speed Kit Options Supplement: Foot Directional Control Group Options Supplement: Engine Shutdown Kit (LPG Models Only) Options Supplement: Enclosed Alternator Field Kit Options Supplement: Disconnect Switch Kit Options Supplement: UL Fuel Cap Kit (Gasoline models only) Options Supplement: Key Kit Options Supplement: Back Buzzer Kit Options Supplement: Dual Element Air Cleaner Options Supplement: Dust and Foundry Kit Options Supplement: Back Mirror Kit File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveCATERPILLAR CAT GC40K FORKLIFT LIFT TRUCKS Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: https://www.aservicemanualpdf.com/ Thanks for visiting!

1. Chassis & Mast
Service Manual
99739-82100
For use with GM4.3L, G6 Engine Service Manual and
Fuel System Supplements
Lift
Trucks
®
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

2. 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. 99739-82100
FOREWORD

3. 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.
WARNING
WARNING
SAFETY
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 compo-
nents is important before the removal or disassem-
bly of any component.
Because of the size of some of the truck compo-
nents, the serviceman or mechanic should check the
weights noted in this Manual. Use proper lifting pro-
cedures 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 particu-
lar, 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 cloth-
ing appropriate to the welding job being per-
formed. Do not wear loose-fitting or torn cloth-
ing. Remove all rings from fingers when work-
ing 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 perform-
ing any disassembly.
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.
WARNING
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 correct-
ly. 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.

4. 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.

5. Unit: mm (in.)
Clearance A
0.020 to 0.105
between (0.00079 to 0.00413)
cylinder and
B
0.15
piston (0.0059)
A: Assembly standard
B: Repair or service limit
HOW TO READ THIS MANUAL
Disassembly diagram (example)
Each disassembly diagram is followed
by Disassembly sequence and
Suggestions disassembly.
Disassembly sequence
1 Cover, Bolt, Washer (part name)
2 Output shaft (part name)
Suggestion for disassembly
(1) Output shaft removal
1
2
3
4
▲
▲
▲
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)

6. GROUP INDEX
1
2
3
4
5
6
7
8
9
10
11
12
Group Items
GENERALINFORMATION Vehicle Exterior, Models, Serial Number Locations, Dimensions, Technical Data.
COOLING SYSTEM Description, Removal and Installation, Inspection and Adjustment, Fan Belt
Inspection, Fan Belt Adjustment.
ELECTRICAL SYSTEM Description, Disassembly and Re-assembly, Major Electrical Components,
Battery Maintenance, Typical Open Circuit Voltage, Lamp Bulb Specifications,
Electrical System Schematics.
POWER TRAIN Specifications, Structure, Reduction Ratio, Procedures and Key Points for
Removal and Installation.
POWERSHIFTTRANSMISSION 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.
FRONT AXLE Specifications, Structure, Procedures and Key Points for Removal and
Installation, Axle Shaft and Hub, Reduction Differential, Troubleshooting,
Service Data.
REAR AXLE Specifications, Structure, Procedures and Key Points for Removal and
Installation, Rear Axle Assembly, Steering Cylinder, Adjustment,
Troubleshooting, Service Data.
BRAKE SYSTEM Specifications, Structure, Master Cylinder, Wheel Cylinder, Wheel Brake,
Parking Brake Lever, Adjustment and Tests, Troubleshooting, Service Data.
STEERING SYSTEM Specifications, Structure, Procedures and Key Points for Removal and
Installation, Steering Control Valve, Troubleshooting, Service Data.
HYDRAULIC SYSTEM Specifications, Description, Removal and Installation, Disassembly and
Re-assembly, Inspection and Adjustment, Hydraulic Circuit Diagram,
Troubleshooting, Service Data.
MASTS AND FORKS Specifications, Description, Disassembly and Re-assembly, Inspection and
Adjustment,Troubleshooting, Service Data.
SERVICE DATA Inspection Standards, Periodic Replacement of Parts, Special Tool Table.

