Gillison's Variety Fabrication GVF 5000 User manual

Forklift Owners Manual
Model Numbers:
GVF 5000
GVF 6000
GVF 8000
3033 BENZIE HWY. � BENZONIA, MI 49616
[phone] � [phone]
email: [email protected]
website: www.gillisons.com
Manual Part Number: GL 11495
Gillison’sVariety
Fabrication, Inc.
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INTRODUCTION 1
SAFETY 2
Intro to Safety 2
Safety Alert Symbol 2
Signal Words 2
General Safety Rules 3
General Safety While Operating 4
Safety While Servicing Machine 5
Electrical System 6
Hydraulic System 6
Fuel System 7
Wheels and Tires 7
Replacement Parts 7
Instruction Decals 8
Serial Number 8
Safety While Operating 9
Load Handling Safety 9
Rules of The Road 10
Modifications 10
Record Retention 10
Ownership Records 10
Fork Safety 11
Fork Inspection 11
Fork Inspection Poster 13
Fork Maintenance 14
Forklift Mast Safety 16
CONTROLS 17
Instrument Panel Diagram 17
Instrument Panel Info 18
Various Controls 19
OPERATION 21
Pre Start Up 21
Starting the Engine 21
Cold Weather Starting Aid 21
Forklift Shutdown 21
Operating the GVF 5000 21
LUBRICATION AND MAINTENANCE 23
Maintenance Chart 23
Lubrication Chart 24
Instructions for Pressure Washing 25
Engine 25
Transmission 27
Health and Safety 27
Lubricants and Capacities 28
Service Schedule 29
Synchro Shuttle Transmission 30
PD 70 FrontAxle 31
Axle Oil Level 31
Lubricants and Capacities 32
Service Schedule 32
SD 55 RearAxle 33
Drive head Axles 33
Greasing Axles 35
Health and Safety 36
Lubricants and Capacities 37
Service Schedules 37
Mast Maintenance 39
Mast Sideshifter Maintenance 43
Brake Fluid 44
Hydraulic System 44
Hydraulic Diagram 45
Electrical 46
Battery 46
4 WD TimingAdvance Electrical
Circuit 47
FNR Neutral Safety Start and Shift Dis-
connect Electrical Circuit 48
Gauges and Indicator Lights Electrical
Circuit 49
Ignition Switch and Power Supply Relay
Electrical Circuit 50
Front and Rear Work Lights Electrical
Circuit 51
12 PWER Adaptor and Alternator Sig-
nal Electrical Circuit 52
Flasher and Turn Signals Electrical
Circuit 53
Main Wiring Harness 54
FNR Switch Wire Harness 55
Work Light Harness 56
Reference Documents 57
Filter Part Numbers 57
WARRANTY 58
Table of Contents
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Gillison Forklift Manual INTRODUCTION - 1
INTRODUCTION
The information in this publication describes the safety
requirements, operation, maintenance and servicing of
the Gillison Forklift. Every effort has been made to pro-
vide correct and concise information to you, the opera-
tor, as available at the date of publication.Your Gillison
dealer is available should items in this book or details of
your machine not be understood.
This book is supplied with each machine to familiarize
the operator with proper instructions needed for opera-
tion and maintenance. Studying and adhering to these
instructions will insure optimum machine performance
and longevity. A machine that is maintained properly
and operated in the intended manner will provide great-
er dividends than one that is neglected and/or operated
in a manner other than as intended. Design and servic-
ing of this machine has been kept as simple as possible
to permit maintenance operations to be carried out with
tools normally available.
This book should be thoroughly read and understood
prior to operation of this machine. Inexperienced op-
erators should study contents of this publication and
receive instruction from an experienced operator when
possible. Your Gillison dealer can assist in areas con-
cerning machine operation and provide details concern-
ing safe operation. It is suggested that this booklet be
kept readily accessible, preferably with the machine,
for future reference if questions or concerns arise. If the
original book should become lost or damaged, consult
your Gillison dealer in regards to acquiring a replace-
ment.
Customers are strongly advised to use an authorized
Gillison dealer in connection with any service problems
and adjustments that may occur.
CAUTION: READ THIS BOOK IN ITS
ENTIRETY PRIOR TO OPERATING
THE MACHINE. Use only parts from
your Gillison dealer for repairs and/or
replacement.
INTRODUCTION
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Gillison Forklift Manual
- SAFETY2
INTRO TO SAFETY
The safety of the operator is one of the main concerns
in designing a new piece of equipment. Designers build
in as many safety features as possible. However, ev-
ery year many accidents occur which could have been
avoided by a few seconds of thought and a more care-
ful approach to handling equipment. You, the operator,
can avoid many accidents by observing the following
precautions. To avoid personal injury, study the follow-
ing precautions and insist those working with you or for
you to follow them.
