Service Manual

Chassis & Mast

GC35K AT87-00001-up GC55K AT88-00001-up
AT87A-00001-10230 AT88A-00001-10230
AT87A-10231-up AT88A-10231-up

GC40K AT87-00001-up GC55K STR AT88-00001-up

AT87A-00001-10230 AT88A-00001-10230
AT87A-10231-up AT88A-10231-up

GC40K STR AT87-00001-up GC60K AT89-00001-up

AT87A-00001-10230 AT89A-00001-10230
AT87A-10231-up AT89A-10231-up

GC45K SWB AT87-00001-up GC70K AT89-00001-up

AT87A-00001-10230 AT89A-00001-10230
AT87A-10231-up AT89A-10231-up

GC45K 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
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.
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.
WARNING
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 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.
10. Always use tools that are in good condition and 18. Loose or damaged fuel, lubricant and hydraulic
be sure you understand how to use them before lines, tubes and hoses can cause fires. Do not
performing any service work. bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect
11. Reinstall all fasteners with same part number.
lines, tubes and hoses carefully. Do not check
Do not use lesser quality fastener if
for leaks with your hands. Pin hole (very small)
replacements are necessary. Do not mix metric
leaks can result in a high velocity oil stream
fastener with standard nuts and bolts.
that will be invisible close to the hose. This oil
12. If possible, make all repairs with the truck can penetrate the skin and cause personal injury.
parked on a level, hard surface. Block truck so Use cardboard or paper to locate pin hole leaks.
it does not roll while working on or under truck.
19. Tighten connections to the correct torque. Make
13. Disconnect battery and discharge any sure that all heat shields, clamps and guards are
capacitors (electric trucks) before starting to installed correctly to avoid excessive heat,
work on truck. Hang “Do not Operate” tag in vibrations or rubbing against other parts during
the Operator’s Compartment. operation. Shields that protect against oil spray
14. Repairs, which require welding, should be onto hot exhaust components in event of a line,
performed only with the benefit of the tube or seal failure, must be installed correctly.
appropriate reference information and by 20. Relieve all pressure in air, oil or water systems
personnel adequately trained and before any lines, fittings or related items are
knowledgeable in welding procedures. disconnected or removed. Always make sure all
Determine type of metal being welded and raised components are blocked correctly and be
select correct welding procedure and alert for possible pressure when disconnecting
electrodes, rods or wire to provide a weld metal any device from a system that utilizes pressure.
strength equivalent at least to that of parent
21. Do not operate a truck if any rotating part is
metal.
damaged or contacts any other part during
15. Do not damage wiring during removal operation. Any high speed rotating component
operation. Reinstall the wiring so it is not that has been damaged or altered should be
damaged nor it will be damaged in operation by checked for balance before reusing.
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.
 HOW TO READ THIS MANUAL
Disassembly diagram (example)

1 Each disassembly diagram is followed

by Disassembly sequence and
4 Suggestions disassembly.
3

Disassembly sequence

1 Cover, Bolt, Washer (part name)

▲

2 Output shaft (part name)

▲

▲
Suggestion for disassembly
(1) Output shaft removal
Unit: mm (in.)
Clearance 0.020 to 0.105
A
between (0.00079 to 0.00413)
cylinder and 0.15
piston B
(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,

ELECTRICAL SYSTEM 3
Electrical system schematic

POWER TRAIN 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

Tank, Pump, Control valve, Lift and tilt cylinders, Flow regulator valve,
HYDRAULIC SYSTEM 10
Down safety valve

MASTS AND FORKS Simplex Mast, Duplex Mast, Triplex Mast 11

Inspection standards, Periodic replacement of parts, Lubrication standards,

SERVICE DATA Main component weight, Tightening torque for standard bolts and nuts, 12
Special tools
 GENERAL INFORMATION

Vehicle Exterior .......................................................................................................................... 1 - 1

Models ........................................................................................................................................ 1 - 1 1

Serial Number Locations ............................................................................................................ 1 - 2

Dimensions.................................................................................................................................. 1 - 5

Technical Data ............................................................................................................................ 1 - 6

