Forklift Manual
Forklift Manual
Forklift Manual
Fabrication, Inc.
Model Numbers:
GVF 5000
GVF 6000
GVF 8000
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. 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 opera-
tion 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 great-
er dividends than one that is neglected and/or operated
in a manner other than as intended. Design and servic-
ing 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 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 machine operation and provide details concern-
ing 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 replace-
ment.
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.
2 - SAFETY Gillison 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, 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. You, the operator,
can avoid many accidents by observing the following
precautions. To avoid personal injury, study the follow-
ing 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.
SIGNAL WORDS
FIG. 2: The words DANGER, WARNING, or CAU-
TION are used with the safety alert symbol. Learn to
recognize these safety alerts, and follow the recom-
mended precautions and safe practices.
DANGER indicates an imminently haz-
ardous situation that, if not avoided, will
result in death or serious injury.
WARNING indicates an imminently
hazardous situation that, if not avoided, FIG. 2
could result in death or serious injury.
CAUTION indicates an imminently
hazardous situation that, if not avoided,
could result in minor or moderate inju-
ry.
Replace any DANGER, WARNING, CAUTION or in-
structional decal that is not readable or is missing. The
locations and part numbers of these decals are identified
later in this section of the manual.
Gillison Forklift Manual SAFETY - 3
FIG. 10
6 - SAFETY Gillison Forklift Manual
Electrical System
FIG. 11: To prevent serious injury or death from ex-
ploding gases:
Do not work on batteries without proper
instruction and training.
INSTRUCTION DECALS
16 2 & 13
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. 6
Each decal below has its part number labeled below the
decal.
15
5 9 & 11
Nameplate
12
4. SP 6207 5. SP 6285 6. SP 6315
4 & 7
1 & 3
7. SP 6208 8. SP 6211 8
10
FIG. 16
9. SP 6265
10. SP 6290
11. SP 6250
Nameplate - SP 6305
Includes important information such as: Warning, Model,
Serial Number, Type, Tire Pressure & Size, Mast Type,
Degrees Max Back Tilt, Date of Manufacture, Drive Tread,
15. SP 6320 16. SP 6325 17. FOPS decal SP 6300 Truck Wt., Capacity
Gillison Forklift Manual SAFETY - 9
RECORD RETENTION
The owner shall retain the following records for at least
3 years:
A. Purchase Information
FIG.18
B. Records of persons trained upon de-
Know the route you will be traveling. livery of the GVF 5000 Forklift
Use flashing lights when traveling on C. Written records of frequent inspec-
roads, day or night, unless prohibited by tions, maintenance performed and parts
law. replaced
Observe all local or national regulations
regarding the road speed of your ma-
chine.
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-
Wait for traffic to clear before entering a lison’s Variety Fabrication Inc. with the following in-
public road. formation within 60 days of the sale:
FORK SAFETY
Fork Inspection
12 - SAFETY Gillison Forklift Manual
Fork Maintenance
Gillison Forklift Manual SAFETY - 15
CONTROLS
INSTRUMENT PANEL DIAGRAM
2 5
11 12
8 10
3 4
14
6 13
9 7
15 1
4. Low Engine Oil Pressure Light (Red) When switched back, front and rear lights are
illuminated.
The warning light illuminates when key is in
the On position. After engine startup the light When in the center position, lights are off.
should extinguish in seconds. Stop engine and
investigate the reason for the loss of pressure if
13. Warning Lights Switch
the light does not go off.
VARIOUS CONTROLS
1. Optional Preheat Switch
Push to activate preheat.
Maximum time is 30 seconds.
FIG. 19
1 2
FIG. 20
5. Steering Wheel FIG. 21
Turn wheel left for left turn.
Turn wheel right for right turn.
FIG. 24
B
9. Throttle Pedal FIG. 24
Push to increase engine speed.
C D
FIG. 27
10
13. Mirror
Adjust before operation.
FIG. 25
14. Operator’s Manual Storage FIG. 28
11. Shift Disconnect Switch FIG. 26
Push to shift transmission.
Shift Knob
Shift Switch 11
FIG. 28
FIG. 26
Gillison Forklift Manual OPERATION - 21
OPERATION (read CONTROLS section first)
NOTE: Max crank time = 30 seconds 8. Release all hydraulic pressure by operating
mast control levers.
