Gillison's Variety Fabrication GVF 5000 Owner's Manual
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Gillison's Variety Fabrication GVF 5000 Owner's Manual

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Gillison's
Forklift Owners Manual
FIRST PAGE
Manual Part Number: GL 11495
Model Numbers:
GVF 5000
GVF 6000
GVF 8000
3033 BENZIE HWY.
BENZONIA, MI 49616
�
(231) 882-5921
�
email: gillison@gillisons.com
website: www.gillisons.com
PREVIOUS
PAGE
Variety
Fabrication, Inc.
(800) 392-6059
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Summary of Contents for Gillison's Variety Fabrication GVF 5000

  • Page 1 Gillison’s Variety Fabrication, Inc. Forklift Owners Manual Manual Part Number: GL 11495 Model Numbers: GVF 5000 GVF 6000 GVF 8000 3033 BENZIE HWY. BENZONIA, MI 49616 � (231) 882-5921 (800) 392-6059 � email: gillison@gillisons.com website: www.gillisons.com PREVIOUS FIRST PAGE NEXT PAGE...

  • Page 2: Table Of Contents

    OPERATION Reference Documents Pre Start Up Filter Part Numbers Starting the Engine Cold Weather Starting Aid WARRANTY Forklift Shutdown Operating the GVF 5000 LUBRICATION AND MAINTENANCE Maintenance Chart Lubrication Chart Instructions for Pressure Washing Engine Transmission Health and Safety Lubricants and Capacities...

  • Page 3: Introduction

    Gillison Forklift Manual INTRODUCTION - 1 INTRODUCTION 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.

  • Page 4: Safety

    Gillison 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 care- ful approach to handling equipment.

  • Page 5: General Safety Rules

    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.

  • Page 6: General Safety While Operating

    Gillison Forklift Manual - SAFETY FIG. 6: Additional equipment: A fi re extinguisher and fi rst 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...

  • Page 7: Safety While Servicing Machine

    Gillison Forklift Manual SAFETY - 5 FIG. 9: Do not use starting fl uid. Starting fl uid must only be used when an ether-start aid is fi tted as original equipment by the manufacturer or when installed by a dealer as an approved accessory. The forklift is equipped with an intake heater.

  • Page 8: Electrical System

    Gillison 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) fi...

  • Page 9: Fuel System

    Gillison Forklift Manual SAFETY - 7 checking for leaks always use a piece of cardboard or wood. Never use your hands to fi nd a pressure leak. If ANY fl uid is injected into the skin, it must be attend- ed to by a doctor immediately.

  • Page 10: Instruction Decals

    Gillison Forklift Manual - SAFETY Gillison’s will not claim responsibility for installation Decal Locations 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.

  • Page 11: Safety While Operating

    Gillison Forklift Manual SAFETY - 9 SERIAL NUMBER b. Use eye protection Location of serial number is on the nameplate and is c. Use hard hat provided as a reference. Fasten seat belt securely before starting the forklift. See FIG. 16 When mounting and dismounting the forklift, use the steps and hand holds provided.

  • Page 12: Rules Of The Road

    OWNERSHIP RECORDS Use extreme caution when transporting When a change of ownership of a GVF 5000 Forklift on snow covered or slippery roads. occurs, it is the responsibility of the seller to notify Gil- lison’s Variety Fabrication Inc. with the following in- Wait for traffi...

  • Page 13: Fork Safety

    Gillison Forklift Manual SAFETY - 11 FORK SAFETY Fork Inspection PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...
  • Page 14 Gillison Forklift Manual - SAFETY Fork Inspection Cont. PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 15: Fork Inspection Poster

    Gillison Forklift Manual SAFETY - 13 Fork Inspection Poster PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 16: Fork Maintenance

    Gillison Forklift Manual - SAFETY Fork Maintenance PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...
  • Page 17 Gillison Forklift Manual SAFETY - 15 Fork Maintenance Cont. PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 18: Forklift Mast Safety

    Gillison Forklift Manual - SAFETY FORKLIFT MAST SAFETY Refer to the following illustrations for mast safety: PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 19: Controls

    Gillison Forklift Manual CONTROLS - 17 CONTROLS INSTRUMENT PANEL DIAGRAM 9. Voltmeter Gauge 1. Ignition Switch 10. Fuel Gauge 2. High Transmission Temperature Light (Red) 3. Low Transmission Oil Pressure Light (Red) 11. Four Wheel Drive Switch 12. Front and Rear Work Lights 4.