In order to provide a better view, certain photographs
or illustrations in this manual may show an assembly
with a safety shield removed. However, the equipment
should never be operated in this condition. Keep all
shields in place. If shield removal becomes necessary
for repairs, replace shield prior to further operation.
SAFETYALERT SYMBOL
FIG. 1: This is the safety alert symbol. It means AT-
TENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED! Look for it, both in this manual and on
safety decals on the equipment. It will direct your at-
tention to information that involves your safety and the
safety of others.
SIGNALWORDS
FIG. 2: The words DANGER, WARNING, or CAU-
TION are used with the safety alert symbol. Learn to
recognize these safety alerts, and follow the recom-
mended precautions and safe practices.
DANGER indicates an imminently haz-
ardous situation that, if not avoided, will
result in death or serious injury.
WARNING indicates an imminently
hazardous situation that, if not avoided,
could result in death or serious injury.
CAUTION indicates an imminently
hazardous situation that, if not avoided,
could result in minor or moderate inju-
ry.
Replace any DANGER, WARNING, CAUTION or in-
structional decal that is not readable or is missing. The
locations and part numbers of these decals are identified
later in this section of the manual.
FIG. 1
FIG. 2
SAFETY
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Gillison Forklift Manual SAFETY - 3
GENERAL SAFETY RULES
FIG. 3: Always keep this manual with the machine.
This manual must be made available to the operator of
the machine at all times. Special care must be taken to
keep this manual safe from the weather and in readable
condition.
Read this manual carefully and learn how to use the
machine correctly.
Do not let anyone operate this machine without thor-
ough instruction.
Beware of bystanders, particularly children!Always
look around to make sure that everyone is clear before
starting the engine or moving the machine. This is par-
ticularly important with higher noise levels as you may
not hear people shouting.
FIG. 4: No passengers allowed. Do not carry passen-
gers anywhere on the machine.
Dismount and park machine in the correct manner.
When dismounting and/or leaving the operator’s plat-
form FOR ANY REASON always:
1. Shift to Neutral.
2. Come to a complete stop.
3. Lower forks completely.
4. Park on level ground.
5. Activate parking brake.
6. Shut off engine and remove key.
WARNING: An operator should not use
alcohol or drugs which can affect their
alertnessorcoordination.Anoperatoron
prescription or ‘over the counter’ drugs
needs medical advice on whether or not
he/she can properly operate equipment.
FIG. 5: Wear protective clothing. Do not wear loose
clothing, as this may catch on moving parts of the ma-
chine causing injury.
Always wear protective clothing and appropriate safety
equipment.
It is recommended that suitable protective hearing and
safety glasses be worn.
Do not attempt to service machine, clear obstruc-
tions or unplug blockages with the engine running.
Always shut off the engine first.
Keep all shields and guards in place.
FIG. 3
FIG. 4
FIG. 5
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Gillison Forklift Manual
- SAFETY4
FIG. 6: Additional equipment: A fire extinguisher
and first aid kit should be carried with the machine or
be kept readily available at all times.
Have emergency telephone numbers for immediate ac-
cess.
GENERAL SAFETY WHILE OPERATING
CAUTION: READ THIS BOOK IN ITS
ENTIRETY PRIOR TO OPERATING
MACHINE.
Keep the machine properly maintained. Do not operate
a machine when it is broken or has missing parts. Make
sure that the maintenance procedures in this operator’s
book are completed before using the machine.
Check all controls regularly and adjust where neces-
sary.
Periodically check all nuts and bolts for tightness, espe-
cially wheel nuts.
Clear the area. Ensure that all bystanders, particularly
children, are at a safe distance before starting the en-
gine.
FIG. 7: Be aware of electrocution haz-
ards. To prevent injury or death from
electrocution:
Stay away from overhead power lines
when operating forklift in raised po-
sition. This machine is not grounded.
Electrocution can occur without direct
contact.
Be observant of the operating area and terrain.
Watch for holes, rocks or other hidden hazards. AL-
WAYS inspect area prior to operation.
FIG. 8: Be aware of side hill hazard. To
prevent serious injury or death:
DO NOT operate near edge of banks. Setback distance
from bank should equal or exceed the overall height of
the bank.
DO NOT operate on steep slopes as overturning may
result.
If necessary to cross a steep slope, avoid turning uphill.
Slow down and make a wide turn. Travel directly up or
down the slope, never cross it. Keep the heavy end of
the machine on the uphill side.
