Gillison's Variety Fabrication Tier IV GL 11491 User manual

Tier IV
GVF Rough Terrain Forklift
Owners Manual
Model Numbers:
TIER IV
GVF 5000
GVF 6000
GVF 8000
Manual Part Number:
GL 11491
3033 B
enzie
H
wy
. B
enzonia
, Mi 49616 231-882-5921
Fax [phone]
Gillison’s Va r i e t y
Fabrication, Inc.
email: [email protected]
online: www.gillisons.com
GVF
PREVIOUS
NEXT
LAST
INDEX

Table of Contents
TABLE OF CONTENTS
INTRODUCTION 1
SAFETY 2
Forklift Mast Safety 16
Fork Safety 11
General Safety Rules 3
General Safety While Operating 4
Instruction Decals 8
Intro to safety 2
Load Handling Safety 9
Modications 10
OwnershipRecords 10
RecordRetention 10
RulesoftheRoad 10
Safety Alert Symbol 2
Safety While Operating 9
Safety While Servicing the Machine 5
Serial Number 9
Signal Words 2
CONTROLS 17
Display Screen Information 18
Display Screen - Pop Up Warning Lights 21
Instrument Panel Diagram 17
Various Controls 25
OPERATION 28
Cold Weather Starting 28
Forklift Shutdown 28
Operating GVF Forklift 28
Pre Start Up 28
Starting The Engine 28
LUBRICATION & MAINTENANCE 30
Grease Points 32
Hydraulic System 54
Instructions for Pressure Washing 34
Lubrication&MaintenanceChart 30
Lubrication & Maintenance Reference Diagram 31
Mast Maintenance 49
PD70FrontAxle 41
SD55RearAxle 43
ELECTRICAL 56
REFERENCE 63
Filter Part Numbers 63
Manuals 63
GVF WARRANTY 64
PREVIOUS
NEXT
LAST
INDEX

GVF Rough TerrainTier IV 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
provide correct and concise information to you, the
operator, 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
operation 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 greater dividends than one that is neglected
and/or operated in a manner other than as intended.
Design and servicing 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
operators should study contents of this publication
andreceiveinstructionfromanexperiencedoperator
when possible. Your Gillison dealer can assist in areas
concerning machine operation and provide details
concerning 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 replacement.
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.
GVF Tier IV Turbo Rough Terrain Forklift
PREVIOUS
NEXT
LAST
INDEX

- SAFETY2GVF Rough TerrainTier IV Forklift Manual
SAFETY
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,
every year many accidents occur which could have
been avoided by a few seconds of thought and a more
careful approach to handling equipment. You, the
operator, can avoid many accidents by observing the
following precautions. To avoid personal injury, study
the following 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.
SAFETY ALERT SYMBOL
FIG. 1: This is the safety alert symbol. It means
ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED! Look for it, both in this manual and on
safety decals on the equipment. It will direct your
attention to information that involves your safety and
the safety of others.
SIGNAL WORDS
FIG.2:The words DANGER,WARNING,or CAUTION
are used with the safety alert symbol.Learn to recognize
these safety alerts, and follow the recommended
precautions and safe practices.
DANGER indicates an imminently
hazardous 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, may result in minor or
moderate injury.
Replace any DANGER, WARNING, CAUTION or
instructional decal that is not readable or is missing.
The locations and part numbers of these decals are
identiedlaterinthissectionofthemanual.
FIG. 1
FIG. 2
PREVIOUS
NEXT
LAST
INDEX

SAFETY - 3
GVF Rough TerrainTier IV Forklift Manual
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
thorough 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
particularly important with higher noise levels as you
may not hear people shouting.
FIG. 4: No passengers allowed. Do not carry passengers
anywhere on the machine.
Dismount and park machine in the correct manner.
When dismounting and/or leaving the operator’s
platform 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 alertness or coordination. An
operator on 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
machine 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 obstructions
or unplug blockages with the engine running. Always
shutofftheenginerst.
Keep all shields and guards in place.
FIG. 3
FIG. 4
FIG. 5
PREVIOUS
NEXT
LAST
INDEX

