Gillison's Variety Fabrication Tier IV GL 11491 Owner's Manual
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Gillison's Variety Fabrication Tier IV GL 11491 Owner's Manual

Gvf rough terrain forklift
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GVF
GVF Rough Terrain Forklift
Gillison's
3033 B
enzie
F
231-882-5637
ax
INDEX
Tier IV
Owners Manual
Manual Part Number:
GL 11491
Model Numbers:
TIER IV
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 Tier IV GL 11491

  • Page 1 Tier IV GVF Rough Terrain Forklift Owners Manual Manual Part Number: GL 11491 Gillison’s Model Numbers: TIER IV V ariety GVF 5000 Fabrication, Inc. 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 Hydraulic System SAFETY Instructions for Pressure Washing Forklift Mast Safety Lubrication & Maintenance Chart Fork Safety Lubrication & Maintenance Reference Diagram 31 General Safety Rules Mast Maintenance General Safety While Operating PD70 Front Axle Instruction Decals SD55 Rear Axle Intro to safety 2 ELECTRICAL Load Handling Safety REFERENCE 63...

  • Page 3: Introduction

    GVF Rough Terrain Tier 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.

  • Page 4: Safety

    GVF Rough Terrain Tier IV 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, every 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 Tier IV 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 Tier IV 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 access. GENERAL SAFETY WHILE OPERATING CAUTION: READ THIS BOOK ENTIRETY PRIOR TO OPERATING MACHINE.

  • Page 7: Safety While Servicing The Machine

    GVF Rough Terrain Tier IV Forklift Manual SAFETY - 5 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 intake heater can result in severe engine damage. Make sure there is plenty of ventilation.
  • Page 8 GVF Rough Terrain Tier IV Forklift Manual - SAFETY 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) first to prevent short circuits.
  • Page 9 GVF Rough Terrain Tier IV 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 attended to by a doctor immediately. Fuel System FIG. 14: Diesel fuel is flammable and must be handled 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 Tier IV Forklift Manual - SAFETY Gillison’s will not claim responsibility for installation of Decal Locations 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.

  • Page 11: Load Handling Safety

    GVF Rough Terrain Tier IV Forklift Manual SAFETY - 9 SERIAL NUMBER a. No baggy clothing Location of serial number is on the nameplate and is b. Use eye protection provided as a reference. c. Use hard hat See FIG. 16 Fasten seat belt securely before starting the forklift.

  • Page 12: Modifications

    GVF Rough Terrain Tier IV Forklift Manual - SAFETY RULES OF THE ROAD DO NOT attempt to pass at any intersection. Before operating your forklift on a public road, a Slow down for turns and curves. number of precautions must be taken. Familiarize yourself with, and obey, Make wide, gentle turns.

  • Page 13: Fork Safety

    GVF Rough Terrain Tier IV Forklift Manual SAFETY - 11 FORK SAFETY Fork Inspection Fork Inspection Log Forks in use shall be inspected at intervals of not more than 12 months (for single shift operations) or whenever any defect or permanent deformation is detected. Certain applications will require more frequent inspections, and possibly non-destructive testing methods to check for cracks.
  • Page 14 GVF Rough Terrain Tier IV Forklift Manual - SAFETY Fork Inspection Cont. USER FORK WEAR STANDARDS Reprinted from ASME/ANSI B56. 1-2000 carrier shall be checked. If the difference in tip heights 6.2.8 Inspection and Repair of Forks in Service on Fork exceeds 3% of the length of the blade, the set of forks Lift Trucks shall not be returned to service until repaired in accor-...
  • Page 15 GVF Rough Terrain Tier IV Forklift Manual SAFETY - 13 Fork Inspection Poster Fork Check Inspection Locking Mechanism Check Fork Marking a n d g u i d e l i n e s Check Angle Check Hooks 1. Wear 2.
  • Page 16 GVF Rough Terrain Tier IV Forklift Manual - SAFETY Fork Maintenance FORK MAINTENANCE AND INSPECTION OUTSIDE INSIDE Fork calipers perform two tasks at once. JAWS JAWS They measure the thickness of the fork arm 100% shank (Fig. 1) and then automatically indicate what a 10% wear factor would be when the calipers are applied to the blade cross section (Fig.
  • Page 17 GVF Rough Terrain Tier IV Forklift Manual SAFETY - 15 FORK MAINTENANCE AND INSPECTION Fork Maintenance Cont. FORKS ARE A WEARING PART Once in service, the bottom of forks may wear badly. This wear may not be noticed, but the consequences are. There are ASME/ANSI Finished forks are usually painted red, yellow or black when the truck specifications for User Fork Wear Standards.