FIG. 6
FIG. 7
FIG. 8
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Gillison Forklift Manual SAFETY - 5
FIG. 9: Do not use starting fluid. Starting fluid must
only be used when an ether-start aid is fitted as original
equipment by the manufacturer or when installed by a
dealer as an approved accessory.
The forklift is equipped with an intake heater. This
must be removed prior to the use of starting fluid or
ether aid.
Use of starting fluid on an engine equipped with an in-
take heater can result in severe engine damage.
Make sure there is plenty of ventilation. Never oper-
ate the engine in a closed building.
Always start and operate engine in a well-ventilated
area.
If in an enclosed area, vent the exhaust to the outside.
Do not tamper with or modify the exhaust system with
unapproved extensions.
SAFETY WHILE SERVICING THE MACHINE
Stop the machine. DO NOT service the machine
while the engine is running or hot, or if the machine
is in motion.
NOTE: When making major repairs or
complicated adjustments, it is recommend-
ed that you consult your Gillison Dealer
and have the work carried out by trained
personnel.
The following precautions should be observed. These
have been arranged by machine area or component.
Cooling System
FIG. 10: DO NOT remove the radiator cap (see 1)
when the engine is running or hot.
DO NOT add coolant to the radiator while the engine
is running.
Before removing the radiator cap, turn the cap slowly to
relieve the pressure.
When adding coolant, make sure coolant being added is
compatible and will mix with existing coolant.
FIG. 9
FIG. 10
E
T
H
E
R
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Gillison Forklift Manual
- SAFETY6
Electrical System
FIG. 11: To prevent serious injury or death from ex-
ploding gases:
Do not work on batteries without proper
instruction and training.
FIG. 12: Before making adjustments or servicing the
electrical system, disconnect the battery negative (-)
cable (see 1) first to prevent short circuits.
Keep sparks, flames and cigarettes away. Use a flash-
light to check the battery electrolyte level if necessary.
Do not produce sparks with cable clamps when charg-
ing the battery or starting the machine engine with a
slave (jumper) battery.
Batteries contain sulfuric acid electrolyte. Always wear
protective clothing and eye protection when servicing.
In case of electrolyte contact, rinse area with plenty of
water and seek medical attention.
Batteriesproduceexplosivehydrogengaswhencharged.
Charge in area with adequate ventilation. Halt charging
if battery temperature exceeds 52°
Wash hands after handling battery.
Hydraulic System
FIG. 13: High pressure fluid hazard. To prevent seri-
ous injury or death:
Relieve pressure on system before re-
pairing, adjusting or disconnecting.
Wear proper hand and eye protection
when searching for leaks. Use wood or
cardboard instead of hands.
Keep all components in good repair.
Ensure that all hydraulic connections are tight.
Relieve all pressures before disconnecting hoses or
lines. Escaping oil under pressure can cause serious in-
jury.
All fluids should be handled with care. If you are in-
jured by or swallow any fluid, seek medical attention
immediately and show the label on the product.
Fluid escaping from a very small hole can be almost
invisible and can penetrate the skin causing serious in-
jury. Keep hands and body away from pin holes and
nozzles which eject fluids under high pressure. When
FIG. 11
FIG. 12
FIG. 13
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Gillison Forklift Manual SAFETY - 7
checking for leaks always use a piece of cardboard or
wood. Never use your hands to find a pressure leak.
If ANY fluid is injected into the skin, it must be attend-
ed to by a doctor immediately.
Fuel System
FIG. 14: Diesel fuel is flammable and must be han-
dled with care.
Never refuel or service the fuel system on the machine
while smoking or when near open flames or sparks.
Never refuel the machine while the engine is running.
DO NOT use a fuel can unless necessary.
Always clean up any spilled fuel.
Fuel system components rely upon clean fuel for lubri-
cation and optimum performance. Extreme care must
be taken to prevent contamination from dirt and mois-
ture so as to prevent damage to system.
Fuel injection system servicing must be referred to your
Gillison Dealer. Unauthorized servicing may void all
warranties.
Wheels and Tires
Do not attempt to service a tire unless you have the
proper equipment and experience to perform the job.
Have the work carried out by your Gillison Dealer or a
qualified repair service.
The machine must be supported on suitable blocks or
stands, NOT a hydraulic jack.
When seating tire beads onto rims, never exceed 2.4 bar
(35 psi) or the maximum inflation pressure specified on
the tire. Inflation beyond this maximum pressure may
break the bead, or even the rim, with dangerous, explo-
sive force.