  • Page 20: Instrument Panel Info

    Gillison Forklift Manual - CONTROLS INSTRUMENT PANEL INFO Allow engine to warm up to above 160° F be- fore operating. 1. Ignition switch 8. Hour meter Gauge • Position 1 – Stop Records hours of engine operation. • Position 2 – Ignition powers all electrical equipment Observe this gauge for periodic maintenance schedules.

  • Page 21: Various Controls

    Gillison 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 Gillison 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 – Seat Belts FIG.

  • Page 23: Operation

    8. Release all hydraulic pressure by operating NOTE: Max crank time = 30 seconds mast control levers. Observe indicator lights and gauges to ensure OPERATING GVF 5000 everything is operating correctly. Learn about all controls, have knowl- Transmission pressure, and engine oil pressure edge of the machine and it’s workings,...
  • Page 24 Gillison Forklift Manual - OPERATION 6. Operation of Parking Brake FIG. 23 Release Bin Clamp Clamp Left Right Engaged FIG. 23 Disengaged Side Shift 7. Four Wheel Drive Operation 4. Raise the mast until forks are a safe distance from the ground. On forklifts equipped with the four- wheel drive option, the four-wheel drive Always carry loads low to ground to...

  • Page 25: Lubrication And Maintenance

    Gillison Forklift Manual LUBRICATION & MAINTENANCE - 23 LUBRICATION & MAINTENANCE MAINTENANCE CHART Maintenance Chart 1000 2000 Page in ITEM Daily 50 hrs 100 hrs 500 hrs this manual Tire Pressure Engine ( refer to engine manual) Transmission 27 - 30 Hydraulic Oil Level Filter Change Suction Strainer...
  • Page 26 Gillison Forklift Manual - LUBRICATION & MAINTENANCE Grease Tilt Cylinder & Mast Pivot - every 100 hrs. Forks Radiator Fill Break Fluid Reservoir Air Cleaner Mast Rear Axle Front Axle PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 27: Lubrication Chart

    Gillison Forklift Manual LUBRICATION & MAINTENANCE - 25 LUBRICATION CHART E. Fuel fi lters FIG. 34 & 35 INSTRUCTIONS FOR PRESSURE WASHING F. Fuel lift pump FIG. 35 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 28 Gillison Forklift Manual - LUBRICATION & MAINTENANCE H. Radiator Fill Tank FIG. 37 I. Air Cleaner FIG. 37 & 39 J. Hydraulic Oil Fill FIG. 38 FIG. 37 Radiator Pressure Cap FIG. 39 FIG. 38 PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 29: Transmission

    Gillison Forklift Manual LUBRICATION & MAINTENANCE - 27 TRANSMISSION Health and Safety PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 30: Lubricants And Capacities

    Gillison Forklift Manual - LUBRICATION & MAINTENANCE Lubricants and Capacities (Transmission) PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 31: Service Schedule

    Gillison Forklift Manual LUBRICATION & MAINTENANCE - 29 Service Schedule (Transmission) PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 32: Synchro Shuttle Transmission

    Gillison Forklift Manual - LUBRICATION & MAINTENANCE Synchro Shuttle Transmission PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 33: Pd70 Front Axle

    Gillison Forklift Manual LUBRICATION & MAINTENANCE - 31 PD70 FRONT AXLE Axle Oil Level PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 34: Lubricants And Capacities

    Gillison Forklift Manual - LUBRICATION & MAINTENANCE Lubricants & Capacities (Front Axle) Service Schedules (Front Axle) PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 35: Sd55 Rear Axle

    Gillison Forklift Manual LUBRICATION & MAINTENANCE - 33 SD55 REAR AXLE Drive head Axles PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...
  • Page 36 Gillison Forklift Manual - LUBRICATION & MAINTENANCE Drive head Axles Cont. (Rear Axle) PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 37: Greasing Axles

    Gillison Forklift Manual LUBRICATION & MAINTENANCE - 35 Greasing Axles (Rear Axle) PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 38: Health And Safety

    Gillison Forklift Manual - LUBRICATION & MAINTENANCE Health & Safety (Rear Axle) PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 39: Lubricants And Capacities

