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GVF Forklift Owners Manual - Gillison`s Variety Fabrication Inc.

1. 17 Instrument Panel Info 18 Various Controls 19 OPERATION mee 21 Pre Start Up oos ener ere 21 Starting the Engine 21 Cold Weather Starting Aid 21 Forklift Shutdown 21 Operating the GVF 5000 21 LUBRICATION AND MAINTENANCE 23 Maintenance Chart 23 Lubrication Chart 24 Instructions for Pressure Washing 25 IET c 25 Transmission eseseseeseses 27 Health and Safety 27 Lubricants and Capacities 28 Service Schedule 29 Synchro Shuttle Transmission 30 PD 70 Front Axle 3l PREVIOUS 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 Brake Fluid 44 Hydraulic System AA Hydraulic Diagram 45 Electrical e A
2. 10 20 30 40 50 60 70 80 90 100 Percentage Reduction in Blade Thickness Percentage Remaining of Specified ger This chart shows how fork wear reduces truck capacity ANSI standards require that each fork be rated at least half the capacity of the truck at the rated load center distance as shown on the truck nameplate SAFETY 15 Once in service the bottom of forks may wear badly This wear may not be noticed but the consequences are There are ASME ANSI Specifications for User Fork Wear Standards They are part of the B56 standards by which lift trucks are manufactured and tested Few operators or fleet managers know of the standards or understand that forks must be inspected While the Industrial Truck Association ITA recommends that forks be withdrawn from service when fork blade thickness has been reduced by 10 few users understand that a 10 reduction in blade thickness results in a capacity reduction of 2095 This means that the safety factor for a pair of forks has also been reduced by 2095 Measuring fork wear is not intuitive You should make it a part of maintenance or inspection routines HERE S HOW FORKS ARE INSPECTED Forks should be inspected at least once a year single shift operation and more frequently in severe applications for wear and distortion The best method is to use a fork caliper which is a type of adjustable go no go gauge Fach fork consists of two sections the shank which is the v
3. 005 x 48 24 or B 005 x 1 219 mm 6 10 mm 3 Check for excessive fork angle 3 When Y value exceeds 2 3 8 60 mm or 2 3 4 70 mm on fully tapered the fork is rejected 4 Check tip alignment 4 When A is less than or equal to 42 1 067 mm then the maximum recommended difference in fork tip elevation is B 25 6 35 mm If A is greater than 42 1 067 mm then the maximum recommended difference in fork tip elevation is B 375 9 53 mm MEM 5 Check for positioning lock damage 5 Check the positioning lock and other fork retention devices to make sure they are in place and working 6 Check for wear 6 Set the top jaws ot caliper by measuring the thickness of the shank Position the gt bottom jaws over the flanks of the fork Cascada Kennar p eg gt bu TIN Dd arm blade If inside jaws of caliper hit fork it is OK If inside jaws of caliper pass over the fork arm it must be taken out of service Refer fo clipboard T Check fork marking If the fork identification marking is not clearly legible it shall be renewed LAST PAGE 12 SAFETY Fork Inspection Cont USER FORK WEAR STANDARDS Reprinted from ASME ANSI B56 1 2000 6 2 8 Inspection and Repair of Forks in Service on Fork Lift Trucks a Forks in use shall be inspected at intervals of not more than 12 months for single shift operations or whenever any defect
4. Always keep lubricants out of the reach of children Never store lubricants in open or unlabelled containers Waste Disposal All waste products should be disposed of in accordance with ail the relevant regulations The collection and disposal of used oil should be in accordance with any local regulations Never pour used oil into sewers drains or on the ground Handling New Oil There are no special precautions needed for the handling or use of new oil beside the normal care and hygiene practices Used Oil Used lubricants contain harmful contaminants Here are precautions to protect your health when handling used oil 1 Avoid prolonged excessive or repeated skin contact with used oils LUBRICATION amp MAINTENANCE 27 2 Apply a barrier cream to the skin before handling used oil 3 Note the following when removing oil from skin a Wash your skin thoroughly with soap and water b Using a nail brush will help c Use special hand cleansers to help clean dirty hands d Never use petrol diesel fuel or paraffin for washing 4 Avoid skin contact with oil soaked clothing 5 Don t keep oily rags in pockets 6 Wash dirty clothing before re use 7 Throw away oil soaked shoes First Aid Oil Eyes In the case of eye contact flush with water for 15 minutes If irritation persists get medical attention Swallowing If oil is swallowed do not induce vomiting Get medical advice Skin In the case of excessive
5. A badly maintained axle is a danger to the operator and the people working around him Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the axle in a safe and efficient working condition The schedules are based on machine running hours Do not use a machine which is due for a service Make sure any defects found during the regular maintenance checks are rectified immediately Calendar equivalents 50 Hours Weekly 500 Hours Six Months 1000 Hours Yearly 2000 Hours 2 Years Service checks should be carried out as in the table at whichever time occurs first Service Points and Fluid Levels Operation 10 50 100 500 1000 2000 Hr Hr Hr Hr Hr Hr Axle Oil Level incl Hubs when applicable Check e e Axle Oil incl Hubs when applicable Change De e Tightness of mounting bolts Check T Note First 100 Hours Service only Note Check for leaks every 50 hours check level if leaking Note Limited Slip Differential and Differential Lock only Note Faults in the braking system must be rectified immediately Ensure the correct brake fluid is used see Lubricants and Capacities Section 1 and all equipment is clean and free from water contamination Under no circumstances should water be allowed to enter the braking system Gillison Forklift Manual SD55 REAR AXLE Drive head Axles Checking the Differential Oil Level AA WARNING Make t
6. 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 NEXTPAGE LASTPAGE 2 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 a
7. 12 PWER Adaptor and Alternator Signal Electrical Circuit Q3el MU T13A elLi L 2 3NNLIJO NId Ol IJd CIONJ IOS aslavlsS isSUd s AV lda Lal S Ae 3llVvg AlddNS Ac davida 4SN4 YO L2 NND 3423n8 0I 194 WD d AlddNsS Act eli L dvav 39nv5 43 Dd Ac SIHOI UNI S3JHOLIIAS SIE Jl Ca NOLLOSNNOD SO JVNIWa3L LAST PAGE NEXT PAGE un Q p gt ce PAGE LUBRICATION amp MAINTENANCE 53 Gillison Forklift Manual Flasher and Turn Signals Electrical Circuit d c Wifi hans MLL dl LE SIE NL T T THT Wi Ec PI LI id MOLOSNNOD 3DL23NND2 DA 1900S 2 124 MId Z 3T 8 3LIHA a I38 31IHA E SN 18 7 31IH A C3DNVaSD E ag 4sn4 Nal A ldadNS Aet dy Oz ER HILIMS IWWNOIS Nant amp LLLO3NNLDIO eL L23NNLIO NId vT CU l332D0s vT 34 LAST PAGE ut PAGE un Q p gt z ce 54 LUBRICATION amp MAINTENANCE Gillison Forklift Manual E i Main Wiring Harness i Part Number GL 11325 g d 35 s A d Hi F Ze s E ijs gH alg la g il E M e a pent oy 2 fi 2 i Gw EI g I ki tga 5 XN zi 8 i 583 7 Sars i Me DS s T pst ui E a Ps pe im s D ii A Ep R d r E pii Ga Z P j MES a saki i T Ze E 2 amp 8 TM ic i i ag if de e d r d Bez Ey L rn wf T 97 BF anton oa sius sisi aie e caged d NEXT NEXT PAGE LAST PA
8. Fuel Gauge 3 Low Transmission Oil Pressure Light Red 11 Four Wheel Drive Switch 4 Low Engine Oil Pressure Light Red 12 Front and Rear Work Lights 5 Parking Brake Light Red 13 Warning Lights Switch 6 Engine Preheat Light Red 14 Turn Signal Switch 7 Engine Water Temperature Gauge 15 12 V Power Source 8 Hour meter Gauge NEXT PAGE LAST PAGE 18 CONTROLS INSTRUMENT PANEL INFO l Ignition switch e Position 1 Stop Position 2 Ignition powers all electrical equipment Position 3 Start Turn to position 1 to shut off the engine and all of the electrical equipment Forklift runs in Position 2 2 High Transmission Temperature Light Red If this light is on stop the engine and investi gate the reason for the high transmission tem perature 3 Low Transmission Oil Pressure Light Red The warning light illuminates when the key is in the On position After the engine starts up the light should extinguish in seconds Stop en gine and investigate the low transmission pres sure if the light does not go off 4 Low Engine Oil Pressure Light Red The warning light illuminates when key is in the On position After engine startup the light should extinguish in seconds Stop engine and investigate the reason for the loss of pressure if the light does not go off 5 Parking Brake Light Red When illuminated parking brake is engaged When extinguished parking brake is disen gage