 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
GC40K AT87A-00001~10230
STR AT87A-10231-up
GC45K 1-Speed
SWB
GC45K
GM4.3L Gasoline Engine
GC55K AT88-00001-up
AT88A-00001~10230
GC55K AT88A-10231-up
STR
GC60K
GC70K Automatic AT89-00001-up
2-Speed AT89A-00001~10230
GC70K AT89A-10231-up
STR

1
GENERAL INFORMATION

Serial Number Locations

Name Plate Chassis Serial Number Gasoline Engine Serial Number

Mast Number Transmission 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 J K

I D

G H

C L M
E 206999

1-5
GENERAL INFORMATION

Technical Data Unit: mm (in.)

Ref. Truck Models GC40K GC45K

No. GC35K GC40K 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)
Duplex mast
B (Floor to 3.0 m (118 in.) mast 2.8 m (112 in.) mast
forktop) 800 (31.5) 920 (36.2)
Triplex mast
4.0 m (157 in.) mast 4.3 m (169 in.) mast
C Fork length 1220 (48)
Tilt angle 5/10 Simplex, Duplex mast
D
(forward – backward) deg. 6/5 Triplex mast
E Overall length (OLH) 2510 (98.5) 2550 (100) 2360 (93) 2620 (103)
Overall width Standard 1180 (46.5)
F
(outside) Wide tread (option) 1270 (50.0)
Overall height
G 2155 (85.0)
(to top of mast lowered)
Overall height
H 2155 (85.0)
(to top of overhead guard)

Simplex mast 4250 (167) 4125 (162)

I Overall height 4250 (167) 4080 (160.6)

(mast extended) Duplex mast 3.0 m (118 in.) mast 2.8 m (112 in.) mast
5250 (206.7) 5560 (218.9)
Triplex mast 4.0 m (157 in.) mast 4.3 m (169 in.) mast
Standard 940 (37.0)
J Tread (front)
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)

1-6
 GENERAL INFORMATION

Unit: mm (in.)

GC55K GC70K
GC45K GC55K STR GC60K GC70K 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)

1-7
GENERAL INFORMATION

Technical Data

GC35K GC40K GC40K GC45K

Truck Models STR SWB

kg/mm 3500/500 4000/500 4500/600

Capacity/load center (lb/in.) (7000/24) (8000/24) (10000/24)
Work performance

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)
Loaded 19 (12.0) 18.5 (11.5)
Travel Powershift km/h
speed transmission (mph)
models No load 19.5 (12.5)
Traveling performance

Minimum turning radius 2235 (88.0) 2285 (90) 2090 (82.5) 2340 (92.0)
Minimum mm (in.)
intersecting isle Standard 2245 (88.5) 2295 (90.5) 2100 (82.5) 2350 (92.5)

Gradeability at 1 mph Loaded 37 33 32 27

(1.6 km/h) No loaded 23.8 21.1 21.5 17.7
%
Loaded 42 37 36 30
Gradeability at stall
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
(lowered) 2200 (86.5) 2350 (92.5)

Overall To top of mast

height (extended) 4250 (167.5) 4130 (162.5)

To top of
2155 (85.0)
Dimensions

overhead guard mm (in.)

Wheelbase 1575 (62.0)
Standard 940 (37.0)
Front Wide tread
Tread (optional) 1040 (41.0)

Rear 980 (38.5)

Overhang Rear 485 (18.8) 525 (20.3) 335 (13.3) 565 (22.1)
Underclearance (at frame) 150 (5.9)
Single
Front wheels 22×9×16
Tire size mm
Rear 18×7×12.12
Service weight
-no load 5200 (11500) 5600 (12300) 5700 (12700) 6500 (14300)
Weight

Single wheels
kg (lb)
(without load) Axle Front 2050 (4600) 2025 (4400) 2150 (4900) 1925 (4200)
loading Rear 3150 (6900) 3575 (7900) 3550 (7800) 4575 (10100)
1-8
 GENERAL INFORMATION

GC55K GC70K
GC45K GC55K STR GC60K 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)
1-9
GENERAL INFORMATION

MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems.
Truck Models
GC35K GC40K GC40K GC45K
Items STR SWB
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)
Engine

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
Type Pointless
Ignition system

Distributor Type of spark advance

control Internal solid state circuit, ECU Controlled
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
system
Fuel

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.

