tier iii gvf rough terrain forklift owners manual

Tier III GVF Rough Terrain Forklift

Owners ManualModel Numbers:

GVF 5000GVF 6000GVF 8000

Manual Part Number: GL 11497Revised 11/13/2014

GVF

3033 Benzie Hwy. Benzonia, Mi 49616 231-882-5921Fax 231-882-5637 800-392-6059

Gillison’s Variety Fabrication, Inc.

email: [email protected] online: www.gillisons.com

Table of Contents

TABLE OF CONTENTS

INTRODUCTION 1

SAFETY 2

Forklift Mast Safety 16

Fork Safety 11

General Safety Rules 3

General Safety While Operating 4

Instruction Decals 8

Intro to safety 2

Load Handling Safety 9

Modifications 10

OwnershipRecords 10

RecordRetention 10

Rules of the Road 9

Safety Alert Symbol 2

Safety While Operating 9

Safety While Servicing the Machine 5

Serial Number 9

Signal Words 2

CONTROLS 17

Instrument Panel Diagram 17

Instrument Panel Information 17

Various Controls 19

OPERATION 21

Cold Weather Starting Aid 21

Forklift Shutdown 21

Operating GVF Forklift 21

Pre Start Up 21

Starting The Engine 21

LUBRICATION & MAINTENANCE 23

Brake Fluid 42

Electrical 44

FilterPartNumbers 50

Hydraulic System 42

Instructions for Pressure Washing 24

Lubrication & Maintenance Chart 23

Mast Maintenance 38

PD70FrontAxle 30

ReferenceDocuments: 50

SD55RearAxle 32

Tier III Air Cleaner 25

Transmission 25

GVF WARRANTY 51

GVF Rough Terrain Forklift Manual INTRODUCTION - 1

INTRODUCTION

The information in this publication describes the safety requirements, operation, maintenance and servicing of the Gillison Forklift. Every effort has been made to 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 thismachine. Inexperienced op-erators should study contents of this publication and receiveinstructionfromanexperiencedoperatorwhenpossible. 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.

GVF Tier III Turbo Rough Terrain Forklift

- SAFETY 2 GVF Rough Terrain 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 careful approach to handling equipment. You, the operator, can avoid many accidents by observing the following pre-cautions. To avoid personal injury, study the following 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.

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 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 identi-fiedlaterinthissectionofthemanual.

FIG. 1

FIG. 2

SAFETY - 3GVF Rough Terrain 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 operator 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. Alwaysshutofftheenginefirst.

Keep all shields and guards in place.

FIG. 3

FIG. 4

FIG. 5


FIG. 6: Additional equipment: A fire extinguisherandfirstaidkitshouldbecarriedwiththemachineorbe 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 children, are at a safe distance before starting the en-gine.

FIG. 7: Be aware of electrocution haz-ards. To prevent injury or death from electrocution:

Stay away from overhead power lines when operating forklift in raised po-sition. This machine is not grounded. Electrocution can occur without direct contact.

Be observant of the operating area and terrain. Watch for holes, rocks or other hidden hazards. AL-WAYS 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 frombankshouldequalorexceedtheoverallheightofthe 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.

FIG. 9: Do not use starting fluid.Startingfluidmust

FIG. 6

FIG. 7

FIG. 8


onlybeusedwhenanether-startaidisfittedasoriginalequipment 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 orether aid.

Useofstartingfluidonanengineequippedwithanin-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.

Ifinanenclosedarea,venttheexhausttotheoutside.

Donottamperwithormodifytheexhaustsystemwithunapprovedextensions.

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 compatibleandwillmixwithexistingcoolant.

FIG. 9

FIG. 10

Ether


Electrical System

FIG. 11: To prevent serious injury or death from ex-ploding gases:

Do not work on batteries without proper instruction and training.

FIG. 12: Before making adjustments or servicing the electrical system, disconnect the battery negative (-) cable(see1)firsttopreventshortcircuits.

Keepsparks,flamesandcigarettesaway.Useaflash-light to check the battery electrolyte level if necessary.

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.

Batteriesproduceexplosivehydrogengaswhencharged.Charge in area with adequate ventilation. Halt charging ifbatterytemperatureexceeds52°.

Wash hands after handling battery.

Hydraulic System

FIG. 13: High pressure fluid hazard. To prevent seri-ous injury or death:

Relieve pressure on system before re-pairing, adjusting or disconnecting.

Wear proper hand and eye protection when searching for leaks. Use wood or cardboard instead of hands.

Keep all components in good repair.

Ensure that all hydraulic connections are tight.