9. Heavy Load Red Grease 42 LUBRICATION amp MAINTENANCE Gillison Forklift Manual MAST MAINTENANCE CONT Measuring Chain Stretch Regular inspection and lubrication of the chains will increase their service life and reduce downtime Chain If the chains stretch beyond the recommended amount Wear they should be replaced in pairs Chain stretch can be Scale measured with chain wear scale Measure the chains according to the instructions printed on the chain wear scale without a load on the carriage o ois 9X o 9 To check the free lift chains raise the carriage 1 ft 30 cm off the ground to put tension on the chains Sie ei To check the main lift chains raise the mast until the inner upright starts to extend putting tension on the chains e exe sXe SS exe exe 9 MAD634 eps New Chain Stretched Chain Figure 43 Measuring Chain Stretch CUSHION TIRE PNEUMATIC TIRE Main Lift Chain Adj ustment 3 in Underclearance 5 in Underclearance The main lift chains should be adjusted so that when the unloadeded mast is fully lowered the uprights are positioned as shown in figure 44 l Uprights and 1 Adjust one chain to achieve the correct upright position aha l when fully lowered See Figure 45 a die ush 2 Adjust the other chain to achieve equal chain tension l l Tighten the nuts together to a torque of 50 70 ft Ibs Carriage 2 in 98 96 Nm Below T m MA0414 eps 3 Raise and lower th
10. 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 FIG 20 5 Steering Wheel FIG 21 Turn wheel left for left turn Turn wheel right for right turn PREVIOUS NEXT PAGE CONTROLS 19 FIG 21 6 Lift Valve FIG 22 A Lift B Tilt C Side shift D Auxiliary IL I Den FORM LEFT HELPAS IM 1 1 000 Off B i SE s 1 A Ur BACK FACT CLAMP FIG 22 7 Parking Brake FIG 23 Position Engaged 2 Position Disengaged FIG 23 LAST PAGE Engaged Disengaged 20 CONTROLS Gillison Forklift Manual 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 24 9 Throttle Pedal FIG 24 Push to increase engine speed 10 Gear Shifter FIG 25 PUSH BUTTON TO SHIFT FIG 27 13 Mirror Adjust before operation FIG 25 14 Operator s Manual Storage FIG 28 11 Shift Disconnect Switch FIG 26 Push to shift transmission G Shift Switch K Gillison Forklift Manual OPERATION 21 OPERATION read CONTROLS section first PRE START UP Check engine oil transmission hydraulic oil and radiator fluid level Do a walk aro
11. against the upright Measure the clearance for the pair of rollers at XXX shown See Figure 14 MAOGS4 eps M Check the chains for wear and stretch Refer to Section ICES 5 6 1 for NEXT PAGE LAST PAGE 40 LUBRICATION amp MAINTENANCE Gillison Forklift Manual MAST MAINTENANCE CONT Carriage Inspection 1 Inspect the rollers for excessive wear or damage Rollers with visible flat spots or cracks should be re placed 2 Inspect the roller bearings by turning the rollers on their shafts Rollers with roughness or noticeable restrictions to turning should be replaced 3 Inspect all welds between the carriage side plates and the carriage fork bars If any welds are cracked replace the carriage 4 Inspect the roller stub shafts If they are damaged or if there are cracks at the base of the stub shafts the carriage must be replaced or repaired Contact Lift Tek for repair procedures Carriage Weldment Side Thrust Roller Load Roller Pin Cotter Pin s d MAO0938 eps LAST PAGE Gillison Forklift Manual LUBRICATION amp MAINTENANCE 41 MAST MAINTENANCE CONT Chains Inspection and Tension Each pair of chains has been factory lubricated using heat and pressure to force the lubricant thoroughly into the chain links Avoid removal or contamination of this factory applied lubricant Do not wash sand blast etch steam clean or paint the chains on initial mast installatio
12. skin contact wash with soap and water Spillage Absorb on sand or a locally approved brand of absorbent granules Scrape up and remove to a chemical disposal area Fires Extinguish with carbon dioxide dry chemical or foam Fire fighters should use self contained breathing apparatus LAST PAGE 28 LUBRICATION amp MAINTENANCE Lubricants and Capacities Transmission Gillison Forklift Manual ITEM CAPACITY FLUID LUBRICANT INTERNATIONAL i SPECIFICATION litres UK gal US gal 13 0 2 9 3 43 14 0 3 1 3 70 198700 Gearbox 2WD TSS700 Gearbox 4WD Kuwait EL4117 SAE 10w Cat TO 4 Kuwait EL4118 SAE 30 Cat TO 4 Mobil ATF 210 ESP M2C 33G Grease Points e zs Mobil HP222 Mobil HP222 Electrical Connections T Capacities shown with an asterisk are approximate total system and dependent on vehicle circuit Use the maximum and minimum marks on dipstick when filling Transmission Oil Fill Procedure Note When installing a transmission in a machine whether new or in service it is extremely important to follow the correct oil fill procedure to prevent internal damage to the transmission 1 With the engine stopped fill the transmission with specified transmission fluid to dipstick maximum mark see Synchro Shuttle Transmission Check Oil Level 2 Start the engine and run slowly for a period not exceeding five minutes This allows the oil to fill filter pump torque convert
13. 210 5 Set the machine level with the machine tyres just clear of the ground Manually rotate both wheels of the axle to bring the OIL LEVEL mark on the hubs to the vertical position with the fill level plugs C at the bottom 9209320 Remove fill level plugs C from the hubs and drain plug B fram the drive head casing Allow time for the oil to drain out Clean and refit drain plug B Set both hub OIL LEVEL marks to the horizontal Fill the axle with the specified quantity of oil through drive head casing fill level plug A see Lubricants and Capacities Section 1 If the machine has been set level oil should just dribble out both hub fill level points Clean and refit both hub fill level plugs C and fill level plug A 3209320 32 LUBRICATION amp MAINTENANCE Gillison Forklift Manual Lubricants amp Capacities Front Axle ITEM CAPACITY FLUID LUBRICANT INTERNATIONAL Litres UK Gal SPECIFICATION PD70 Axle 23 50 Mobil 424 Q8 T2000 API GL4 M2C 41B 134D JD20C MF M1135 M1141 M1143 Grease s Mobil HP222 Q8 Rubens EP2 5 Mobil HP222 Brake System 1 2 0 26 Mobil DTE11M Q8 Handel 15 ISO VG15 CAUTION DO NOT USE ORDINARY BRAKE FLUID J1703 Note 1 Mobil 424 should always be used for axles fitted with brakes For axles without brakes Mobilube HD90 or Mobil Fluid 424 can be used Note 2 Axles with limited slip differentials must use Mobil Fluid 424 Service Schedules Front Axle
14. Change hydraulic oil every 1000 hours FIG Check level every 100 hours m Change oil every 1500 hours Clean suction strainer every 1000 hours Use Brake Fluid Mobile 424 Hydraulic Oil Fill see FIG 40 keep strainer clean 22 Xa A free of debris FIG 43 HYDRAULIC SYSTEM Check hydraulic oil level daily FIG 41 FIG 41 Change hydraulic oil filter every 500 hours FIG 42 NEXT PAGE LAST PAGE Gillison Forklift Manual LUBRICATION amp MAINTENANCE 45 Hydraulic Diagram Forks Lift Steering LL Side Shift E paa 1 ez pa ER 20 ci e 2200 x 24 GPM le he rome or INPUT I Z GILLISON S VARIETY FAB GVF 5000 HYDRAULIC SCHEMATIC PREVIOUS 46 LUBRICATION amp MAINTENANCE Gillison Forklift Manual ELECTRICAL Battery Fuses FIG 44 45 amp 45A See FIG 46 amp 12 Battery Box SA Fuse Access Panel S A 4 WD Timing gem Advance BS ja JT T c 7 5 AMP Flashers ui ERES Turn 10 AMP EP T AMP ies FIG 12 ECC Front amp Rear Work Lights E d py Power Supply Relay NEXTPAGE LAST PAGE LUBRICATION amp MAINTENANCE 47 Gillison Forklift Manual 4 WD and Timing Advance Electrical Circuit e L3490 s NOUap 311HA i 1334208 3LIHA Z3 T 18 CIONA 105 JINVATY DINIHLL al aava 351 4 mE WOAS Ada AeI dr S JFN CAD 2 L3320S 2V38 31IHA
15. G 15 Where replacement parts are necessary for periodic maintenance and servicing replacement parts from Gillison s must be used to restore your equipment to original specifications SAFETY 7 AA DANGER EXPLOSION HAZARD To prevent an explosion or a fire e Do not smoke while refuelling e Keep smoking material sparks and open flames away Eni FIG 14 NEXT PAGE LAST PAGE 8 SAFETY 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 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 Each decal below has its part number labeled below the decal A DANGER Tis parau upm marp oe mal ba Herm pmorsacra mr synka brkrr resa pr erpmderg ra leering Bss better Bad amd ab pecan sas marire for GRE as eect us cedo urina zi ania to Raga ll iasa mu in gend rugs 3 SP 6210 PUSH TO PREHEAT 30 SEC MAX xe rior id zs crum cs resche sier mmm 1 SP 6255 2 SP 6260 i DANGER Mhir ham cancum br Pike e iehi 4 m LE IL D xut il lur ER pari EI l LE E eni Dora oe rium Terum ee amma ae regen rant parim 4 SP 6207 5 SP 6285 6 SP 6315 ii DANGER To pred serius injury or detis ire
16. G DAU yo seat acetate HOPED euro a 46 4 WD Timing Advance Electrical Circuit A7 FNR Neutral Safety Start and Shift Dis connect Electrical Circuit 48 Gauges and Indicator Lights Electrical ST VE 49 Ignition Switch and Power Supply Relay Electrical Circuit 50 Front and Rear Work Lights Electrical Circuit 51 12 PWER Adaptor and Alternator Sig nal Electrical Circuit 52 Flasher and Turn Signals Electrical Circuit oorr aaa 53 Main Wiring Harness 54 FNR Switch Wire Harness 55 Work Light Harness 56 Reference Documents 57 Filter Part Numbers 57 WARRANTY de 58 NEXT PAGE LAST PAGE 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 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