    Gillison Forklift Manual LUBRICATION & MAINTENANCE - 37 Lubricants & Capacities (Rear Axle) Service Schedules (Rear Axle) PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...
  • Page 40 Gillison Forklift Manual - LUBRICATION & MAINTENANCE Service Schedules Cont. (Rear Axle) PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 41: Mast Maintenance

    Gillison Forklift Manual LUBRICATION & MAINTENANCE - 39 MAST MAINTENANCE PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...
  • Page 42 Gillison Forklift Manual - LUBRICATION & MAINTENANCE MAST MAINTENANCE CONT. PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...
  • Page 43 Gillison Forklift Manual LUBRICATION & MAINTENANCE - 41 MAST MAINTENANCE CONT. PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...
  • Page 44 Gillison Forklift Manual - LUBRICATION & MAINTENANCE MAST MAINTENANCE CONT. PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 45: Mast Sideshifter Maintenance

    Gillison Forklift Manual LUBRICATION & MAINTENANCE - 43 MAST SIDESHIFTER MAINTENANCE PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 46: Brake Fluid

    Gillison Forklift Manual - LUBRICATION & MAINTENANCE BRAKE FLUID • Change hydraulic oil every 1000 hours FIG. • Check level every 100 hours • Clean suction strainer every 1000 hours • Change oil every 1500 hours • Use Brake Fluid Mobile 424 Hydraulic Oil Fill see FIG.

  • Page 47: Hydraulic Diagram

    Gillison Forklift Manual LUBRICATION & MAINTENANCE - 45 Hydraulic Diagram PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 48: Electrical

    Gillison Forklift Manual - LUBRICATION & MAINTENANCE ELECTRICAL Battery Fuses FIG. 44 , 45 & 45A See FIG. 46 & 12 Battery Box Fuse Access Panel FIG. 46 FIG. 44 FNR Switch Shift Disconnect 4 WD Timing Advance 12 V Power Plug 10 AMP 7.5 AMP Flashers...
  • Page 49 Gillison Forklift Manual LUBRICATION & MAINTENANCE - 47 4 WD and Timing Advance Electrical Circuit PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...
  • Page 50 Gillison Forklift Manual - LUBRICATION & MAINTENANCE F. N. R. , Neutral Safety Start and Shift Disconnect Electrical Circuit PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...
  • Page 51 Gillison Forklift Manual LUBRICATION & MAINTENANCE - 49 Gauges and Indicator Lights Electrical Circuit PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 52: Electrical Circuit

    Gillison Forklift Manual - LUBRICATION & MAINTENANCE Ignition Switch and Power Supply Relay Electrical Circuit PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...
  • Page 53 Gillison Forklift Manual LUBRICATION & MAINTENANCE - 51 Front and Rear Work Lights Electrical Circuit PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 54: Pwer Adaptor And Alternator Sig

    Gillison Forklift Manual - LUBRICATION & MAINTENANCE 12 PWER Adaptor and Alternator Signal Electrical Circuit PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 55: Flasher And Turn Signals Electrical Circuit

    Gillison Forklift Manual LUBRICATION & MAINTENANCE - 53 Flasher and Turn Signals Electrical Circuit PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 56: Main Wiring Harness

    Gillison Forklift Manual - LUBRICATION & MAINTENANCE Main Wiring Harness Part Number GL11325 PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 57: Fnr Switch Wire Harness

    Gillison Forklift Manual LUBRICATION & MAINTENANCE - 55 FNR Switch Wire Harness Part Number GL11330 1 Pc PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 58: Work Light Harness

    Gillison Forklift Manual - LUBRICATION & MAINTENANCE Work Light Harness Part Number GL11340 2 Pc PREVIOUS FIRST PAGE NEXT PAGE LAST PAGE PAGE...

  • Page 59: Reference Documents

    Gillison Forklift Manual PARTS - 63 REFERENCE DOCUMENTS: FILTER PART NUMBERS GVF 5000 Parts Manual Engine Oil Filter Part Number: GL11485 Part Number: GL 11670 GVF 5000 Service Manual Fuel Prefi lter and Water Trap Part Number: GL11490 Part Number: GL 11675...

  • Page 60: Warranty

    Gillison Forklift Manual - WARRANTY G V F 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 fi...

This manual is also suitable for:

Gvf 6000Gvf 8000

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