Relieve all pressures before disconnecting hoses or lines. Escaping oil under pressure can cause serious in-jury.

Allfluids shouldbehandledwithcare. Ifyouare in-juredbyor swallowanyfluid, seekmedical attentionimmediately 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 nozzleswhichejectfluidsunderhighpressure.When

FIG. 11

FIG. 12

FIG. 13


checking for leaks always use a piece of cardboard or wood.Neveruseyourhandstofindapressureleak.

IfANYfluidisinjectedintotheskin,itmustbeattend-ed to by a doctor immediately.

Fuel System

FIG. 14: Diesel fuel is flammable and must be han-dled with care.

Never refuel or service the fuel system on the machine whilesmokingorwhennearopenflamesorsparks.

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 optimumperformance.Extreme caremustbe 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 qualifiedrepairservice.

The machine must be supported on suitable blocks or stands, NOT a hydraulic jack.

Whenseatingtirebeadsontorims,neverexceed2.4bar(35psi)orthemaximuminflationpressurespecifiedonthe tire.Inflationbeyondthismaximumpressuremaybreakthebead,oreventherim,withdangerous,explo-sive force.

When preparing a calcium chloride solution for fluidblasting the tires, NEVER pour water onto the calcium chloride. A chlorine gas can be generated which is poi-sonousandexplosive.Thiscanbeavoidedbyslowlyaddingcalciumchlorideflakestowaterandstirringun-til they are dissolved.

Wear suitable protective clothing, gloves and eye/face protection.

Replacement Parts

FIG. 15: Where replacement parts are necessary for periodic maintenance and servicing, replacement parts from Gillison’s must be used to restore your equipment tooriginalspecifications.

FIG. 14

FIG. 15


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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 provid-ed 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.

FIG. 16

1. SP 6255 2.SP6260 3.SP6210

4.SP6207 5. SP 6285 6. SP 6315

7.SP6208 8. SP 6211

9. SP 6265

10.SP629011.SP6250

12.SP6270 13. SP 6221 14. SP 6275

15.SP6320 16. SP 6325

Decal Locations

17.FOPSdecalSP6300

Nameplate - SP 6305 Includes important information such as: Warning, Model, Serial Number, Type, Tire Pressure & Size, Mast Type, DegreesMaxBackTilt,DateofManufacture,DriveTread,Truck Wt., Capacity

1 3

4

10

12

17

7

8

Nameplate

&

&

2

5 119

6

16

15

13&


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 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 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.

Heed these safety rules:

Inspect the forklift each day.

Perform scheduled maintenance to ensure optimum performance.

Wear proper clothing.

a. No baggy clothing

b. Use eye protection

FIG. 17

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.

Donotoperate theforkliftunder the influenceofanykind of drugs or alcohol that impair judgment or per-formance.

Do not operate the forklift without overhead guard in place.

Lower forks completely to the ground when adjusting and when work is completed.

Do not allow anyone to stand under or work under raised forks.

Never raise persons with the forks.

Never leave 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.

Nevercarrymaximumratedloadwithcenterofload24inches 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.

Donotexceedtheliftingcapacityoftheforklift.

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.

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 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

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.

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

Modificationoralterationoftheforkliftshallbemadeonly 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 trained upon de-livery of the GVF Forklift

C. Written records of frequent inspec-tions, maintenance performed and parts replaced

OWNERSHIP RECORDS

When a change of ownership of a GVF Forklift occurs, it is the responsibility of the seller to notify Gillison’s Variety Fabrication Inc. with the following information within60daysofthesale:

A. Serial number of machine

B. Name & address of new owner

FIG.18


FORK SAFETY

Fork Inspection


Fork Inspection Cont.


Fork Inspection Poster


Fork Maintenance


Fork Maintenance Cont.


FORKLIFT MAST SAFETY

Refer to the following illustrations for mast safety:

CONTROLS - 17GVF Rough Terrain Forklift Manual

CONTROLS

INSTRUMENT PANEL DIAGRAM

INSTRUMENT PANEL INFORMATION

1. Push button Start

1. Push button Start

2. High Transmission Temperature Light (Red)

3. Low Transmission Oil Pressure Light (Red)

4. Low Engine Oil Pressure Light (Red)

5. Parking Brake Light (Red)

6. Engine Preheat Light (Red)

7. Engine Water Temperature Gauge

8. Hour meter Gauge

9. Voltmeter Gauge

10.FuelGauge

11. Four Wheel Drive Switch

12. Front and Rear Work Lights

13. Warning Lights Switch

14. Turn Signal Switch

15. 12 V Power Source

1

2

3 4

51011 12

9

6

7

15

13

8

14

Ignition Switch

Turn Clockwise to Run position.

