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

Page 1: ...000 GVF 6000 GVF 8000 3033 BENZIE HWY BENZONIA MI 49616 231 882 5921 800 392 6059 email gillison gillisons com website www gillisons com Manual Part Number GL 11495 Gillison sVariety Fabrication Inc PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 2: ...25 Engine 25 Transmission 27 Health and Safety 27 Lubricants and Capacities 28 Service Schedule 29 Synchro Shuttle Transmission 30 PD 70 Front Axle 31 Axle Oil Level 31 Lubricants and Capacities 32 Service Schedule 32 SD 55 Rear Axle 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 Br...

Page 3: ...s 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 ...

Page 4: ...SAFETY ALERT 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 SIGNAL WORDS FIG 2 The words DANGER WARNING or CAU TION are used with the safety alert symbol Learn to recognize these...

Page 5: ...rrect 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 alertness orcoordination An operatoron prescription or over the counter drugs need...

Page 6: ...ren 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 i...

Page 7: ...ith 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 sho...

Page 8: ...ed 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 compon...

Page 9: ...rvice 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...

Page 10: ...able 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 Pressur...

Page 11: ...hen 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 forklif...

Page 12: ... 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 ...

Page 13: ...Gillison Forklift Manual SAFETY 11 FORK SAFETY Fork Inspection PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 14: ...Gillison Forklift Manual SAFETY 12 Fork Inspection Cont PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 15: ...Gillison Forklift Manual SAFETY 13 Fork Inspection Poster PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 16: ...Gillison Forklift Manual SAFETY 14 Fork Maintenance PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

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

Page 18: ...Gillison Forklift Manual SAFETY 16 FORKLIFT MAST SAFETY Refer to the following illustrations for mast safety PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 19: ...n 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 PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 20: ...ff 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 Ho...

Page 21: ...nt FIG 20 1 Position Height adjustment Pull up to ex tend the column 2 Position Angle adjustment Push down to tilt the wheel DANGER Adjustments of steering wheel must be done with the forklift stopped 5 Steering Wheel FIG 21 Turn wheel left for left turn Turn wheel right for right turn 6 Lift Valve FIG 22 A Lift B Tilt C Side shift D Auxiliary FIG 22 B D C A 7 Parking Brake FIG 23 1 Position Engag...

Page 22: ... 11 Shift Disconnect Switch FIG 26 Push to shift transmission FIG 25 10 FIG 26 11 Shift Knob Shift Switch 12 Suspension Seat FIG 27 A Slide adjustment B Weight adjustment Push down to increase stiffness C Back Rest Adjustment D Seat Belts B D A C FIG 28 13 Mirror Adjust before operation 14 Operator s Manual Storage FIG 28 FIG 27 PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 23: ...button up to 30 seconds Hold button in and turn key to start position Crank over until engine is running Release key and push button If no start repeat steps FIG 28 FORKLIFT SHUTDOWN read CONTROLS sec tion first 1 Reduce engine speed to idle Make sure fork lift has come to a complete stop 2 Move gearshift lever to Neutral 3 Move FNR switch to Neutral 4 Apply parking brake 5 Lower forks to ground 6...

Page 24: ...hen operating on highway Side Shift Release Bin Clamp Clamp Left Right FIG 30 Push to turn warning flashers on Push to activate 4 wheel drive Push to turn on FRONT work lights Push for LEFT turn signal Push for RIGHT turn signal 6 Operation of Parking Brake FIG 23 Engaged Disengaged FIG 23 7 Four Wheel Drive Operation On forklifts equipped with the four wheel drive option the four wheel drive is e...

Page 25: ...ge in this manual Tire Pressure Engine refer to engine manual Transmission Hydraulic Oil Level Filter Change Suction Strainer Hydraulic Oil Change Brake Fluid Level Wheel Nut Torque Front Axle Rear Axle MAINTENANCE CHART 25 27 30 39 39 39 39 39 31 32 33 38 LUBRICATION MAINTENANCE PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 26: ... l F i l l E n g i n e A c c e s s Grease Tilt Cylinder Mast Pivot every 100 hrs Forks BreakFluidReservoir Radiator Fill Air Cleaner Hydraulic Oil Level Mast Front Axle Battery Transmission Rear Axle Grease Tilt Cylinder Mast Pivot every 100 hrs PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 27: ...n el Electrical harness and connections and Safety decals ENGINE PLEASE REFER TO THE ENGINE MANUAL Part Number 9801 9310 A Oil filter FIG 32 B Engine oil dipstick FIG 32 C Oil filler cap FIG 32 D B C A FIG 32 FIG 33 FIG 35 D Oil drain plug FIG 33 E Fuel filters FIG 34 35 F Fuel lift pump FIG 35 G Fuel Tank FIG 36 36 A FIG 36 G Drain Supply to Engine FIG 36 A E F E Primary Fuel Filter Secondary Fue...