7. GENERAL INFORMATION
Vehicle Exterior .......................................................................................................................... 1 - 1
Models ........................................................................................................................................ 1 - 1
Serial Number Locations ............................................................................................................ 1 - 2
Dimensions.................................................................................................................................. 1 - 4
Technical Data ............................................................................................................................ 1 - 5
1

8. GENERAL INFORMATION
1
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.
Models
This manual applies to the following vehicle models (names).
102530A
Truck Models Transmission Serial Number Engine Mounted
GC35K
AT87-00001-up
GC40K AT87A-00001~10230
AT87A-10231-20230
GC40K STR AT87A-20231-up
GC45K SWB 1-Speed
GC45K STR
GM4.3L Gasoline Engine
GC45K AT88-00001-up
AT88A-00001~10230
GC55K AT88A-10231-20230
AT88A-20231-up
GC55K STR
GC60K
Automatic AT89-00001-up
GC70K 2-Speed AT89A-0000~10230
AT89A-10231-20230
GC70K STR AT89A-20231-up

9. GENERAL INFORMATION
1-2
Serial Number Locations
Name Plate
Chassis Serial Number
(Former Models) Gasoline Engine Serial Number
Mast Number Transmission Serial Number Chassis Serial Number
(New Models)

10. Chassis and Mast Model Identification
[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 designa-
tion 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

11. Dimensions
F J K
G H
E
N
MC
D
A
B
I
L
206999
GENERAL INFORMATION
1-4

12. GENERAL INFORMATION
1-5
Unit: mm (in.)
Truck ModelsRef.
GC35K GC40K
GC40K GC45K
No. STR SWBItems
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

13. GENERAL INFORMATION
1-6
GC45K STR 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.)

14. GENERAL INFORMATION
1-7
GC40K GC45KGC35K GC40K
STR SWBTruck 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 DataWeightWorkperformanceTravelingperformanceDimensions

15. GENERAL INFORMATION
1-8
GC45KSTR GC45K GC55K GC55K STR GC60K GC70K GC70K 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)

16. GENERAL INFORMATION
1-9
Truck Models
GC40K GC45KGC35K GC40K
STR SWBItems
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 Controlledcontrol
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
EngineIgnitionsystem
MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems.

17. GC45K STR GC45K GC55K GC55K STR GC60K GC70K GC70K 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.
GENERAL INFORMATION
1-10

18. GENERAL INFORMATION
1-11
Truck Models
GC40K GC45KGC35K GC40K
STR SWBItems
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) 18.2 (4.82)
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
StarterEnginelubricationsystemBatteryCoolingsystemAlternator MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems.

19. GC45K STR GC45K GC55K GC55K STR GC60K GC70K GC70K 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.
GENERAL INFORMATION
1-12

20. GENERAL INFORMATION
1-13
Truck Models
GC40K GC45KGC35K GC40K
STR SWBItems
Type 3-element, 1-stage, 2-phase
Torque converter Manufacturer’s model Okamura M15
Stall torque ratio 3.2
Control and shift Hydraulic and column shift
Transmission Powershift
Ratios
Forward 2.898
Reverse 2.907
Reduction Type of gear Spiral bevel
gear Gear ratio 4.571
Housing Banjo
Differential Type of gear and Gear Straight bevel-2
pinion number Pinion Straight bevel-4
Transmission/ torque converter oil 14 (3.7)
liter (U.S. gal)
Differential gear oil 9.1 (2.4)
liter (U.S. gal)
Type Full Hydrostatic power steering
Steering wheel diameter, mm (in.) 330 (13)
Power cylinder ID ×
85×60 (3.3×2.4)rod diam., mm (in.)
Power Effective stroke, mm (in.) 155 (6.1)
steering Relief pressure,
11768 (120) [1706]kPa (kgf/cm2
) [psi]
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.) 0
Wheel Camber 1.0°
alignment Caster 0°
Kingpin inclination 0°
TravelingsystemPowertrainSteeringsystem

21. GENERAL INFORMATION
1-14
GC45K STR GC45K GC55K GC55K STR GC60K GC70K GC70K STR
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°