  • Page 18: Forklift Mast Safety

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

  • Page 19: Controls

    GVF Rough Terrain Tier IV Forklift Manual CONTROLS - 17 CONTROLS INSTRUMENT PANEL DIAGRAM See FIG. 19 FIG. 19 1. Display - see detailed instructions after this page. 9. Low Transmission Oil Pressure LIght (Red) 2. Ignition 10. Parking Brake Light (Red) 3. 4 WD 11. Air Filter Dirty/Change Light (Red) 4. Lights 12. Engine Temperature 5.

  • Page 20: Display Screen Information

    GVF Rough Terrain Tier IV Forklift Manual - CONTROLS DISPLAY SCREEN INFORMATION 1. Start Up Screen ENGINE TEMPERATURE ENGINE OIL PRESSURE ENGINE HOURS FUEL LEVEL 0=EMPTY 100=FULL 2. Main Screen - shows engine temperature, engine oil pressure, engine hours & fuel level. INDEX PREVIOUS NEXT...
  • Page 21 GVF Rough Terrain Tier IV Forklift Manual CONTROLS - 19 ENGINE WATER TEMPERATURE ENGINE HOURS MAX TEMPERATURE IS 230 DEGREES FARENHEIGHT. IF REACHED THEN ENGINE DERATES. KEY TO ACCESS NAVIGATION SCREEN TAKES USER TO SCROLL DOWN SCROLL UP MAIN MENU WINDOW WINDOW 3.
  • Page 22 GVF Rough Terrain Tier IV Forklift Manual - CONTROLS PRESS KEY TO ACCESS CONTRAST SCREEN 5. Push key on the far left once to get contrast adjustment option to appear. Press that key to get contrast adjustment to appear. BRIGHTNESS CONTRAST ADJUSTMEN ADJUSTMENT...

  • Page 23: Display Screen - Pop Up Warning Lights

    GVF Rough Terrain Tier IV Forklift Manual CONTROLS - 21 DISPLAY SCREEN - POP UP WARNING LIGHTS See FIG. 20 LIGHT ILLUMINATES WHEN TEMPERATURE IS HIGH LIGHT ILLUMINATES WHEN PRESSURE LOW THE LIGHT SHOULD EXTINGUISH IN SECONDS AFTER ENGINE START UP LIGHT ILLUMINATES WHEN PARK BRAKE IS APPLIED THE LH KEY WILL RESET THE POP UP WINDOW FOR...
  • Page 24 GVF Rough Terrain Tier IV Forklift Manual - CONTROLS MAIN MENU BASIC SETUP ALLOWS ACCESS TO DATE AND TIME ADJUSTMENT DIAGNOSTICS VIEW ERROR CODES SCREEN SETUP NOT USED SYSTEM SETUP NOT USED 7. Main Menu 8. Basic Setup is where time and date can be set. INDEX PREVIOUS NEXT...
  • Page 25 GVF Rough Terrain Tier IV Forklift Manual CONTROLS - 23 9. Time and date set - under Basic Setup DIAGNOSTICS SCREEN FAULT LOG ALLOWS YOU TO VIEW PREVIOUS AND ACTIVE ERROR CODES 10. Fault Log under the Diagnostics Screen is where previous and active error codes can be viewed.
  • Page 26 GVF Rough Terrain Tier IV Forklift Manual - CONTROLS FAULT MENU SCREEN SELECT ACTIVE OR PREVIOUS FAULTS ENTER KEY BACK KEY SCROLL UP SCROLL DOWN 11. Under the Fault Menu screen is where you can choose to see either Active Faults or Previous Faults. ACTIVE FAULT CODE SCREEN BACK KEY...