GC55K GC70K
GC45K GC55K STR GC60K 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

1-11
GENERAL INFORMATION

MPFI specs in Bold. If not indicated in bold, specs are for Carbureted and MPFI systems.
Truck Models
GC35K GC40K GC40K GC45K
Items STR SWB
Type Pressure feed
Engine lubrication system

Oil pump Gear pump

Oil filter Paper element
Oil cooler Oil to water type
Oil pan 4.2 (1.1)
Refill capacities,
Oil filter & cooler 0.8 (0.2)
liter (U.S.gal)
Total 5.0 (1.3)
Type Forced circulation
Cooling system

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
Battery

Voltage, V 12
Capacity, AH (5Hr) 45
Type 3-Phase AC
Alternator

Manufacturer MANDO, AC Delco

Rated output, V-A 12-50, 12-70
Regulator Built in IC type
Type Electromagnetic
Starter

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.

GC55K GC70K
GC45K GC55K STR GC60K 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

1-13
GENERAL INFORMATION

Truck Models
GC35K GC40K GC40K GC45K
Items STR SWB
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 Forward 2.898
Ratios
Reverse 2.907
Power train

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)
Steering system

Power cylinder ID ×
rod diam., mm (in.) 85×60 (3.3×2.4)

Power Effective stroke, mm (in.) 155 (6.1)

steering Relief pressure,
kPa (kgf/cm2) [psi] 11768 (120) [1706]
Flow rate, liter (U.S.gal)/min 23 (6.07)
Front axle Full-floating tubular type
Rear axle Elliott type
Traveling system

Front Fixed type

Suspension system
Rear Center-pivot type
Toe-in, mm (in.) 0
Wheel Camber 1.0°
alignment Caster 0°
Kingpin inclination 0°

1-14
 GENERAL INFORMATION

GC55K GC70K
GC45K GC55K STR GC60K 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°

1-15
GENERAL INFORMATION

Truck Models
GC35K GC40K GC40K GC45K
Items STR SWB
Type Self-adjusting, duo-servo
Drum diameter, mm (in.) 317.5 (12.50)
Brake system

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
brake 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 KFP3240 AMBAS
Gear
pump Rated discharge,
liter (U.S.gal)/rpm 98 (25.89)/2450
Drive line Universal joint
Type 6000-C193
Control
valve Relief pressure, +0.5 +5 +71
MPa (kgf/cm2) [psi] 19.12 0 (195 0 ) [2773 0 ]

Flow Type Variable (Adjustable)

Hydraulic system

regulator Regulated flow rate,

valve liter (U.S.gal)/min 100 (26.4) 115 (30.38)

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)
First lift cylinders Stroke, mm (in.) 820 (32.28) 845 (33.27)
Duplex mast ID, mm (in.) 55 (2.17) 60 (2.36)
Second lift cylinders Stroke, mm (in.) 1590 (62.60) 1585 (62.40)
Triplex mast ID, mm (in.) 90 (3.54) 110 (4.33)
First lift cylinders Stroke, mm (in.) 820 (32.28) 845 (33.27)
Triplex mast ID, mm (in.) 60 (2.36) 70 (2.75)
Second lift cylinders 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)

1-16
 GENERAL INFORMATION

GC55K GC70K
GC45K GC55K STR GC60K 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
+0.5 +5 +71
19.12 0 (195 0 ) [2773 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
GENERAL INFORMATION

Truck Models
GC35K GC40K GC40K GC45K
Items STR SWB
Mast model CJ type
Flange ID × flange 130×30×26×15
Outer 118×28×24×13 (4.6×1.1×0.9×0.5) (5.1×1.2×1.0×0.6)
back thickness ×
flange front thickness × 130×26×26×13
web thickness Inner, Middle 118×24×24×12 (4.6×0.9×0.9×0.47) (5.1×1.0×1.0×0.5)
Mast and forks

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)

1-18
 GENERAL INFORMATION

GC55K GC70K
GC45K GC55K STR GC60K 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 2