17. GE LUBRICATION amp MAINTENANCE 55 NAOH N33sD AvVeaD JALA I S WaLANAN XIV 18 AVeaD JAIA T 9E NADH N33elD AVeD JAIM 2 amp d nd daa SJAA 2 S WALANAN XIVIEZAVAD JAIA v av ABD N33eD JALA T CS a5M0d Cid SJAA NEXT PAGE LAST PAGE 8 9 Jjss8dA A3e AN JAIA T SIN3 HIDE NO Jk 3A V3i 9 May MADA N3389 JelI HISLNaU L332D0 9 ADLISNNOD SJal IVeld v JS33 3s JO 18 JAIA Nid S31 JIHS aNd NId IJd NId 9 amp DLI23NNU REVIOUS Part Number GL 11330 Gillison Forklift Manual FNR Switch Wire Harness 1 Pc Gillison Forklift Manual 3ivW34 ON Id dVNS N334D 3 18 T TT LHDI1 Ae IN 2 z I E un lt z F x Ll Z ole T N3335 3n78 TT DN H2V3 NI sp 3 V31 8NId 07003 JAIA SS3N3VH GIIVME BDI23NNDJ 194 NId 2 jVH3J 5nd dVNS 34 3078 T 2 LH NDA Iau 56 LUBRICATION A MAINTENANCE Work Light Harness Part Number GL 11340 2 Pc Gillison Forklift Manual REFERENCE DOCUMENTS GVF 5000 Parts Manual Part Number GL11485 GVF 5000 Service Manual Part Number GL11490 Transmission SS 700 Service Manual Part Number 9803 9070 Front Axle PD 70 Service Manual Part Number 9803 9100 Rear Axle SD 55 Service Manual Part Number 9803 9283 JCB 444 Engine Service Manual Part Number 9806 3000 PARTS 63 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 Tra
18. L3AJ0S NADNE 31IHA 40 1 23NND2J amp U L23NNUJ NId 0T 134 13 20s 01 IDs LINA DNIIN3S WAN L3 IEN en H lt 2 13430 29 18 EH JE CB HCH 98 LAST PAGE z x Ll Z Gillison Forklift Manual 48 LUBRICATION amp MAINTENANCE F N R Neutral Safety Start and Shift Disconnect t ircui Electrical C GIONS IS 331leV1S 133 A DT13A lSDd S AYI3 L VIS S en vNaLTV AS3ILVE g DI AlddNS Aci TO 2 T YOLISNNOI amp LL23NND2 39 2 L n wg Id NId 2 123 LUS e T L3X42D0S N3335 IUNI DS 3S 3A3I Bot vit N3339 AD 2 L3 x2D0S XIV K T L13 9U0S 3nd CION3 IDS C VMADA Du St 3n 18 wavy dn ave 124 lt N32 9 AY 9 gt IN 18 AVAD gt 401 UNN NId 01 IJd SLLLO3NND2 l3329U0S 00I 1243 40LISNNO9 13X90s 9 194 I3 q32 A0LI3NNDI NId 9 Lu HILIMS 1293NNDOSIG LJIHS 39NVa3ID C Ht ayoa 3Sn3 WDe4 AlddNS AzI dWY OT 3sn3 2 z I E un lt z F x Ll Z H LIAS NOILINSI LSOd S WOAd A WAT AZT 0 G8 9 8 98 AN 139 leVIS WaLNAN L8 NNDI HS ILL l3 90sS 9 HILIMS INA LUBRICATION amp MAINTENANCE 49 Gillison Forklift Manual DG TM DIE AldW3 SSINVLSISSS PNI IINA dJMUd Acl 6 ESE 3 0 D cor 2 001 D 2002 2 06 0 caso e 1V3H33d M HON MI XN NOLLING HSfld SMON d cg 9 8 98 a AE 193H3 d 8 GION
19. S 10S LV3Hdeld OL IWNOIS HILIMS JAVI X Yyd oH SD L93NND2 eL LO 3NND2 Di LUS d 123 Nid g HOLIMS JANSSIAd 204 J10 3NIDN3 S i GT HOLIMS 33Q1VN3dW3l NDISSIASNVIL d E 204 HOLIMS 3ANSSI3Ad 2 NOISSIASNV L O v LINN ONIGNSS 13N4 eos Lit 9 WWNIWASL Ta5 V TVNIW331 833 N3S em JINIS 3a 1 Val 3dW31 8431VA 3NIDBN3 02 Gauges and Indicator Lights Electrical C UA 3S ME Na AlddNS Ad aU LO3NND2 NId vT I23 ADT13A lt XNId gt Gand NV AValD lt ALIHM gt SOLOSNNOD L3 2DS l 124 GONV3D N333 9 2 z I E un lt z F x El Z A IddNS Ad3llV8 Acel e 5 gt z C33 T z S F 7 0 E 4 Gg 0 8 98 NIMOd S bel CH 284 D 113A E 18 gt AMIS LAVLS TIBN3A4HS dWhd AL334S WSLO3N NULLO3CNI 1304 eos DL CT Sg 3sn4 OL Adds AZT ALL 3NND2 I0L93NNO9 anna i1H9IT Nid Ol 124 L3329B0S 017 I24 50 LUBRICATION amp MAINTENANCE Ignition Switch and Power Supply Relay Electrical Circuit Gillison Forklift Manual LUBRICATION amp MAINTENANCE 51 Front and Rear Work Lights Electrical Circuit 2 PIN FCI 8 SOCKET FCI CONNECTOR CONNECTOR lt BLUE RED gt lt BLUE GREEND lev SUPPLY FROM FUSE BOARD lt BLUE RED gt lt BLUE GREEN gt a vad SG 2 PIN FCI 28 SOCKET FCI CONNECTOR CONNECTOR Gillison Forklift Manual 52 LUBRICATION A MAINTENANCE
20. Series Sideshifters The product model number and serial number are stamped on the back surface of the LH vertical bar driver s view and must be provided when ordering replacement parts The cylinder anchor bracket assembly part number is stamped on the front surface RH end of the anchor bracket driver s view Stamped model number serial number specifications LUBRICATION amp MAINTENANCE 43 Fork Stops Backrest Cylinder U pper and e ee lower hook or leaks engagement 990186 ill Fasteners 1000 Hour After each 1000 hours of truck operation in addition to the 100 and 300 hour maintenance perform the following procedures Inspect upper and lower bearings for wear If any bearing is worn to less than 3 32 in 2 5 mm thickness replace the entire bearing set See Service Manual for replacement procedure nspect forks for wear NOTE Fork Safety Kit 3014162 is available containing wear calipers inspection sheets and safety poster Also available is fork hook amp carriage wear gauge 209560 CL II and 209561 CL III WARNING For the safety of yourself and others DO NOT install the parts shown in this Manual unless you have thoroughly reviewed the appropriate Service Manual Sticker showing patent numbers phone numbers for service se Stamped cylinder assembly part number front side 44 LUBRICATION amp MAINTENANCE Gillison Forklift Manual BRAKE FLUID
21. Variety Fabrication Inc Gillison Forklift Owners Manual Manual Part Number GL 11495 Model Numbers GVF 5000 GVF 6000 GVF 8000 3033 BENZIE HWY e BENZONIA MI 49616 231 882 5921 e 800 392 6059 email gillison gillisons com website www gillisons com EATEN PA EATEN NEXT NEXTPAGE LAST PAGE Table of Contents INTRODUCTION 1 SAPE TY EE 2 Intro to Safety 2 Safety Alert Symbol 2 Signal Words 2 General Safety Rules 3 General Safety While Operating 4 Safety While Servicing Machine 5 Electrical System 6 Hydraulic System 6 Fuel System 7 Wheels and Tires 7 Replacement Parts T Instruction Decals 8 Serial Number 8 Safety While Operating 9 Load Handling Safety 9 Rules of The Road 10 Modrftcatons 10 Record Retention 10 Ownership Records 10 Fork Safety ees eee ieee tees 11 Fork Inspection 11 Fork Inspection Poster 13 Fork Maintenance 14 Forklift Mast Salety onere 16 CONTROLS oet aestate mprbnievruibU RU E MbesaM ecd 17 Instrument Panel Diagram
22. a parts for lift trucks in some fleet repair shops but you ll seldom see spare forks Even when all the trucks on the fleet are the same fleet maintenance managers rarely order spare forks Forks last a long time if treated properly but they can deceive by looking as good from most viewing angles when they are worn as when they are new It s true that most forks are customized to the truck by model and capacity they are big and heavy and thought of as indestructible But forks can be abused or ruined in the course of daily work Here are some examples of ways that forks can be damaged m Forks can be overloaded either by picking up a load too far out on the forks or simply by picking up loads heavier than the truck rating Maintenance shops may bend forks back into shape weld on them or drill holes through them Lift truck users can add attachments to the truck that stress the forks Drum forks but what is contained in the drum or on the boom hook makes the safety difference m Forks are often used to open rail car doors and break loads out or away from other loads They are also used to pick up capacity loads not seated against the fork shank and to pick up off balanced loads far from the side of the truck The fork tips are sometimes inserted under other fork trucks to lift them during maintenance operations m Lift trucks may collide with building columns and walls and though the forks show no discernible bend they may be dam
23. aged beyond safety m Anytime excessive heat is applied to any part of a fork during repair for instance hidden damage may occur The fork itself is a concern but so are the hooks that secure them to the lift carriage DESIGNED TO TAKE A BEATING Forks for counterbalanced and straddle lift trucks are not just bent bars of steel The manufacturing process is careful and precise with many checks and inspections critical to their safety Some factors essential to fork manufacture include the steel the bend and thickness of the heel the welding of the hooks that hold them on the carriage and the heat treatment of the finished product PREVIOUS PAGE NEXT PAGE LAST PAGE Gillison Forklift Manual Fork Maintenance Cont FORKS ARE A WEARING PART Finished forks are usually painted red yellow or black when the truck is new The paint is quickly scrapped off once the truck is put into service The top paint is abraded by the pallet or load and the bottom is worn mostly by contact with the floor Lift truck operators are taught to keep their forks low and parallel with the travel surface when traveling empty and tilted back when carrying a load But some operators go to extremes and travel with the heel of the fork riding on the floor This practice wears the heel or the bottom surface of the fork and reduces the capacity of the fork Fork Wear vs Capacity LILI B TN TTT FEE Il UU WEIN LINII LLL LEES