  • Page 27: Various Controls

    GVF Rough Terrain Tier IV Forklift Manual CONTROLS - 25 VARIOUS CONTROLS 1. Forward, Neutral, Reverse Switch FIG. 19 Center position is Neutral. 2. Horn Switch FIG. 19 Push to activate. FIG. 21 5. Lift Valve FIG. 22 A – Lift B –...
  • Page 28 GVF Rough Terrain Tier IV Forklift Manual - CONTROLS 7. Brakes FIG. 24 & FIG. 24A 8. Throttle FIG. 24 Brake Pedal Locking Pin FIG. 24A THROTTLE FIG. 24 LH BRAKE RH BRAKE BRAKE PEDAL LOCKING PIN. PULL OUT UNTIL IT DETENTS FOR TURNING BRAKES.
  • Page 29 GVF Rough Terrain Tier IV Forklift Manual CONTROLS - 27 9. Gear Shifter FIG. 25 12. Seat FIG. 28 A – Seat slide adjustment B – Seat suspension adjustment C – Seat belt FIG. 25 10. Shift Disconnect Switch FIG. 26 Push to shift transmission.

  • Page 30: Operation

    - OPERATION GVF Rough Terrain Tier IV Forklift Manual OPERATION FORKLIFT SHUTDOWN ( Read CONTROLS section first. ) (read CONTROLS section first) PRE START UP 1. Reduce engine speed to idle. Make sure forklift has come to a complete stop. Check engine oil, transmission, hydraulic oil 2. Move gearshift lever to Neutral. and radiator fluid level.
  • Page 31 GVF Rough Terrain Tier IV Forklift Manual OPERATION - 29 6. Operation of Parking Brake FIG. 23 Release Bin Clamp Clamp  Left Right Engaged FIG. 23 Disengaged Side Shift 7. Four Wheel Drive Operation Always carry loads low to ground On forklifts equipped with the four- to prevent roll over and to avoid overhead obstructions.

  • Page 32: Lubrication & Maintenance

    GVF Rough Terrain Tier IV Forklift Manual - LUBRICATION & MAINTENANCE LUBRICATION & MAINTENANCE LUBRICATION & MAINTENANCE CHART * First 100 hours service only to be completed by your distributor. As  100  500  1000  2000  Reference  Item Daily Weelky Monthly Needed Hours Hours...

  • Page 33: Lubrication & Maintenance Reference Diagram

    GVF Rough Terrain Tier IV Forklift Manual LUBRICATION & MAINTENANCE - 31 LUBRICATION & MAINTENANCE REFERENCE DIAGRAM Forks Grease Points: Mast - 2 qty. Grease Points: Brake Pedal - 2 qty. Grease Points: Front Drive Shaft - 3 qty. Grease Points: Tilt Cylinder - 4 qty. Transmission Battery Fuel Fill...

  • Page 34: Grease Points

    GVF Rough Terrain Tier IV Forklift Manual - LUBRICATION & MAINTENANCE GREASE POINTS Grease Point Locations Brake Pedal Hood Hinges Mast - Also see page 50. Front Drive Shaft Rear Drive Shaft Tilt Cylinder INDEX PREVIOUS NEXT LAST...
  • Page 35 GVF Rough Terrain Tier IV Forklift Manual LUBRICATION & MAINTENANCE - 33 Grease Point Locations continued Tilt Cylinder Center Axle Pivot Steering Cylinder Rear Axle INDEX PREVIOUS NEXT LAST...