22. GENERAL INFORMATION
1-15
Truck Models
GC40K GC45KGC35K GC40K
STR SWBItems
Type Self-adjusting, duo-servo
Drum diameter, mm (in.) 317.5 (12.50)
Service Lining (length×width 330×63×10-2
brakes thick×number), mm (in.) (13×2.48×0.39-2)
Master cylinder ID, mm (in.) 28.57 (1.125)
Wheel cylinder ID, mm (in.) 31.75 (1.250)
Parking
Type Mechanical, mounted on wheelsbrake
Brake fluid cc (cu.in) 130 (7.9)
Brake booster Mastervac (vacuum suspended)
Body Assembled-frame type
Type Gear
Manufacturer’s type KFP3240 AMBAS
Gear
Rated discharge,
98 (25.89)/2450pump
liter (U.S.gal)/rpm
Drive line Universal joint
Control
Type 6000-C193
valve Relief pressure,
19.12 (195 ) [2773 ]MPa (kgf/cm2
) [psi]
Flow Type Variable (Adjustable)
regulator Regulated flow rate,
100 (26.4) 115 (30.38)valve liter (U.S.gal)/min
Simplex mast ID, mm (in.) 60 (2.36) 70 (2.75)
Lift cylinders Stroke, mm (in.) 1650 (65)
Duplex mast ID, mm (in.) 90 (3.54) 110 (4.33)
Firstliftcylinders Stroke, mm (in.) 820 (32.28) 845 (33.27)
Duplex mast ID, mm (in.) 55 (2.17) 60 (2.36)
Secondliftcylinders Stroke, mm (in.) 1590 (62.60) 1585 (62.40)
Triplex mast ID, mm (in.) 90 (3.54) 110 (4.33)
Firstliftcylinders Stroke, mm (in.) 820 (32.28) 845 (33.27)
Triplex mast ID, mm (in.) 60 (2.36) 70 (2.75)
Secondliftcylinders Stroke, mm (in.) 1480 (58.27) 1530 (60.24)
Tilt ID, mm (in.) 100 (3.937)
cylinders Stroke, mm (in.) 120 (4.724)
Hydraulic tank capacity, liter (U.S.gal) 46 (12.1)
BrakesystemHydraulicsystem
+0.5
0
+5
0
+71
0

23. GENERAL INFORMATION
1-16
GC45K STR GC45K GC55K GC55K STR GC60K GC70K GC70K STR
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 (195 ) [2773 ]
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)
+0.5
0
+5
0
+71
0

24. GENERAL INFORMATION
1-17
Truck Models
GC40K GC45KGC35K GC40K
STR SWBItems
Mast model CJ type
Flange ID × flange Outer 118×28×24×13 (4.6×1.1×0.9×0.5)
130×30×26×15
back thickness × (5.1×1.2×1.0×0.6)
flange front thickness ×
Inner, Middle 118×24×24×12 (4.6×0.9×0.9×0.47)
130×26×26×13
web thickness (5.1×1.0×1.0×0.5)
Main Bearing Ball bearing
rollers Diam × width, mm (in.) 118×32 (4.65×1.26) 130×34(5.12×1.34)
Side Bearing Lubricated type needle roller bearing
rollers Diam × width, mm (in.) 52×36 (2.05×1.42)
Lift chains BL834 BL1034
Fork (length × width × thick), mm (in.) 1220×150×50 (48×6×2)
Fork spread (outer width), mm (in.) 1060 (41.5)
Mastandforks

25. GENERAL INFORMATION
1-18
GC45K STR GC45K GC55K GC55K STR 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)

26. 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

27. COOLING SYSTEM
2-1
1 Engine
2 Universal joint
3 Gear pump
4 Fan belt
207009
5 Cooling fan
6 Upper hose
7 Lower hose
8 Radiator
9 Transmission Oil Cooler
4
2 3
• •
•
7
•
•
8•
5
•
9
•
6
1
Description

28. Removal and Installation
Fan Belt Removal
1. Method by removing radiator
COOLING SYSTEM
2-2
207010
Removal sequence
1 Universal joint
2 Tension pulley bolt (loosening only)
3 Belt
Start by:
Remove the radiator cover.
2
3
1

29. COOLING SYSTEM
2-3
Suggestions for removal and installation
(1) Loosen the tension pulley bolt until the fan
tension becomes loose.
(2) Move the tension pulley toward the fan,
then remove the belt.
Installation
To install, follow the reverse of removal procedure
and do the following steps:
(1) Before installing the belt, turn the fan to check
for smooth rotation. Replace the bearing if it
generates abnormal sound.
(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.
CAUTION
Do not loosen the lock bolt to such an
extent that the tension pulley is removed.

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