24. al deforma tions If these are apparent to such an extent that the clearance between the fork and the fork carrier becomes excessive the fork shall not be returned to service until repaired in accordance with para 6 2 8 2 g Legibility of Marking When Originally Provided If the fork marking in accordance with para 7 25 2 is not clearly legible it shall be renewed Marking shall be renewed per instructions from original supplier 6 2 8 2 Repair and Testing a Repair Only the manufacturer of the fork or an expert of equal competence shall decide if a fork may be repaired for continual use and the repairs shall only be carried out by such parties It is not recommended that surface cracks or wear be repaired by welding When repairs necessitating resetting are required the fork shall subsequently be subjected to an appropriate heat treat ment as necessary _ NEXT PAGE LAST PAGE Gillison Forklift Manual SAFETY 13 Fork l a inspection and guidelines Fork Inspection Poster Z 50 mm 2 Step 1 Set Calipers Checking shank thickness Set the top jaws by measuring the thickness of the shank Ensure that the caliper is held square across the shank for an accurate reading The caliper is now sel to measure the fork arm blade Fork Use Guidelines Use your forks correctly 1 Inspect forks regularly and use Cascade Kenhar inspection log 2 Make sure capacity meets or exceeds truck ratin
25. ating this machine Fasten seat belt securely before starting Keep both hands on controls at all times when operating this vehicle Carry load low Use low range for hillside or ramp op eration Block elevated components before ser vicing equipment Do not leave machine with mast raised Do not allow riders Do not leave machine with engine run ning Review operator s manual before operating this machine Fasten seat belt securely before starting Keep both hands on controls at all times when operating this vehicle Carry load low Use low range for hillside or ramp operation Block elevated components before servicing equipment Do not leave machine with mast raised Do not allow riders Do not leave machine with engine running SWS FIG 17 Heed these safety rules Inspect the forklift each day Perform scheduled maintenance to ensure optimum performance Wear proper clothing a No baggy clothing SAFETY 9 b Use eye protection c Use hard hat Fasten seat belt securely before starting the forklift When mounting and dismounting the forklift use the steps and hand holds provided Do not use steering wheel or controls Keep body feet and hands inside the operators plat form when 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 fo
26. chine 1 Make sure no obstructions are in the way 2 Release parking brake 3 Select a gear with the gear selector FIG 29 PUSH BUTTON TO SHIFT Forward o Lift d Down LAST PAGE 22 OPERATION Release a m Bin Clamp B d Wal Clamp Side Shift 4 Raise the mast until forks are a safe distance from the ground Always carry loads low to ground to prevent roll over and overhead obstruc tions 5 Select Forward or Reverse on FNR selector In Reverse make sure back up alarm is functioning Check operation of brakes Use throttle pedal to increase engine speed and forklift speed Use horn when going in blind spots Always use Warning flashers when op erating around hazards including roads FIG 30 Turn signals Use on road right of ways to indicate direction turning FIG 30 Lights FIG 30 Never use rear work lights when operating on highway e Push to turn on FRONT work lights Push to turn on FRONT and REAR work lights NM EN X P K Push to turn warning flashers on k Push for LEFT turn signal nus Push for RIGHT turn signal Gillison Forklift Manual 6 Operation of Parking Brake FIG 23 Engaged FIG 23 Disengaged 7 Four Wheel Drive Operation On forklifts equipped with the four wheel drive option the four wheel drive is engaged by switching the rocker switch FIG 30 The light will illuminate Four wheel drive can be sel
27. d 6 Engine Preheat Light Red When illuminated Preheat 1s 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 PREVIOUS D Ze Gillison Forklift Manual Allow engine to warm up to above 160 F be fore operating 8 Hour meter Gauge Records hours of engine operation Observe this gauge for periodic maintenance schedules 9 Voltmeter Gauge Indicates battery charge Normal readings are between 12 15 volts 10 Fuel Gauge 11 Four Wheel Drive Switch When light is illuminated four wheel drive is on 12 Front and Rear Work Lights When switched ahead front lights are illumi nated When switched back front and rear lights are illuminated When in the center position lights are off 13 Warning Lights Switch 14 Turn Signal Switch When switched to left position left hand lights flash When switched to right position right hand lights flash When in the center position the switch 1s off 15 12V Power Source NEXT PAGE LAST PAGE Gillison Forklift Manual 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 Push to activate FIG 19 4 Steering Wheel Adjustment FIG 20 Position Height
28. e mast several times to confirm the adjustments u Figure 44 Upright and Carriage Position CH ed Tu Main Lift Chain Adjusting Nuts NEXT PAGE MAO4 15 ill LAST PAGE Gillison Forklift Manual MAST SIDESHIFTER MAINTENANCE WARNING After completing any service procedure always test the sideshifter through five complete cycles First test with no load then test with a load to make sure the attachment operates correctly before returning it to the job Daily Check items shown each day Report problems to your supervisor See Service Manual for troubleshooting maintenance and repair procedures 100 Hour Every time the lift truck is serviced or every 100 hours of truck operation whichever comes first complete the following maintenance procedures Check for loose or missing bolts worn or damaged hoses hydraulic leaks and damaged or missing fork stops Inspect lower hooks for wear and proper clearance Adjust if necessary see Step 4 Installation Tighten lower hook capscrews to 120 ft Ibs 165 Nm 300 Hour After each 300 hours of truck operation in addition to the 100 hour maintenance perform the following procedures Tighten backrest capscrews Cascade to 145 ft lbs 195 Nm Apply general purpose lithium based chassis grease to Sideshifter upper and lower bearings _P Ants Product Identification This Section shows replacement parts for F
29. e starting fluid Starting fluid must 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 Use of starting fluid on an engine equipped with an in take heater can result in severe engine damage Make sure there is plenty of ventilation Never oper ate the engine in a closed building Always start and operate engine in a well ventilated area If in an enclosed area vent the exhaust to the outside Do not tamper with 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 should be observed These have been arranged by machine area or component Cooling System FIG 10 DO NOT remove the radiator cap see 1 when the engine is running or hot DO NOT add coolant to the radiator while the engine is running Before removing the radiator cap turn the cap slowly to relieve the pressure When adding coolant make sure coolant being added is compatible and will mix with exist
30. ected while traveling straight 8 Fueling FIG 31 Shut off engine Do NOT smoke while refueling Clean debris from around cap to prevent contamination Remove Cap Insert nozzle Fill Replace cap A DANGER EXPLOSION HAZARD To prevent an explosion or a fire Do not smoke while refuelling Keep smoking material sparks and open flames away 501 FIG 31 NEXT PAGE LAST PAGE Gillison Forklift Manual LUBRICATION amp MAINTENANCE 23 LUBRICATION amp MAINTENANCE MAINTENANCE CHART 1000 2000 Page in ITEM 50 hrs 100 hrs 500 hrs ducem refer to engine manual 25 SSES BEE p E e C LL Brake Fluid Level mE Wheel Nut Torque MEN Front Axle PREVIOUS PAGE NEXT PAGE LAST PAGE 24 LUBRICATION amp MAINTENANCE Gillison Forklift Manual Pivot every 100 hrs IF Grease Tilt Cylinder amp Mast gt X ud TA Ge 2 SR N emm TAs MNT L o d la cd Pen Li a Cap Break Fluid Reservoir 77 Radiator Fill Front Axle ML is NEXT PAGE LASTPAGE Gillison Forklift Manual LUBRICATION amp MAINTENANCE 25 LUBRICATION CHART E Fuel filters FIG 34 amp 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 el Electrical harnes
31. ed upon de livery of the GVF 5000 Forklift C Written records of frequent inspec tions maintenance performed and parts replaced OWNERSHIP RECORDS When a change of ownership of a GVF 5000 Forklift occurs it is the responsibility of the seller to notify Gil lison s Variety Fabrication Inc with the following in formation within 60 days of the sale A Serial number of machine B Name amp address of new owner NEXT PAGE LAST PAGE Gillison 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 Lift Truck Serial o EE 1 Inspect for surface cracks Pay special attention to the heel and welds Inspection Date Inspected By Observations Comments attaching all mounting components to thc vi de fork blank Forks with surface cracks shall 1 not be returned to service md 2 Check for straightness of blade and shank The fork should be withdrawn from service if weg Lk the deviation from straightness exceeds allowable A and B values 25 Allowable A 005 x S x Allowable B 005 x L I 1 Example 48 or 1 219 mm long blade Allowable B