  • Page 36: Instructions For Pressure Washing

    GVF Rough Terrain Tier IV Forklift Manual - LUBRICATION & MAINTENANCE INSTRUCTIONS FOR PRESSURE WASHING E. Fuel filters 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 panel, Electrical...
  • Page 37 GVF Rough Terrain Tier IV Forklift Manual LUBRICATION & MAINTENANCE - 35 H. Coolant tank level & fill J. Air Cleaner FIG. 39 FIG. 37 & 37 A Radiator Pressure Cap FIG. 37 Level Indicator FIG. 37A I. Hydraulic Oil Fill FIG. 38 FIG.
  • Page 38 GVF Rough Terrain Tier IV Forklift Manual - LUBRICATION & MAINTENANCE Air Filter Removal 39A-E FIG. 39 A FIG. 39 D FIG. 39 B FIG. 39 E FIG. 39 C INDEX PREVIOUS NEXT LAST...
  • Page 39 GVF Rough Terrain Tier IV Forklift Manual LUBRICATION & MAINTENANCE - 37 Health and Safety INDEX PREVIOUS NEXT LAST...
  • Page 40 GVF Rough Terrain Tier IV Forklift Manual - LUBRICATION & MAINTENANCE Lubricants and Capacities - Transmission INDEX PREVIOUS NEXT LAST...
  • Page 41 GVF Rough Terrain Tier IV Forklift Manual LUBRICATION & MAINTENANCE - 39 Service Schedule - Transmission INDEX PREVIOUS NEXT LAST...
  • Page 42 GVF Rough Terrain Tier IV Forklift Manual - LUBRICATION & MAINTENANCE Synchro Shuttle Transmission FIG. 40 Strainer location FIG. 40 FIG. 40A FIG. 40A Transmission Filter INDEX PREVIOUS NEXT LAST...

  • Page 43: Pd70 Front Axle

    GVF Rough Terrain Tier IV Forklift Manual LUBRICATION & MAINTENANCE - 41 PD70 FRONT AXLE Axle Oil Level INDEX PREVIOUS NEXT LAST...
  • Page 44 GVF Rough Terrain Tier IV Forklift Manual - LUBRICATION & MAINTENANCE Lubricants & Capacities - Front Axle Service Schedules - Front Axle INDEX PREVIOUS NEXT LAST...

  • Page 45: Sd55 Rear Axle

    GVF Rough Terrain Tier IV Forklift Manual LUBRICATION & MAINTENANCE - 43 SD55 REAR AXLE Drive head Axles INDEX PREVIOUS NEXT LAST...
  • Page 46 GVF Rough Terrain Tier IV Forklift Manual - LUBRICATION & MAINTENANCE Drive head Axles Cont. - Rear Axle INDEX PREVIOUS NEXT LAST...
  • Page 47 GVF Rough Terrain Tier IV Forklift Manual LUBRICATION & MAINTENANCE - 45 Greasing Axles - Rear Axle INDEX PREVIOUS NEXT LAST...
  • Page 48 GVF Rough Terrain Tier IV Forklift Manual - LUBRICATION & MAINTENANCE Health & Safety - Rear Axle INDEX PREVIOUS NEXT LAST...
  • Page 49 GVF Rough Terrain Tier IV Forklift Manual LUBRICATION & MAINTENANCE - 47 Lubricants & Capacities - Rear Axle Service Schedules - Rear Axle INDEX PREVIOUS NEXT LAST...
  • Page 50 GVF Rough Terrain Tier IV Forklift Manual - LUBRICATION & MAINTENANCE Service Schedules Cont. - Rear Axle INDEX PREVIOUS NEXT LAST...