Page 28: ...lift Manual LUBRICATION MAINTENANCE 26 H Radiator Fill Tank FIG 37 I Air Cleaner FIG 37 39 J Hydraulic Oil Fill FIG 38 H FIG 37 FIG 38 FIG 39 I Radiator Pressure Cap J I PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 29: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 27 TRANSMISSION Health and Safety PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 30: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 28 Lubricants and Capacities Transmission PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 31: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 29 Service Schedule Transmission PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 32: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 30 Synchro Shuttle Transmission PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 33: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 31 PD70 FRONT AXLE Axle Oil Level PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 34: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 32 Lubricants Capacities Front Axle Service Schedules Front Axle PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 35: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 33 SD55 REAR AXLE Drive head Axles PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 36: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 34 Drive head Axles Cont Rear Axle PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 37: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 35 Greasing Axles Rear Axle PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 38: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 36 Health Safety Rear Axle PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 39: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 37 Lubricants Capacities Rear Axle Service Schedules Rear Axle PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 40: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 38 Service Schedules Cont Rear Axle PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 41: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 39 MAST MAINTENANCE PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 42: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 40 MAST MAINTENANCE CONT PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 43: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 41 MAST MAINTENANCE CONT PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 44: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 42 MAST MAINTENANCE CONT PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 45: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 43 MAST SIDESHIFTER MAINTENANCE PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 46: ...IG 40 Brake Fluid HYDRAULIC SYSTEM Check hydraulic oil level daily FIG 41 FIG 41 Hydraulic oil level sight glass Change hydraulic oil filter every 500 hours FIG 42 FIG 42 Change hydraulic oil every 1000 hours FIG 43 Clean suction strainer every 1000 hours FIG 43 Hydraulic Oil Fill keep strainer clean free of debris PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 47: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 45 Hydraulic Diagram PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 48: ...s Indicator Lights 12 V Power Plug Alternator Flashers T u r n Signals 10 AMP 15 AMP 5 AMP 7 5 AMP 10 AMP 20 AMP Power Supply Relay Shift Disconnect Relay 4 WD Relay Neutral Safety Start Relay FIG 45 A Battery Box FIG 46 FIG 12 ELECTRICAL Fuses FIG 44 45 45A FIG 44 Fuse Access Panel Battery See FIG 46 12 PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 49: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 47 4 WD and Timing Advance Electrical Circuit PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 50: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 48 F N R Neutral Safety Start and Shift Disconnect Electrical Circuit PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 51: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 49 Gauges and Indicator Lights Electrical Circuit PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 52: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 50 Ignition Switch and Power Supply Relay Electrical Circuit PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 53: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 51 Front and Rear Work Lights Electrical Circuit PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 54: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 52 12 PWER Adaptor and Alternator Signal Electrical Circuit PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 55: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 53 Flasher and Turn Signals Electrical Circuit PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 56: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 54 Main Wiring Harness Part Number GL11325 PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 57: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 55 FNR Switch Wire Harness Part Number GL11330 1 Pc PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 58: ...Gillison Forklift Manual LUBRICATION MAINTENANCE 56 Work Light Harness Part Number GL11340 2 Pc PREVIOUS PAGE NEXT PAGE LAST PAGE FIRST PAGE ...

Page 59: ...55 Service Manual Part Number 9803 9283 JCB 444 Engine Service Manual Part Number 9806 3000 FILTER PART NUMBERS Engine Oil Filter Part Number GL 11670 Fuel Prefilter and Water Trap Part Number GL 11675 Fuel Filter 5 Micron Part Number GL 11680 Transmission Oil Filter Part Number GL 11685 Hydraulic Oil Filter Part Number GL 11690 Engine Air Filters Primary Filter Part Number GL 11695 Safety Filter ...

Page 60: ...components are warranted by the original equipment manufacturer GVF controls the installation of these products but not the manufacture therefore GVF warranty applies to the proper installation but not the OEM component itself Retail Customer Responsibility It is the Retail Customer and or Operator s responsibility to read the Operator s Manual to operate lubricate maintain and store the product i...