32. er oil cooler and hoses 3 Stop the engine wait approximately one minute Re check the oil level and fill to dipstick level ITL Dipstick Details Tube size 1 O D x 16 S W G ERW 1 Locknut and seal required for securing and sealing dipstick filler tube Part No 155 10600 Filler tube must sit fully home in transmission casing counterbore Note Figures given below are for transmissions installed horizontally Allowance may be needed if installed at an angle Front to Rear ITL should be consulted if transmission is to be inclined in vehicle chassis Transmission Figures Dimension A 63 mm max X Seal Ferrule As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly NB Petroleum jelly must NOT be used on sealed type connectors A234630 Dimension B 88 mm min Y Male nut fitting 11 2 in Hex A F Gillison Forklift Manual LUBRICATION amp MAINTENANCE 29 Service Schedule Transmission A badly maintained machine is a danger to the operator and the people working around him Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition Apart from the daily jobs the schedules are based on machine running hours Keep a regular check on the hourmeter readings to correctly gauge service intervals Do not use a machine which is due for a service Make sure any de
33. ertical part attached to the carriage and the blade which is the portion that picks up the load The caliper is first set using the shank of the fork on which there is little or no wear See the illustration Then that dimension is used to check the shank back near the heel of the blade The four contact points of the special fork caliper automatically measure the wear on the blade Wear is checked by first measuring the thickness of the vertical shank portion of the fork because this part wears little The interior part of the caliper has two additional points that automatically show a 1096 reduction of the shank thickness These points are slid over the fork blade If the caliper slides down the blade to the heel the fork is worn beyond safety and usefulness It should be replaced The accompanying chart shows the reduction in capacity as the forks wear Reprinted from Material Handling Engineering March 1995 Copyright 1995 Penton Publishing Inc Cleveland Ohio 44114 NEXT PAGE 16 SAFETY Gillison Forklift Manual FORKLIFT MAST SAFETY Refer to the following illustrations for mast safety Safety Decals 1 2 679150 NO STEP d 2 5 665595 HANDS OFF 4 1 684166 WARNING AN WARNING MAOB65 eps NEXTPAGE LASTPAGE Gillison Forklift Manual CONTROLS 17 CONTROLS INSTRUMENT PANEL DIAGRAM l Ignition Switch 9 Voltmeter Gauge 2 High Transmission Temperature Light Red 10
34. fects found during the regular maintenance checks are rectified immediately Calendar equivalents 10Hours Daily 50 Hours Weekly 500 Hours Six Months 1000 Hours Yearly 2000 Hours 2 Years Service checks should be carried out as in the table at whichever time occurs first Pre start Cold Checks Operation 10 50 T1100 500 1000 2000 Service Points and Fluid Levels i Hr ir Hr Hr Hr TRANSMISSION Transmission Oil Level Check e Transmission Oil Change e D Transmission Filter Change e e RH H Transmission Strainer Clean e Drive Shafts Security Grease a D Functional Test Operation 10 50 1100 500 1000 2000 and Final Inspection Hr Hr Hr Hr Hr Hr TRANSMISSION 2WD AWD Selection Check e e Forward Reverse and Gear Change Operation Check e v H e Transmission Main Line Pressure tt Check e D e Clutch Disconnect Check E H Neutral Start Operation Check H H Clutch Pack Pressures tt Check H E e t First 100 Hours Service only to be completed by your Distributor tt Indicates jobs which should only be done by a specialist LAST PAGE Gillison Forklift Manual 30 LUBRICATION amp MAINTENANCE Synchro Shuttle Transmission Check Oil Level for Interval see Service Schedule Q Dipstick Filler Oil level should be to the full mark on the dipstick when the oil is cold i e before starting machine operation If the engine has been running wait approximately five minu
35. g and load weight 3 Obtain written approval from fork manufacturer prior to making fork modifications Step 2 Check Blade 4 Determine fork wear cycle and replacement schedule for your operation Use of larger forks in demanding applications will extend fork life Thickness 5 All locating pins must he in place at all times Forks must he properly seated on the Checking blade thickness Position the carriage and the pins fully located in the slot before use bottom jaws of the caliper over the flanks of the fork arm blade If inside jaws of caliper hit fork it has less J P What not to do than 10 wear and can remain in service Do not overload beyond the rated capacity Do not change fork from one lift truck to another without knowing capacities Note Standard Cascade Kenhar calipers can he used on forks up ta and including 65 emm 2 56 thick They are NOT TO BE of each USED ON FULL OR LUMBER TAPERED FORKS where the upright 3 Do nat use a fork in an application for which it is nat designed eegen is pires of the blade In ay d Do not add a fork extension longer than 150 of the supporting fork s length 2 f tan must be y measurement Fou wl need to is P A GG Step 3 Replace if know the original fork blade thickness 5 Do not try to repair or modify forks in the field especially by welding Lmproper welding destroys heat treat properties and makes the Forks brittle Necessary 6 Do nat carry full or partial load
36. he machine safe before getting beneath it Lower the attachments to the ground engage the parking brake remove the starter key disconnect the battery 2 3 2 2 AA CAUTION The axle oil level must be checked with the machine level otherwise a false indication of the amount of oil in the axle will be given 16 3 5 3 1 Park the machine on level ground Engage the parking brake Set the transmission to neutral Lower the attachments to the ground Stop the engine and remove the starter key 2 Clean the area around the fill level plug A then remove the plug and its sealing washer Oil should be level with the bottom of the hole Add recommended oil if necessary See Lubricants and Capacities for recommended oil Clean the plug and sealing washer before refitting them LUBRICATION amp MAINTENANCE 33 Changing the Differential Oil The axle oil is used to lubricate the brake components and cool the brake plates It is important that the oil is changed regularly as specified in the service schedule the lubricating properties of the oil will reduce as a result of brake wear Consult your OEM for advice if necessary A WARNING Make the machine safe before getting beneath it Lower the attachments to the ground engage the parking brake remove the starter key disconnect the battery 2 3 2 2 1 Park the machine on level ground Engage the parking brake Set the transmission to neutral Lower the attachments to the g
37. ildren are at a safe distance before starting the en gine 3 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 inspect area prior to operation FIG 8 Be aware of side hill hazard To prevent serious injury or death DO NOT operate near edge of banks Setback distance from bank should equal or exceed the overall height of the bank DO NOT operate on steep slopes as overturning may result If necessary to cross a steep slope avoid turning uphill Slow down and make a wide turn Travel directly up or down the slope never cross it Keep the heavy end of the machine on the uphill side Gillison Forklift Manual FIG 6 A DANGER ELECTROCUTION HAZARD To Prevent Serious Injury or Death from Electrocution Stay away from overhead powerlines when operating forklift in raised position This machine is not grounded Electrocution can occur without direct contact FIG 7 AA DANGER SIDE HILL HAZARD To Prevent Serious Injury or Death Do not operate forklift on 10 or greater side hill with mast raised FIG 8 NEXT PAGE LAST PAGE Gillison Forklift Manual FIG 9 Do not us
38. ing coolant SAFETY Starting Fiid Ke e FIG 9 To prevent serious burning or scalding Pressurized cooling system Allow system to cool Remove cap slowly with gloves on 5 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 i AES i UP d To prevent serious injury or death instruction and training from exploding gases Do not work on batteries without proper instruction and training FIG 12 Before making adjustments or servicing the See operator s manual electrical system disconnect the battery negative cable see 1 first to prevent short circuits Keep sparks flames and cigarettes away Use a flash light to check the battery electrolyte level 1f necessary FIG 11 Do not produce sparks with cable clamps when charg ing the battery or starting the machine engine with a slave Jumper battery Batteries contain sulfuric acid electrolyte Always wear protective clothing and eye protection when servicing In case of electrolyte contact rinse area with plenty of water and seek medical attention Batteries produce explosive hydrogen gas when charged Charge in area with adequate ventilation Halt charging if battery temperature exceeds 52 Wash hands after handling battery Hydraulic System FIG 12 FIG 13 High pressure fluid hazard To preve