- SAFETY4GVF Rough TerrainTier IV Forklift Manual
FIG. 6:Additionalequipment:A reextinguisher and
rstaidkitshouldbecarriedwiththemachineorbe
kept readily available at all times.
Have emergency telephone numbers for immediate
access.
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 necessary.
Periodically check all nuts and bolts for tightness,
especially wheel nuts.
Clear the area. Ensure that all bystanders, particularly
children,are at a safe distance before starting the engine.
FIG. 7: Be aware of electrocution
hazards. To prevent injury or death
from electrocution:
Stay away from overhead power
lines when operating forklift in
raised position. 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. ALWAYS
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.9:Donotusestartinguid.Startinguidmustonly
be used when an ether-start aid is tted as original
equipment by the manufacturer or when installed by a
FIG. 6
FIG. 7
FIG. 8
PREVIOUS
NEXT
LAST
INDEX

SAFETY - 5
GVF Rough TerrainTier IV Forklift Manual
dealer as an approved accessory.
The forklift is equipped with an intake heater. This
mustberemovedpriortotheuseofstartinguidor
ether aid.
Use of starting uid on an engine equipped with an
intake heater can result in severe engine damage.
Make sure there is plenty of ventilation. Never operate
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
recommended 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
PREVIOUS
NEXT
LAST
INDEX

- SAFETY6GVF Rough TerrainTier IV Forklift Manual
Electrical System
FIG. 11: To prevent serious injury or death from
exploding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)rsttopreventshortcircuits.
Keepsparks,amesandcigarettesaway.Useaashlight
to check the battery electrolyte level if necessary.
Do not produce sparks with cable clamps when
charging 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.
Batteries produce explosive hydrogen gas when
charged. Charge in area with adequate ventilation. Halt
chargingifbatterytemperatureexceeds52°.
Wash hands after handling battery.
Hydraulic System
FIG.13:Highpressureuidhazard.Topreventserious
injury or death:
Relieve pressure on system before
repairing, 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
injury.
All uids should be handled with care. If you are
injuredbyorswallowanyuid,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
injury. Keep hands and body away from pin holes and
nozzleswhichejectuidsunderhighpressure.When
FIG. 11
FIG. 12
FIG. 13
PREVIOUS
NEXT
LAST
INDEX

SAFETY - 7
GVF Rough TerrainTier IV Forklift Manual
checking for leaks always use a piece of cardboard or
wood.Neveruseyourhandstondapressureleak.
IfANYuidisinjectedintotheskin,itmustbeattended
to by a doctor immediately.
Fuel System
FIG.14:Dieselfuelisammableandmustbehandled
with care.
Never refuel or service the fuel system on the machine
whilesmokingorwhennearopenames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
lubrication and optimum performance. Extreme care
must be taken to prevent contamination from dirt and
moisture 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qualied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inationpressurespecied
on the tire. Ination beyond this maximum pressure
may break the bead, or even the rim, with dangerous,
explosiveforce.
When preparing a calcium chloride solution for uid
blasting the tires, NEVER pour water onto the calcium
chloride. A chlorine gas can be generated which is
poisonousandexplosive.Thiscanbeavoidedbyslowly
adding calcium chloride akes to water and stirring
until 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specications.
FIG. 14
FIG. 15
PREVIOUS
NEXT
LAST
INDEX

- SAFETY8GVF Rough TerrainTier IV Forklift Manual
1
1
2
2
3
3
4
4
A A
B B
C C
D D
SHEET 1 OF 1
DRAWN
CHECKED
QA
MFG
APPROVED
matt 12/15/2010
DWG NO
GVF9500_11_MANUAL
TITLE
SIZE
C
SCALE
REV
1
1
2
2
3
3
4
4
A A
B B
C C
D D
SHEET 1 OF 1
DRAWN
CHECKED
QA
MFG
APPROVED
matt 12/15/2010
DWG NO
GVF9500_11_MANUAL
TITLE
SIZE
C
SCALE
REV
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, Se-
rial 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
&
PREVIOUS
NEXT
LAST
INDEX