Fan Belt Inspection .............................................................................................................. 2 - 4
Fan Belt Adjustment ............................................................................................................ 2 - 4
 COOLING SYSTEM

Description

•
5

• 8
•

1
•

•
7

• •

2 3

207009

1 Engine 5 Cooling fan

2 Universal joint 6 Upper hose
3 Gear pump 7 Lower hose
4 Fan belt 8 Radiator
9 Transmission Oil Cooler

2-1
COOLING SYSTEM

Removal and Installation

Fan Belt Removal
1. Method by removing radiator

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 .................................................................................................... 3-3

Console Box ........................................................................................................................ 3-3
Components in Console Box................................................................................................ 3-4
Combination Meter .............................................................................................................. 3-5 3

Major Electrical Components .................................................................................................... 3-6

Starter Switch (with Anti-restart Lock)................................................................................ 3-6
Lighting Switch ................................................................................................................... 3-7
Fuse Box .............................................................................................................................. 3-8
Spare Terminals .................................................................................................................... 3-8

Battery Maintenance .................................................................................................................. 3 - 9

Typical Open Circuit Voltage...................................................................................................... 3 - 10

Lamp Bulb Specifications .......................................................................................................... 3 - 12

Electrical System Schematics .................................................................................................... 3 - 13

Chassis (2007-01~up) .......................................................................................................... 3 - 13
Engine (2007-01~up)............................................................................................................ 3 - 15
Chassis w/ Neutral Safety Switch (2005-11~2006-12)........................................................ 3 - 17
Chassis w/o Neutral Safety Switch (2004-01~2005-10)...................................................... 3 - 19
Engine (2004-01~2006-12) .................................................................................................. 3 - 21
Chassis (1998-01~2003-12) ................................................................................................ 3 - 23
Engine, Gasoline (1998-01~2003-12) .................................................................................. 3 - 25
Engine, LPG (1998-01~2003-12) ........................................................................................ 3 - 27
 ELECTRICAL SYSTEM

Description
Console Box 4

1 Engine coolant temperature gauge 5

2 Speed selector switch
(Only for 6 & 7 ton models) 3
1
(moved to head guard pillar in 2006)
3 Fuel gauge 7
4 Service hourmeter
5 OK monitor (Indicator Lights) 6
6 Starter switch
7 Light switch
8 Fuse box 2
8
102868

OK monitor

1 2 3 4 5 6 7 8

102869
Function

No. Indicator light OFF On or flickering Remarks

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 Option
7 Malfunction indicator lamp (moved to head guard pillar in 2006) Normal Service engine
8 Engine coolant level warning light Normal Low 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 ❙
(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

3
⎧
⎪
⎪
⎪
⎪
⎪
⎪
⎪
⎨
⎪
⎪
⎪
⎪
⎪
⎪
⎩

4 1
207751

Disassembly Reassembly
1. Disconnect the electrical wires at connectors 1. To reassemble the console box, follow the
2. Remove screws 2 (four) securing the cover. reverse of disassembly procedure.
3. Remove screws 3 (six) and separate the front
and rear panels.
4. Remove screws 4 (four) securing the instrument
panel.

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

3-3
ELECTRICAL SYSTEM

Components in Console Box

3
2
1
5

207752

1 Power relay 4 Light switch

2 Power relay 5 Starter switch
3 Turn signal relay 6 Fuses

3-4
 ELECTRICAL SYSTEM

Combination Meter
Disassembly

2
3

8
9
206480

Sequence
1 Instrument panel 6 Meter case
2 Dial 7 Printed circuit
3 Engine coolant temperature gauge 8 Bulb
4 Service hour meter 9 Socket
5 Fuel gauge

CAUTION Bulb replacement

Be careful not to damage the printed circuit For bulb replacement, remove the socket from
when disassembling the combination the printed circuit by turning it counterclockwise.
meter. 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)

(START) B

203561A
Connection
Terminal B M S
Starter, neutral switch
Key Component Fuse box, battery, Fuse box, fuel-cut (powershift
position alternator solenoid transmission)
● (OFF) ●
❙ (ON) ● ●
(START) ● ● ●

3-6
Thank you very much
for your reading.
Please Click Here
Then Get More
Information.