When preparing a calcium chloride solution for fluid
blasting the tires, NEVER pour water onto the calcium
chloride. A chlorine gas can be generated which is poi-
sonous and explosive. This can be avoided by slowly
adding calcium chloride flakes to water and stirring un-
til they are dissolved.
Wear suitable protective clothing, gloves and eye/face
protection.
Replacement Parts
FIG. 15: Where replacement parts are necessary for
periodic maintenance and servicing, replacement parts
from Gillison’s must be used to restore your equipment
to original specifications.
FIG. 14
FIG. 15
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Gillison Forklift Manual
- SAFETY8
Gillison’s will not claim responsibility for installation
of unapproved parts and/or accessories and damages as
a result of their usage.
INSTRUCTION DECALS
FIG. 16: Location of all instruction decals are provided
as a reference. Corresponding numbers show where
decals belong on the machine. Replace any decals that
are damaged, missing or are not readable. Consult your
dealer.
Each decal below has its part number labeled below the
decal.
FIG. 16
1. SP 6255 2. SP 6260 3. SP 6210
4. SP 6207 5. SP 6285 6. SP 6315
7. SP 6208 8. SP 6211
9. SP 6265
10. SP 6290 11. SP 6250
12. SP 6270 13. SP 6221 14. SP 6275
15. SP 6320 16. SP 6325
Decal Locations
17. FOPS decal SP 6300
Nameplate - SP 6305
Includes important information such as: Warning, Model,
Serial Number, Type, Tire Pressure & Size, Mast Type,
Degrees Max Back Tilt, Date of Manufacture, Drive Tread,
Truck Wt., Capacity
1 3
4
10
12
17
7
8
Nameplate
&
&
2
511
9
6
16
15
13
&
&
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Gillison Forklift Manual SAFETY - 9
SERIAL NUMBER
Location of serial number is on the nameplate and is
provided as a reference.
See FIG. 16
SAFETY WHILE OPERATING
FIG.17 Review ENTIRE operator’s
manual before operating this machine.
Fasten seat belt securely before starting.
Keep both hands on controls at all times
when operating this vehicle.
Carry load low.
Use low range for hillside or ramp op-
eration.
Block elevated components before ser-
vicing equipment.
Do not leave machine with mast raised.
Do not allow riders.
Do not leave machine with engine run-
ning.
Heed these safety rules:
Inspect the forklift each day.
Perform scheduled maintenance to ensure optimum
performance.
Wear proper clothing.
a. No baggy clothing
FIG. 17
b. Use eye protection
c. Use hard hat
Fasten seat belt securely before starting the forklift.
When mounting and dismounting the forklift, use the
steps and hand holds provided. Do not use steering
wheel or controls.
Keep body, feet and hands inside the operators’ plat-
form when the forklift is running.
Do not operate the forklift under the influence of any
kind of drugs or alcohol that impair judgment or per-
formance.
Do not operate the forklift without overhead guard in place.
Lower forks completely to the ground when adjusting
and when work is completed.
Do not allow anyone to stand under or work under
raised forks.
Never raise persons with the forks.
Never leave forklift running unattended. Always set the
parking brake, shift to Neutral, shut off engine and re-
move the key.
LOAD HANDLING SAFETY
Heed these safety rules:
When lifting or loading, tilt the mast back.
Use caution when tilting mast forward to ensure load
does not shift off forks.
Never carry maximum rated load with center of load 24
inches above forks.
Avoid sudden starts and stops to prevent load from
shifting.
Lift loads on level ground to prevent rollover.
Always watch for overhead obstructions when operat-
ing and lifting loads.
Do not exceed the lifting capacity of the forklift.
Always ensure forks of the proper capacity are used.
Never interchange forks with forks of a different rat-
ing.
Do not add or subtract weight from the counterweight
box.
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Gillison Forklift Manual
- SAFETY10
RULES OF THE ROAD
Before operating your forklift on a public road, a num-
ber of precautions must be taken.
Familiarize yourself with, and obey, all
laws appropriate to your machine.
Disengage FWD.
Make sure any required clearance flags
orhazard lightsareinplaceand in work-
ing order.
Clean off all reflectors and road lights,
front and rear, and be certain they are in
working order.
Make sure machine is equipped with a
slow moving vehicle sign (SMV) and oth-
er marking materials recommended for
improved visibility unless prohibited by
law. FIG. 18
Know the route you will be traveling.
Use flashing lights when traveling on
roads, day or night, unless prohibited by
law.
Observe all local or national regulations
regarding the road speed of your ma-
chine.
Use extreme caution when transporting
on snow covered or slippery roads.
Wait for traffic to clear before entering a
public road.