39. ive grease is used the Service Intervals must be reduced to 50 hours weekly O Note Check for leaks every 50 hours check level if leaking Note Jobs which should only be done by a specialist are indicated by a Note Check generally for leaks on ALL systems for example hydraulics axles etc If a leak is evident find the source and repair as required Make sure that the system is topped up with the recommended fluid after repair Note Faults in the braking system must be rectified immediately Ensure the correct brake fluid is used see Lubricants and Capacities and all equipment is clean and free from water contamination Under no circumstances should water be allowed to enter the braking svstem LAST PAGE Gillison Forklift Manual LUBRICATION amp MAINTENANCE 39 MAST MAINTENANCE Periodic Maintenance For proper operation and an extended service life your Lift Tek Mast should be inspected and serviced regularly as part of your normal lift truck maintenance schedule accord ing to the following outlines and ANSI B56 1 procedures The recommended intervals are for masts operating under normal conditions If the mast is operating in severe conditions or corrosive atmospheres the inspections should be per formed more frequently on the forks or attachment in the raised position without supports or while anyone is near the lift _truck control handles per ANSIBS6 1 WARNING Never work on the mast
40. l plugs C at the bottom Place a container of suitable size beneath plug C to catch the oil See Lubricants and Capacities Remove fill level plugs C Allow time for the oil to drain out Set OIL LEVEL marks to the horizontal There is a tolerance of 5 mm 0 2 in above or below the horizontal Fill the hubs with recommended axle oil through the fill level holes C See Lubricants and Capacities Oil should be level with the bottom of the fili leve hole Clean and refit fill level plugs C LAST PAGE Gillison Forklift Manual LUBRICATION amp MAINTENANCE 35 Greasing Axles Rear Axle Note When greasing raise the wheels and swing them from lock to lock This will ensure full penetration Total 8 Grease Points LAST PAGE 36 LUBRICATION amp MAINTENANCE Health amp Safety Rear Axle Hygiene Lubricants are not a health risk when used properly for their intended purposes However excessive or prolonged skin contact can remove the natural fats from your skin causing dryness and irritation Low viscosity oils are more likely to do this so take special care when handling used oils which might be diluted with fuel contamination Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene For details of these precautions we advise you to read the relevant publications issued by your local health authority plus the followi
41. m nepleatirez pmm Do nel werk on botterkea il props instruction and training Een operations mei SP 6211 AA DANGER Recommended Lubricant Start only from seat in park or 9 SP 0205 neutral gear ki E 10 SP 6290 Som ESEL PEL 12 SP 6270 13 SP 6221 14 SP 6275 DOWN FORWARD LEFT RELEASE OPERATION WITHOUT THIS DEVICE IN PLACE MAY BE HAZARDOUS SIDE LIFT TILT WITH AN IMPACT OF 15 SP 6320 16 SP 6325 17 FOPS decal SP 6300 Gillison Forklift Manual Decal Locations RI d Nameplate Variety izillison s Fobricadkan Ire ATEI Lienz try Bonzanla MI 435158 2 22 Mada In U S A GE de 0050 MODEL SERIAL MO TYPE GYF 5000 GL DIESEL CAPACITY WITH MAST VERTICAL AND EQUIPPED A5 SHOWN ES FRONT 35 PSI ul D 169 24 10 PLY Pt SIZE 125 80 18 10PLY 11 CEGREES wax sack mur MASTTYPE 550 MS DATE OF MANUFACTURES 4 T ruen o DRIVE A gl TREAD s ques IN LE L za ol a zio som 3 TRUCK CONFORMS TO ASME R58 86 Nameplate SP 6305 Includes important information such as Warning Model Serial Number Type Tire Pressure amp Size Mast Type Degrees Max Back Tilt Date of Manufacture Drive Tread Truck Wt Capacity NEXT PAGE LAST PAGE Gillison Forklift Manual SERIAL NUMBER Location of serial number is on the nameplate and is provided as a reference See FIG 16 SAFETY WHILE OPERATING FIG 17 Review ENTIRE operator s manual before oper
42. mminently hazardous situation that if not avoided could result in minor or moderate inju ry Replace any DANGER WARNING CAUTION or in structional decal that 1s 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 FIG 1 FIG 2 NEXT PAGE LAST PAGE Gillison Forklift Manual 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 Read this manual carefully and learn how to use the machine correctly Do not let anyone operate this machine without thor ough instruction Beware of bystanders particularly children Always look around to make sure that everyone is clear before starting the engine or moving the machine This is par ticularly important with higher noise levels as you may not hear people shouting FIG 4 No passengers allowed Do not carry passen gers anywhere on the machine Dismount and park machine in the correct 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 ope
43. n The chains must be adjusted with equal tension to ensure Cracked Side Plates proper load distribution and mast operation To determine equal tension extend the unloaded mast to put the chains under tension Press the center of a strand of chain with your thumb then press at the same place on the other chain of the pair Each chain in a pair should have equal give If tension is not equal adjust the chains as de scribed in Chain Adjustment Inspect the chains If inspection reveals that one strand of a pair of chains requires replacement both strands of the pair should be replaced Check for rust and corrosion Check for cracked side plates If you find cracked side plates replace both strands of chain Check for tight joints If tight joints are caused by rust or corrosion loosen them with SAE 40 wt oil or penetrating oil If they cannot be loosened or if the tight joints are caused by bent pins or plates or by peened plate edge replace both strands of the chain Check for protruding or turned pins Replace both strands of the chain Check for chain side wear If pins and outside plates show signs of wear check for misalignment os sheaves anchors or other components Correct the misalignment If wear is excessive replace both strands of chain Check for worn broken or misaligned chain anchors Replace or adjust as required Lubricate the full length of the chains with SAE 40 wt oil or Bowman
44. ng Storage Always keep lubricants out of the reach of children Never store lubricants in open or unlabelled containers Waste Disposal All waste products should be disposed of in accordance with all the relevant regulations The collection and disposal of used oil should be in accordance with any local regulations Never pour used oil into sewers drains or on the ground Handling New Oil There are no special precautions needed for the handling or use of new oil beside the normal care and hygiene practices Used Oil Used lubricants contain harmful contaminants Here are precautions to protect your health when handling used oil 1 Avoid prolonged excessive or repeated skin contact with used oils Gillison Forklift Manual 2 Apply a barrier cream to the skin before handling used oil 3 Note the following when removing oil from skin a Wash your skin thoroughly with soap and water b Usinga nail brush will help c Use special hand cleansers to help ciean dirty hands d Never use petrol diesel fuel or paraffin for washing 4 Avoid skin contact with oil soaked clothing 5 Don t keep oily rags in pockets 6 Wash dirty clothing before re use 7 Throw away oil soaked shoes First Aid Oil Eyes In the case of eye contact flush with water for 15 minutes If irritation persists get medical attention Swallowing If oil is swallowed do not induce vomiting Get medical advice Skin In the case of exce
45. nsmission Oil Filter Part Number GL 11685 Hydraulic Oil Filter Part Number GL 11690 Engine Air Filters Primary Filter Part Number GL 11695 Safety Filter Part Number GL 11700 NEXT PAGE LAST PAGE 64 WARRANTY Gillison Forklift Manual G VE WARRANTY Gillison s Variety Fabrication Inc will replace or repair at GVF option any GVF manufactured item that 1s 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 warrant
46. nt 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 HIGH PRESSURE FLUID HAZARD To prevent serious injury or death Keep all components in good repair Relieve pressure on system before repairing or adjusting or disconnecting Ensure that all hydraulic connections are tight Wear proper hand and eye protection when searching for leaks Use wood or cardboard instead of hands Relieve all pressures before disconnecting hoses or inen id reae di od ioi lines Escaping oil under pressure can cause serious in SH sach FIG 13 All fluids should be handled with care If you are in jured by or swallow any fluid seek medical attention immediately and show the label on the product Fluid escaping from a very small hole can be almost invisible and can penetrate the skin causing serious in jury Keep hands and body away from pin holes and nozzles which eject fluids under high pressure When rissrrAGE EREVIOUS NEXTPAGE LAST PAGE Gillison Forklift Manual 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