  • Page 51: Mast Maintenance

    GVF Rough Terrain Tier IV Forklift Manual LUBRICATION & MAINTENANCE - 49 MAST MAINTENANCE INDEX PREVIOUS NEXT LAST...
  • Page 52 GVF Rough Terrain Tier IV Forklift Manual - LUBRICATION & MAINTENANCE Needle grease tip adapter. Mast grease point. There are 2. This is needed to grease the sideshift. INDEX PREVIOUS NEXT LAST...
  • Page 53 GVF Rough Terrain Tier IV Forklift Manual LUBRICATION & MAINTENANCE - 51 Mast maintenance cont. INDEX PREVIOUS NEXT LAST...
  • Page 54 GVF Rough Terrain Tier IV Forklift Manual - LUBRICATION & MAINTENANCE Mast maintenance cont. INDEX PREVIOUS NEXT LAST...
  • Page 55 GVF Rough Terrain Tier IV Forklift Manual LUBRICATION & MAINTENANCE - 53 Mast maintenance cont. INDEX PREVIOUS NEXT LAST...

  • Page 56: Hydraulic System

    GVF Rough Terrain Tier IV Forklift Manual - LUBRICATION & MAINTENANCE HYDRAULIC SYSTEM • Check hydraulic oil level daily FIG. 42 Hydraulic Oil Fill • keep screen clean • Change hydraulic oil filter every 500 hours FIG. 41 & free of debris • Change hydraulic oil every 1000 hours FIG. 42 • Clean suction strainer every 1000 hours FIG. 43 Hydraulic...
  • Page 57 GVF Rough Terrain Tier IV Forklift Manual LUBRICATION & MAINTENANCE - 55 Hydraulic Diagram INDEX PREVIOUS NEXT LAST...

  • Page 58: Electrical

    GVF Rough Terrain Tier IV Forklift Manual - ELECTRICAL ELECTRICAL Fuses Fuse locations FIG. 43-44 Engine Fuse Box FIG.45 Fuse Access Panel FIG. 43 FIG. 45 Engine Fuses Labeled FIG.45A Engine Fuse Box Intake Heater Fuse 150A Power Relay Module Power Relay Module FIG.46 20 AMP fuse, supply to ignition switch Located behind operator on firewall under hood...
  • Page 59 GVF Rough Terrain Tier IV Forklift Manual ELECTRICAL - 57 Battery Battery box located under the seat FIG. 49 & FIG.12 Main Fuse Box FIG.47 & Fuses FIG. 48 Battery Box FIG. 47 FIG. 49 Neutral Flasher Shift 4 WD Safety Disconnect Start FIG. 48 FIG. 12 INDEX PREVIOUS NEXT LAST...
  • Page 60 GVF Rough Terrain Tier IV Forklift Manual - ELECTRICAL Lights Electrical Circuit INDEX PREVIOUS NEXT LAST...
  • Page 61 GVF Rough Terrain Tier IV Forklift Manual ELECTRICAL - 59 Transmission Electrical Circuit INDEX PREVIOUS NEXT LAST...
  • Page 62 GVF Rough Terrain Tier IV Forklift Manual - ELECTRICAL Power Supply INDEX PREVIOUS NEXT LAST...
  • Page 63 GVF Rough Terrain Tier IV Forklift Manual ELECTRICAL - 61 Power Supply continued INDEX PREVIOUS NEXT LAST...
  • Page 64 GVF Rough Terrain Tier IV Forklift Manual - ELECTRICAL Transmission Brake Electrical Circuit INDEX PREVIOUS NEXT LAST...

  • Page 65: Reference

    GVF Rough Terrain Tier IV Forklift Manual REFERENCE - 63 REFERENCE FILTER PART NUMBERS MANUALS Engine Oil Filter GVF 5000 TIER IV Forklift Parts Manual Part Number: GL 11670 Part Number: GL 11492 Tier IV Fuel Prefilter and Water Trap Transmission SS 700 Service Manual Part Number: GL 13400 Part Number: 9803/9070 Fuel Filter 5 Micron Front Axle PD 70 Service Manual Part Number: GL 13405 Part Number: 9803/9100 Transmission Oil Filter Rear Axle SD 55 Service Manual Part Number: GL 11685 Part Number: 9803/9283 Hydraulic Oil Filter JCB 444 Engine Service Manual...

  • Page 66: Gvf Warranty

    GVF Rough Terrain Tier IV Forklift Manual - WARRANTY 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.

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