Observe indicator lights and gauges to ensure
everything is operating correctly. OPERATING GVF 5000
Transmission pressure, and engine oil pressure Learn about all controls, have knowl-
lights go out within 15 seconds. edge of the machine and it’s workings,
and read this manual before operating
Engine temperature must be above 160° F be- the forklift machine.
fore operation.
1. Make sure no obstructions are in the way.
COLD WEATHER STARTING AID
2. Release parking brake.
WARNING: Do not use ether. FIG. 28 3. Select a gear with the gear selector. FIG. 29
E T HE R
FIG. 29
Tilt
FIG. 28
Forward Back
• Turn key to run position
Up
• Push button up to 30 seconds Lift
Release
Bin Clamp
Clamp
Right Left
Push for LEFT turn signal Push for RIGHT turn signal
FIG. 30 FIG. 31
Gillison Forklift Manual LUBRICATION & MAINTENANCE - 23
Maintenance Chart
Tire Pressure
Engine ( refer to engine manual) 25
Transmission 27 - 30
Filter Change 39
Suction Strainer 39
ill
Fi Oil F
s
es
cc
Fu ulic
eA
ll
a
gin
dr
el
Hy
En
Grease Tilt Cylinder & Mast
Pivot - every 100 hrs.
Forks
M ast
r&
l i nde rs. Radiator Fill
Cy h Break Fluid Reservoir
ilt y 100 el
e T r Lev
eas ve il
Gr ot - e aul
ic O
Piv Hy
dr
Air Cleaner
FIG. 34
FIG. 35
G. Fuel Tank FIG. 36 & 36 A
A
C
FIG. 36
G
Fuel Fill
FIG. 37
I
J
FIG. 39
FIG. 38
Gillison Forklift Manual LUBRICATION & MAINTENANCE - 27
TRANSMISSION
Health and Safety
28 - LUBRICATION & MAINTENANCE Gillison Forklift Manual
MAST MAINTENANCE
40 - LUBRICATION & MAINTENANCE Gillison Forklift Manual
FIG. 43
FIG. 40
HYDRAULIC SYSTEM
• Check hydraulic oil level daily FIG. 41
Hydraulic
oil level
sight glass
FIG. 41
FIG. 42
Gillison Forklift Manual LUBRICATION & MAINTENANCE - 45
Hydraulic Diagram
46 - LUBRICATION & MAINTENANCE Gillison Forklift Manual
ELECTRICAL Battery
Fuses FIG. 44 , 45 & 45A See FIG. 46 & 12
Battery Box
FIG. 46
FIG. 44
FNR Switch
Shift Disconnect 4 WD Timing
Advance
Flusher
Front & Rear
Relay
Work Lights
FIG. 45
4 WD Neutral Safety
Relay Start Relay
FIG. 45 A
Gillison Forklift Manual LUBRICATION & MAINTENANCE - 47
Electrical Circuit
Gillison Forklift Manual LUBRICATION & MAINTENANCE - 51
PARTS
58 - PARTS Gillison Forklift Manual
Gillison Forklift Manual PARTS - 59
60 - PARTS Gillison Forklift Manual
Gillison Forklift Manual PARTS - 61
62 - PARTS Gillison Forklift Manual
Gillison Forklift Manual PARTS - 63
Safety Filter
Part Number: GL 11700
64 - WARRANTY Gillison Forklift Manual
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 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.
The owner is specifically responsible for the operation and service of the machine. This warranty shall not
apply to any product that has been subject to misuse, negligence or accident. In the event of a defect in
material or workmanship, GVF sole responsibility is to the repair or replacement of the defective part and is
not responsible for lost time or any other expenses incurred due to lost time.
All OEM items such as Tires, Batteries, Engines and Hydraulic 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 in accordance with all instructions
and safety procedures. Failure of the operator to read the Operator’s Manual is misuse of this equipment. It
is the Retail Customer and/or Operator’s responsibility to inspect the product and to have any part(s) repaired
or replaced when continued operation would cause damage or excessive wear to other parts or cause a safety
hazard.
It is the Retail Customer’s responsibility to deliver the product to the authorized GVF dealer, from
whom he purchased it, for service or replacement of defective parts, which are covered by warranty.
Repairs to be submitted for warranty consideration must be made within 45 days of failure. The Retail
Customer is responsible for any cost incurred by the Dealer for traveling to or hauling of the product for
the purpose of performing a warranty obligation or inspection.