47. or permanent deformation is detected Several applications will require more frequent inspection b Individual and Load Rating of Forks When forks are used in pairs the normal arrangement the rated capacity of each fork shall be at least half of the manufacturer s rated capacity of the truck and at the rated load center distance shown on the lift truck nameplate 6 2 8 1 Inspection Fork inspections shall be carried out carefully by trained personnel with the aim of detect ing any damage failure deformation etc which might impair safe use Any fork which shows such a defect shall be withdrawn from service and shall not be returned to service unless it has been satisfactorily repaired in accor dance with para 6 2 8 2 a Surface Cracks The fork shall be thoroughly examined visually for cracks and if considered necessary subjected to a non destructive crack detection process special attention being paid to the heel and welds attaching all mounting components to the fork blank This inspection for cracks must also include any special mounting mechanisms of the fork blank to the fork carrier including bolt type mountings and forged upper mounting arrangements for hook or shaft type carriages The forks shall not be returned to service if surface cracks are detected b Straightness of Blade and Shank The straightness of the upper face of the blade and the front face of the shank shall be checked If the deviation from straightnes
48. or service the fuel system on the machine while smoking or when near open flames or sparks Never refuel the machine while the engine is running DO NOT use a fuel can unless necessary Always clean up any spilled fuel Fuel system components rely upon clean fuel for lubri cation and optimum performance Extreme care must be taken to prevent contamination from dirt and mois ture so as to prevent damage to system Fuel injection system servicing must be referred to your Gillison Dealer Unauthorized servicing may void all warranties Wheels and Tires Do not attempt to service 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 may break the bead or even the rim with dangerous explo sive force When preparing a calcium chloride solution for fluid blasting the tires NEVER pour water onto the calcium chloride A chlorine gas can be generated which is poi sonous and explosive This can be avoided by slowly adding calcium chloride flakes to water and stirring un til they are dissolved Wear suitable protective clothing gloves and eye face protection Replacement Parts FI
49. order Make sure machine is equipped with a slow moving vehicle sign SMV and oth er marking materials recommended for improved visibility unless prohibited by law FIG 18 FIG 18 Know the route you will be traveling Use flashing lights when traveling on roads day or night unless prohibited by law Observe all local or national regulations regarding the road speed of your ma chine Use extreme caution when transporting on snow covered or slippery roads Wait for traffic to clear before entering a public road Beware of blind intersections Slow down until you have a clear view DO NOT attempt to pass at any intersec tion Slow down for turns and curves Make wide gentle turns PREVIOUS Gillison Forklift Manual 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 obstructions MODIFICATIONS Modification or alteration of the forklift shall be made only with prior written consent from Gillison s Variety Fabrication Inc Altering safety devices shall be prohibited RECORD RETENTION The owner shall retain the following records for at least 3 years A Purchase Information B Records of persons train
50. rator should not use alcohol or drugs which can affect their alertness or coordination An operator on prescription or over the counter drugs needs medical advice on whether or not he she can properly operate equipment FIG 5 Wear protective clothing Do not wear loose clothing as this may catch on moving parts of the ma chine causing injury Always wear protective clothing and appropriate safety equipment It is recommended that suitable protective hearing and safety glasses be worn Do not attempt to service machine clear obstruc tions or unplug blockages with the engine running Always shut off the engine first Keep all shields and guards in place SAFETY 3 FIG 4 4 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 Keep the machine properly maintained Do not operate a machine when it is broken or has missing parts Make sure that the maintenance procedures in this operator s book are completed before using the machine Check all controls regularly and adjust where neces Sary Periodically check all nuts and bolts for tightness espe cially wheel nuts Clear the area Ensure that all bystanders particularly ch
51. rklift 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 forklift running unattended Always set the parking brake shift to Neutral shut off engine and re move the key LOAD HANDLING SAFETY Heed these safety rules When lifting or loading tilt the mast back Use caution when tilting mast forward to ensure load does not shift off forks Never carry maximum rated load with center of load 24 inches above forks Avoid sudden starts and stops to prevent load from shifting Lift loads on level ground to prevent rollover Always watch for overhead obstructions when operat ing and lifting loads Do not exceed the lifting capacity of the forklift Always ensure forks of the proper capacity are used Never interchange forks with forks of a different rat ing Do not add or subtract weight from the counterweight box NEXT PAGE LAST PAGE 10 SAFETY RULES OF THE ROAD Before operating your forklift on a public road a num ber of precautions must be taken Familiarize yourself with and obey all laws appropriate to your machine Disengage FWD Make sure any required clearance flags or hazard lights are in place and in work ing order Clean off all reflectors and road lights front and rear and be certain they are in working
52. round Stop the engine and remove the starter key 2 Place a container of suitable size beneath plug B to catch the oil See Lubricants and Capacities Remove fill leve plug A and drain plug B together with their bonded washers Allow time for the oil to drain out Clean and refit drain plug B and a new bonded washer Tighten to 79 Nm 58 Ibf ft 3 Fill the axle with recommended axle oil through the fill level hole A Oil should be level with the bottom of the fill level hole See Lubricants and Capacities Clean and refit level plug A and a new bonded washer 34 LUBRICATION amp MAINTENANCE Drive head Axles Cont Rear Axle Checking the Hub Oil Levels Check each hub separately 1 Park the machine on level ground with the OIL LEVEL mark horizontal There is a tolerance of 5 mm 0 2 in above or below the horizontal Engage the parking brake Set the transmission to neutral Lower the attachments to the ground Stop the engine and remove the starter key Clean the area around the fill level plug C Remove the plug Oil shouid be level with the bottom of the hole If necessary add recommended oil See Lubricants and Capacities for recommended oil Clean the plug before refitting it Gillison Forklift Manual Changing the Hub Oil 1 Set the machine level with the tyres just clear of the ground Manually rotate the wheels to bring the OIL LEVEL mark on the hubs to the vertical position with the fill ieve
53. s the schedules are based on machine running hours Keep a regular check on the hourmeter readings to correctly gauge service intervals Do not use a machine which is due for a service Make sure any defects found during the regular maintenance checks are rectified immediately Calendar equivalents 10 Hours Daily 50 Hours Weekly 500 Hours Six Months 1000 Hours Yearly 2000 Hours 2 Years LASTPAGE 38 LUBRICATION amp MAINTENANCE Service Schedules Cont Rear Axle Service checks should be carried out as in the table at whichever time occurs first Gillison Forklift Manual 50 T1100 500 1000 2000 Hr Hr Hr Hr Pre start Cold Checks Operation 10 Service Points and Fluid Levels Hr AXLES AND STEERING Axle Hub Oil Level D Check Axle Hub Oil Change Centre Case Oil Level Check Centre Case Oil Change Steer Axie Movement Shimming Check Axle Steering Joints tT Grease HYDRAULICS Cylinders Chrome Condition Check Functional Test Operation 10 and Final Inspection Hr ed 50 T1100 500 1000 2000 Hr Hr Hr Hr AXLES AND STEERING Steering Modes Operation Check Steering Proximity Switch Operation Check Wheel Nut Torque Check Steer Phasing Check Steer Cylinder Balance Check Steer Circuit Pressure 2 Check T Note First 100 Hours Service only to be completed by your Distributor Tt Note Mobil HP222 Grease must be used at 500 Hour intervals If an alternat
