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Gillison's Variety Fabrication GVF Tier III Owner's Manual

Rough terrain forklift
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GVF Rough Terrain Forklift
Gillison's
3033 B
enzie
F
231-882-5637
ax
INDEX
GVF
Tier III
Owners Manual
Manual Part Number: GL 11497
Revised 11/13/2014
Model Numbers:
GVF 5000
GVF 6000
GVF 8000
H
. B
wy
enzonia
800-392-6059
PREVIOUS
V ariety
Fabrication, Inc.
, Mi 49616
231-882-5921
email: info@gillisons.com
online: www.gillisons.com
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LAST

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Summary of Contents for Gillison's Variety Fabrication GVF Tier III

  • Page 1 Tier III GVF Rough Terrain Forklift Owners Manual Gillison’s Manual Part Number: GL 11497 V ariety Revised 11/13/2014 Model Numbers: Fabrication, Inc. GVF 5000 GVF 6000 GVF 8000 3033 B , Mi 49616 231-882-5921 enzie enzonia email: info@gillisons.com 231-882-5637 800-392-6059 online: www.gillisons.com INDEX PREVIOUS...

  • Page 2: Table Of Contents

    Table of Contents TABLE OF CONTENTS INTRODUCTION Filter Part Numbers SAFETY Hydraulic System Forklift Mast Safety Instructions for Pressure Washing Fork Safety Lubrication & Maintenance Chart General Safety Rules Mast Maintenance General Safety While Operating PD70 Front Axle Instruction Decals Reference Documents: 50 Intro to safety 2 SD55 Rear Axle Load Handling Safety 9 Tier III Air Cleaner...

  • Page 3: Introduction

    Design and servic- ing of this machine has been kept as simple as possible GVF Tier III Turbo Rough Terrain Forklift to permit maintenance operations to be carried out with tools normally available.

  • Page 4: Safety

    GVF Rough Terrain Forklift Manual - SAFETY 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, ev- ery year many accidents occur which could have been avoided by a few seconds of thought and a more careful approach to handling equipment.

  • Page 5: General Safety Rules

    GVF Rough Terrain 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.

  • Page 6: General Safety While Operating

    GVF Rough Terrain Forklift Manual - SAFETY 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.

  • Page 7: Safety While Servicing The Machine

    GVF Rough Terrain Forklift Manual SAFETY - 5 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.
  • Page 8 GVF Rough Terrain Forklift Manual - SAFETY 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.
  • Page 9 GVF Rough Terrain 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.

  • Page 10: Instruction Decals

    GVF Rough Terrain Forklift Manual - SAFETY Decal Locations 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 provid- ed as a reference.

  • Page 11: Load Handling Safety

    GVF Rough Terrain Forklift Manual SAFETY - 9 SERIAL NUMBER c. Use hard hat Location of serial number is on the nameplate and is Fasten seat belt securely before starting the forklift. provided as a reference. When mounting and dismounting the forklift, use the See FIG.

  • Page 12: Modifications

    GVF Rough Terrain Forklift Manual - SAFETY Familiarize yourself with, and obey, all Signal your intent to slow, stop or turn. laws appropriate to your machine. Shift to a lower gear before going up or Disengage FWD. down hills. Make sure any required clearance flags Keep machine in gear.

  • Page 13: Fork Safety

    GVF Rough Terrain Forklift Manual SAFETY - 11 FORK SAFETY Fork Inspection INDEX PREVIOUS NEXT LAST...
  • Page 14 GVF Rough Terrain Forklift Manual - SAFETY Fork Inspection Cont. INDEX PREVIOUS NEXT LAST...
  • Page 15 GVF Rough Terrain Forklift Manual SAFETY - 13 Fork Inspection Poster INDEX PREVIOUS NEXT LAST...
  • Page 16 GVF Rough Terrain Forklift Manual - SAFETY Fork Maintenance INDEX PREVIOUS NEXT LAST...
  • Page 17 GVF Rough Terrain Forklift Manual SAFETY - 15 Fork Maintenance Cont. INDEX PREVIOUS NEXT LAST...

  • Page 18: Forklift Mast Safety

    GVF Rough Terrain Forklift Manual - SAFETY FORKLIFT MAST SAFETY Refer to the following illustrations for mast safety: INDEX PREVIOUS NEXT LAST...

  • Page 19: Controls

    GVF Rough Terrain Forklift Manual CONTROLS - 17 CONTROLS INSTRUMENT PANEL DIAGRAM INSTRUMENT PANEL INFORMATION 1. Push button Start Ignition Switch Turn Clockwise to Run position. 1. Push button Start 9. Voltmeter Gauge 10. Fuel Gauge 2. High Transmission Temperature Light (Red) 11.
  • Page 20 GVF Rough Terrain Forklift Manual - CONTROLS Push to start. (First, turn ignition switch clock- Indicates battery charge. wise to Run position.) Normal readings are between 12-15 volts. 2. High Transmission Temperature Light (Red) 10. Fuel Gauge If this light is on, stop the engine and investi- gate the reason for the high transmission tem- 11.