Bewareofblindintersections.Slowdown
until you have a clear view.
DO NOT attempt to pass at any intersec-
tion.
Slow down for turns and curves.
Make wide, gentle turns.
Signal your intent to slow, stop or turn.
Shift to a lower gear before going up or
down hills.
Keep machine in gear. DO NOT coast
with the clutch disengaged or the trans-
mission in neutral.
Stay out of the path of on coming traf-
fic.
Drive defensively. Anticipate what other
drivers might do.
Watch out for overhead obstructions.
MODIFICATIONS
Modification or alteration of the forklift shall be made
only with prior written consent from Gillison’s Variety
Fabrication Inc.
Altering safety devices shall be prohibited.
RECORD RETENTION
The owner shall retain the following records for at least
3 years:
A. Purchase Information
B. Records of persons trained upon de-
livery of the GVF 5000 Forklift
C. Written records of frequent inspec-
tions, maintenance performed and parts
replaced
OWNERSHIP RECORDS
When a change of ownership of a GVF 5000 Forklift
occurs, it is the responsibility of the seller to notify Gil-
lison’s Variety Fabrication Inc. with the following in-
formation within 60 days of the sale:
A. Serial number of machine
B. Name & address of new owner
FIG.18
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Gillison Forklift Manual SAFETY - 11
FORK SAFETY
Fork Inspection
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Gillison Forklift Manual
- SAFETY12
Fork Inspection Cont.
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Gillison Forklift Manual SAFETY - 13
Fork Inspection Poster
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Gillison Forklift Manual
- SAFETY14
Fork Maintenance
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Gillison Forklift Manual SAFETY - 15
Fork Maintenance Cont.
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Gillison Forklift Manual
- SAFETY16
FORKLIFT MAST SAFETY
Refer to the following illustrations for mast safety:
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Gillison Forklift Manual CONTROLS - 17
INSTRUMENT PANEL DIAGRAM
1
2
34
5
10 11 12
9
6
7
15
13
8
14
1. Ignition Switch
2. High Transmission Temperature Light (Red)
3. Low Transmission Oil Pressure Light (Red)
4. Low Engine Oil Pressure Light (Red)
5. Parking Brake Light (Red)
6. Engine Preheat Light (Red)
7. Engine Water Temperature Gauge
8. Hour meter Gauge
9. Voltmeter Gauge
10. Fuel Gauge
11. Four Wheel Drive Switch
12. Front and Rear Work Lights
13. Warning Lights Switch
14. Turn Signal Switch
15. 12 V Power Source
CONTROLS
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Gillison Forklift Manual
- CONTROLS18
INSTRUMENT PANEL INFO
1. Ignition switch
• Position 1 – Stop
• Position 2 – Ignition powers all electrical
equipment
• Position 3 – Start
Turn to position 1 to shut off the engine and all
of the electrical equipment.
Forklift runs in Position 2.
2. High Transmission Temperature Light (Red)
If this light is on, stop the engine and investi-
gate the reason for the high transmission tem-
perature.
3. Low Transmission Oil Pressure Light (Red)
The warning light illuminates when the key is
in the On position. After the engine starts up,
the light should extinguish in seconds. Stop en-
gine and investigate the low transmission pres-
sure if the light does not go off.
4. Low Engine Oil Pressure Light (Red)
The warning light illuminates when key is in
the On position. After engine startup the light
should extinguish in seconds. Stop engine and
investigate the reason for the loss of pressure if
the light does not go off.
5. Parking Brake Light (Red)
When illuminated, parking brake is engaged.
When extinguished, parking brake is disen-
gaged.
6. Engine Preheat Light (Red)
When illuminated, Preheat is on.
Maximum preheat time is 30 seconds.
7. Engine Water Temperature Gauge
Ensure engine is operating in Normal tempera-
ture zone. Stop engine if needle moves above
250°F.
Allow engine to warm up to above 160°F be-
fore operating.
8. Hour meter Gauge
Records hours of engine operation.
Observe this gauge for periodic maintenance
schedules.
9. Voltmeter Gauge
Indicates battery charge.
Normal readings are between 12-15 volts.
10. Fuel Gauge
11. Four Wheel Drive Switch
When light is illuminated, four-wheel drive is
on.
12. Front and Rear Work Lights
When switched ahead, front lights are illumi-
nated.
When switched back, front and rear lights are
illuminated.
When in the center position, lights are off.
13. Warning Lights Switch
14. Turn Signal Switch
When switched to left position, left hand lights
flash.
When switched to right position, right hand
lights flash.
When in the center position, the switch is off.
15. 12V Power Source
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