54. s an one fork If inside jaws of caliper pass over the fork arm it 7 Do not apply sideways pressure to forks commonly called side loading as they are must be taken out of service This represents 10 designed for vertical loading only wear and 20 reduction in capacity ASME B56 1 recommended practices advise that forks be withdrawn from service when the thickness of the blade has worn by 1096 NEXT PAGE LAST PAGE 14 SAFETY Gillison Forklift Manual Fork Maintenance OUTSIDE JAWS 100 INSID JAWS 90 Fork calipers perform two tasks at once They measure the thickness of the fork arm shank Fig 1 and then automatically indicate what a 1096 wear factor would be when the calipers are applied to the blade cross section Fig 2 Dm 50mmy 2 Figure 1 A 10 reduction in blade thickness results in a 20 reduction of capacity Lift truck forks Not for use on full tapered forks Figure 2 ML br maintenance and inspection Lift truck forks are often mistreated and forgotten As insubstantial as they seem neglecting forks could make them dangerous There is barely a word about forks mentioned in most operator training manuals or instructed courses Lift truck technicians may ignore them completely Yet forks carry larger loads than almost any lifting device but there are no mandatory requirements for maintenance or inspection You can find thousands of extr
55. s 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 FIG 35 G Fuel Tank FIG 36 amp 36A 5 supply to Engine Fuel Fill Keep strainer clean and free of debris FIG 33 FIG 36 A EATEN PA EATEN NEXT NEXTPAGE LAST PAGE 26 LUBRICATION amp MAINTENANCE Gillison Forklift Manual H Radiator Fill Tank FIG 37 I Air Cleaner FIG 37 amp 39 J Hydraulic Oil Fill FIG 38 Air Cleaner Housing metal body amp cover AL E a LU d a e e FIG 37 Primary Filter X Cover Gasket d Body Clamp T __ Vacuator Valve NEXT PAGE LAST PAGE Gillison Forklift Manual TRANSMISSION Health and Safety Hygiene Lubricants are not a health risk when used properly for their intended purposes However excessive or prolonged skin contact can remove the natural fats from your skin causing dryness and irritation Low viscosity oils are more likely to do this so take special care when handling used oils which might be diluted with fuel contamination Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene For details of these precautions we advise you to read the relevant publications issued by your local health authority plus the following Storage
56. s exceeds 0 596 of the length of the blade and or the height of the shank respectively the fork shall not be returned to service until it has been repaired in accordance with para 6 2 8 2 c Fork Angle Upper Face of Blade to Load of the Shank Any fork that has a deviation of greater than 3 deg from the original specification shall not be returned to service The rejected fork shall be reset and tested in accordance with para 6 2 8 2 d Difference in Height of Fork Tips The difference in height of one set of forks when mounted on the fork Gillison Forklift Manual carrier shall be checked If the difference in tip heights exceeds 396 of the length of the blade the set of forks shall not be returned to service until repaired in accor dance with para 6 2 8 2 e Positioning Lock Where Originally Provided It shall be confirmed that the positioning lock is in good repair and correct working order If any fault is found the fork shall be withdrawn from service until satisfactory repair has been effected f Wear 1 Fork Blade and Shank The fork blade and shank shall be thoroughly checked for wear special attention being paid to the vicinity of the heel If the thickness is reduced to 9096 of the original thickness the fork shall not be returned to service 2 Fork Hooks Where Originally Provided The support face of the top hook and the retaining faces of both hooks shall be checked for wear crushing and other loc
57. s 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 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 safety alerts and follow the recom mended precautions and safe practices A A A 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 could result in death or serious injury CAUTION indicates an i
58. ssive skin contact wash with soap and water Spillage Absorb on sand or a locally approved brand of absorbent granules Scrape up and remove to a chemical disposal area Fires Extinguish with carbon dioxide dry chemical or foam Fire fighters should use self contained breathing apparatus LAST PAGE Gillison Forklift Manual LUBRICATION amp MAINTENANCE 37 Lubricants amp Capacities Rear Axle ITEM CAPACITY FLUID LUBRICANT INTERNATIONAL Litres UK Gals SPECIFICATION Axle SD 55 Housing 15 5 3 4 Q8EL3857 Hubs x2 0 9 0 2 Mobil Fluid 424 Q8 EL3857 API GL 4 M2C 41B 134D JD20C MF M1135 M1141 M1143 Grease Points Mobil HP222 Mobil HP222 Brake System Mobil DTE 11M ISO VG 15 CAUTION Do not use ordinary brake fluid J 1703 Service Schedules Rear Axle A badly maintained machine is a danger to the operator and the people working around him Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition 4 amp 4 WARNING A raised and badly supported machine can fall on you Position the machine on a firm level surface before raising one end Ensure the other end is securely chocked Do not rely solely on the machine hydraulics or jacks to support the machine when working under it Disconnect the battery to prevent the engine being started while you are beneath the machine GEN 1 1 Apart from the daily job
59. tes to allow oil to drain from the torque converter before checking the oil level DO NOT OVERFILL Change Oil amp Clean Strainer for Interval see Service Schedule AA CAUTION When the strainer is removed oil will gush out Keep to one side when you remove the strainer 2 3 4 1 Drain oil by removing strainer B Clean strainer using a suitable solvent When refitting strainer renew gasket C and apply Loctite 242 to bolts D Torque Settings Item Nm kgfm Ibfft X D 10 1 0 74 B vO Renew Filter for Interval see Service Schedule 8143031 1 Unscrew and discard element E 2 Smear seal F with transmission oil and fit new element Note the element must be screwed on until it contacts the filter head and then tightened a minimum of 3 4 turn equal to 15 Nm 11 Ibf ft torque 3 Fill system to dipstick mark with specified transmission fluid See Transmission Oil Fill Procedure LAST PAGE ES d Gillison Forklift Manual LUBRICATION amp MAINTENANCE 31 PD70 FRONT AXLE Axle Oil Level Check Oil Level for Interval see Service Schedule Change Oil for Interval see Service Schedule Note It is essential that the machine is parked on level 1 ground to ensure accurate oil level checking 1 At the drive head casing remove fill level plug A Oil should be level with the bottom of the fill level hole 2 H necessary top up with recommended axle oil Clean and refit fill leve plug A 5145
60. und inspection STARTING THE ENGINE Make sure parking brake is on Safety belt is fastened and secure FNR switch is in Neutral position and gear shift lever is in Neutral Turn ignition switch to start position then re lease to Run position when engine is running NOTE Max crank time 30 seconds Observe indicator lights and gauges to ensure everything is operating correctly Transmission pressure and engine oil pressure lights go out within 15 seconds Engine temperature must be above 160 F be fore operation COLD WEATHER STARTING AID WARNING Do not use ether FIG 28 Starting Fiad Re e Turn key to run position Push 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 PREVIOUS b NEXT PAGE 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 Allow engine to cool down for about 1 min ute 7 Turn key to Off position and remove 8 Release all hydraulic pressure by operating mast control levers OPERATING GVF 5000 Learn about all controls have knowl edge of the machine and it s workings and read this manual before operating the forklift ma
61. with a load Daily Inspection Perform the following at the beginning of each work shift 1 Extend the carriage a few inches off the ground and make sure the chains are under equal tension Refer to Section 5 6 3 for chain adjustment 2 Extend the mast to its fullest height to make sure the mast rails and carriage extend freely without binding 3 While the mast is extended inspect the upright rails for proper lubrication Refer to Section 2 5 3 Step for rail lubrication 4 Make sure the internal reeving hoses if equipped travel evenly in the hose guides Adjust the hose ends if re quired Tighten the fittings making sure they do not twist 100 Hour Inspection After each 100 hours of lift truck operation and in addition to the daily inspection 1 Inspect and lubricate the full length of the chains with SAE 40 wt oil or Bowman Heavy Load Red Grease CAUTION The chains must be coated with a film of lubricant at all times Pry Here Load Rollers 500 Hour Inspection After each 500 hours of lift truck operation and in addition to 06 in the Daily and 100 Hour Inspection 1 5 mm 1 Each pair of load rollers on the uprights and carriage MAX should be shimmed so that a total side to side clearance no greater than 1 16 in 1 5 mm occurs at the tightest Un d DRILL CN ee 9 point throughout the travel of the member Pry between the upright and load roller so that the opposite load roller is tight
62. y 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 acp NEXTPAGE Last PAGE

GVF Forklift Owners Manual - Gillison`s Variety Fabrication Inc.

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