  • Page 21: Various Controls

    GVF Rough Terrain Forklift Manual CONTROLS - 19 VARIOUS CONTROLS 1. Optional Preheat Switch Push to activate preheat. Maximum time is 30 seconds. 2. Forward, Neutral, Reverse Switch FIG. 19 Center position is Neutral. 3. Horn Switch FIG. 19 FIG. 21 Push to activate. 6.
  • Page 22 GVF Rough Terrain Forklift Manual - CONTROLS 8. Brake Pedal FIG. 24 12. Suspension Seat FIG. 27 Push to apply service brakes. A – Slide adjustment B – Weight adjustment Push down to increase stiffness C – Back Rest Adjustment D –...

  • Page 23: Operation

    GVF Rough Terrain Forklift Manual OPERATION - 21 OPERATION FORKLIFT SHUTDOWN (read CONTROLS section first) ( Read CONTROLS section first. ) 1. Reduce engine speed to idle. Make sure PRE START UP forklift has come to a complete stop. Check engine oil, transmission, hydraulic oil and radiator fluid level. 2. Move gearshift lever to Neutral. 3.
  • Page 24 GVF Rough Terrain Forklift Manual - OPERATION 7. Four Wheel Drive Operation Release Bin Clamp Clamp  Left Right Engaged FIG. 23 Disengaged Side Shift On forklifts equipped with the four- Always carry loads low to ground to wheel drive option, the four-wheel drive prevent roll over and overhead obstruc- is engaged by switching the rocker tions.

  • Page 25: Lubrication & Maintenance

    GVF Rough Terrain Forklift Manual LUBRICATION & MAINTENANCE - 23 LUBRICATION & MAINTENANCE LUBRICATION & MAINTENANCE CHART Page in 100 500 1000 1500 2000 Item Daily 50 hrs this hrs hrs hrs hrs hrs manual Tire Pressure              ...
  • Page 26 GVF Rough Terrain Forklift Manual - LUBRICATION & MAINTENANCE F. Fuel lift pump FIG. 35 INSTRUCTIONS FOR PRESSURE WASHING G. Fuel Tank FIG. 36 & 36 A When pressure washing, protect and DO NOT direct the jet on the following components: Alternator, Axle pivot pins, Radiator, Starter motor, Hydraulic oil cooler, Transmission oil cooler, Instrument pan-...

  • Page 27: Tier Iii Air Cleaner

    GVF Rough Terrain Forklift Manual LUBRICATION & MAINTENANCE - 25 I. Air Cleaner FIG. 38 & 39 J. Hydraulic Oil Fill FIG. 38 A TRANSMISSION TIER III AIR CLEANER Air cleaner assembly GL 12260 FIG. 37 Radiator Pressure Cap FIG. 37 A FIG.
  • Page 28 GVF Rough Terrain Forklift Manual - LUBRICATION & MAINTENANCE Health and Safety INDEX PREVIOUS NEXT LAST...
  • Page 29 GVF Rough Terrain Forklift Manual LUBRICATION & MAINTENANCE - 27 Lubricants and Capacities - Transmission INDEX PREVIOUS NEXT LAST...
  • Page 30 GVF Rough Terrain Forklift Manual - LUBRICATION & MAINTENANCE Service Schedule - Transmission INDEX PREVIOUS NEXT LAST...
  • Page 31 GVF Rough Terrain Forklift Manual LUBRICATION & MAINTENANCE - 29 Synchro Shuttle Transmission INDEX PREVIOUS NEXT LAST...

  • Page 32: Pd70 Front Axle

    GVF Rough Terrain Forklift Manual - LUBRICATION & MAINTENANCE PD70 FRONT AXLE Axle Oil Level INDEX PREVIOUS NEXT LAST...
  • Page 33 GVF Rough Terrain Forklift Manual LUBRICATION & MAINTENANCE - 31 Lubricants & Capacities - Front Axle Service Schedules - Front Axle INDEX PREVIOUS NEXT LAST...

  • Page 34: Sd55 Rear Axle

    GVF Rough Terrain Forklift Manual - LUBRICATION & MAINTENANCE SD55 REAR AXLE Drive head Axles INDEX PREVIOUS NEXT LAST...
  • Page 35 GVF Rough Terrain Forklift Manual LUBRICATION & MAINTENANCE - 33 Drive head Axles Cont. - Rear Axle INDEX PREVIOUS NEXT LAST...
  • Page 36 GVF Rough Terrain Forklift Manual - LUBRICATION & MAINTENANCE Greasing Axles - Rear Axle INDEX PREVIOUS NEXT LAST...
  • Page 37 GVF Rough Terrain Forklift Manual LUBRICATION & MAINTENANCE - 35 Health & Safety - Rear Axle INDEX PREVIOUS NEXT LAST...
  • Page 38 GVF Rough Terrain Forklift Manual - LUBRICATION & MAINTENANCE Lubricants & Capacities - Rear Axle Service Schedules - Rear Axle INDEX PREVIOUS NEXT LAST...
  • Page 39 GVF Rough Terrain Forklift Manual LUBRICATION & MAINTENANCE - 37 Service Schedules Cont. - Rear Axle INDEX PREVIOUS NEXT LAST...

  • Page 40: Mast Maintenance

    GVF Rough Terrain Forklift Manual - LUBRICATION & MAINTENANCE MAST MAINTENANCE INDEX PREVIOUS NEXT LAST...
  • Page 41 GVF Rough Terrain Forklift Manual LUBRICATION & MAINTENANCE - 39 Mast maintenance cont. INDEX PREVIOUS NEXT LAST...
  • Page 42 GVF Rough Terrain Forklift Manual - LUBRICATION & MAINTENANCE Mast maintenance cont. INDEX PREVIOUS NEXT LAST...
  • Page 43 GVF Rough Terrain Forklift Manual LUBRICATION & MAINTENANCE - 41 Mast maintenance cont. INDEX PREVIOUS NEXT LAST...

  • Page 44: Brake Fluid

    GVF Rough Terrain Forklift Manual - LUBRICATION & MAINTENANCE BRAKE FLUID • Change hydraulic oil filter every 500 hours FIG. 42 • Check level every 100 hours • Change fluid every 1500 hours • Use Brake Fluid Mobile 424 see FIG. 40 Filter Head GH 11604 Brake Fluid Dealer Part GL 11690 FIG. 40 FIG.
  • Page 45 GVF Rough Terrain Forklift Manual LUBRICATION & MAINTENANCE - 43 Hydraulic Diagram INDEX PREVIOUS NEXT LAST...

  • Page 46: Electrical

    GVF Rough Terrain Forklift Manual - LUBRICATION & MAINTENANCE ELECTRICAL Battery FUSES SEE FIG. 44 SEE FIG. 45 & FIG.12 Fuse Access Panel Battery Box FIG. 44 FIG. 45 FIG. 12 INDEX PREVIOUS NEXT LAST...
  • Page 47 GVF Rough Terrain Forklift Manual LUBRICATION & MAINTENANCE - 45 4 WD and Timing Advance Electrical Circuit INDEX PREVIOUS NEXT LAST...
  • Page 48 GVF Rough Terrain Forklift Manual - LUBRICATION & MAINTENANCE Gauges and Indicator Lights Electrical Circuit INDEX PREVIOUS NEXT LAST...
  • Page 49 GVF Rough Terrain Forklift Manual LUBRICATION & MAINTENANCE - 47 Ignition Switch and Power Supply Relay Electrical Circuit INDEX PREVIOUS NEXT LAST...
  • Page 50 GVF Rough Terrain Forklift Manual - LUBRICATION & MAINTENANCE Front and Rear Work Lights Electrical Circuit INDEX PREVIOUS NEXT LAST...
  • Page 51 GVF Rough Terrain Forklift Manual LUBRICATION & MAINTENANCE - 49 Trans Brake Electrical Circuit INDEX PREVIOUS NEXT LAST...

  • Page 52: Filter Part Numbers

    GVF Rough Terrain Forklift Manual - LUBRICATION & MAINTENANCE REFERENCE DOCUMENTS: FILTER PART NUMBERS GVF 5000 Forklift Parts Manual Engine Oil Filter Part Number: GL11485 Part Number: GL 11670 GVF 5000 Forklift Service Manual Tier III Fuel Prefilter and Water Trap Part Number: GL11490 Part Number: GL 12535 Transmission SS 700 Service Manual Fuel Filter 5 Micron Part Number: 9803/9070 Part Number: GL 11680 Front Axle PD 70 Service Manual Transmission Oil Filter Part Number: 9803/9100 Part Number: GL 11685 Rear Axle SD 55 Service Manual...

  • Page 53: Gvf Warranty

    GVF Rough Terrain Forklift Manual WARRANTY - 51 GVF WARRANTY Gillison’s Variety Fabrication, Inc. will replace or repair at GVF option, any GVF manufactured item that is, in the opinion of GVF, defective in material or workmanship for a period of 1 year or 1,000 hours, whichever comes first, from the date of purchase, and is returned to the GVF plant or service center at the expense of the customer. This warranty is made expressly in lieu of all other warranties expressed or implied. The Warranty Registration card must be completed in full and returned to GVF within thirty (30) days of date of delivery to qualify for this warranty.

This manual is also suitable for:

Gvf 5000Gvf 6000Gvf 8000

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