- CONTROLS 18 GVF Rough Terrain Forklift Manual

Push to start. (First, turn ignition switch clock-wise to Run position.)

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, thelightshouldextinguishinseconds.Stopen-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 shouldextinguishinseconds.Stopengineandinvestigate 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-gaged.

6. Engine Preheat Light (Red)

When illuminated, Preheat is on.

Maximumpreheattimeis30seconds.

7. Engine Water Temperature Gauge

Ensure engine is operating in Normal tempera-ture zone. Stop engine if needle moves above 250° F.

Allowenginetowarmuptoabove160° 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 lightsflash.

When in the center position, the switch is off.

15. 12V Power Source

CONTROLS - 19GVF Rough Terrain Forklift Manual

VARIOUS CONTROLS

1. Optional Preheat Switch

Push to activate preheat.

Maximumtimeis30seconds.

2. Forward, Neutral, Reverse Switch FIG. 19

Center position is Neutral.

3. Horn Switch FIG. 19

Push to activate.

FIG. 19

3

2

FIG. 20

4

4. Steering Wheel Adjustment FIG. 20

1Position–Heightadjustment.Pulluptoex-tend the column.

2 Position – Angle adjustment. Push down to tilt the wheel.

DANGER – Adjustments of steering wheel must be done with the forklift stopped.

5. Steering Wheel FIG. 21

Turn wheel left for left turn.

Turn wheel right for right turn.

6. Lift Valve FIG. 22

A – Lift

B – Tilt

C – Side shift

D–Auxiliary

FIG. 22

7. Parking Brake FIG. 23

1 Position – Engaged

2 Position – Disengaged

Engaged DisengagedFIG. 23

FIG. 21

B DCA

1 2

- CONTROLS 20 GVF Rough Terrain Forklift Manual

8. Brake Pedal FIG. 24

Push to apply service brakes.

FIG. 24

9. Throttle Pedal FIG. 24

Push to increase engine speed.

10. Gear Shifter FIG. 25

11. Shift Disconnect Switch FIG. 26

Push to shift transmission.

FIG. 25

FIG. 26

11

Shift Knob

Shift Switch

12. Suspension Seat FIG. 27

A – Slide adjustment

B – Weight adjustment

Push down to increase stiffness

C – Back Rest Adjustment

D – Seat Belts

FIG. 28

13. Mirror

Adjust before operation.

14. Operator’s Manual Storage FIG. 28

FIG. 27

8 9

10

B

DC

A

OPERATION - 21GVF Rough Terrain Forklift Manual

OPERATION (ReadCONTROLSsectionfirst.)

PRE START UP

Check engine oil, transmission, hydraulic oil andradiatorfluidlevel.

Do a walk around 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 clockwise to run position then push start button.

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 before operation.

COLD WEATHER STARTING AID

Ether

WARNING: Do not use ether. FIG. 28

• Turn key to run position.

•Pushpre-heatbuttonupto30seconds.

• Hold button in and push start button.

• Crank over until engine is running.

• Release the push buttons. If there is no start, repeat the steps.

FIG. 28

FORKLIFT SHUTDOWN(readCONTROLSsectionfirst)

1. Reduce engine speed to idle. Make sure forklift 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 minute.

7. Turn key to Off position and remove.

8. Release all hydraulic pressure by operating mast control levers.

OPERATING GVF FORKLIFT

Learn about all controls, have knowl-edge of the machine and its workings, and read this manual before operating the forklift machine.

1. Make sure no obstructions are in the way.

2. Release parking brake.

3. Select a gear with the gear selector. FIG. 29

4. Raise the mast until forks are a safe distance from the ground.

FIG. 29

Forward Back

Up

Down

Lift

Tilt

- OPERATION 22 GVF Rough Terrain Forklift Manual

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.

6. Operation of Parking Brake FIG. 23

Side Shift

ReleaseBin ClampClamp

LeftRight

FIG. 30

7. Four Wheel Drive Operation

FIG. 23

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 selected 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.

FIG. 31

Location of fuel tank

Push to turn warning flasherson

Push to activate 4 wheel drive Push to turn on FRONT work lights

Push for LEFT turn signal Push for RIGHT turn signal

Push to turn on FRONT and REAR work lights

Engaged Disengaged

LUBRICATION & MAINTENANCE - 23GVF Rough Terrain Forklift Manual

LUBRICATION & MAINTENANCE

LUBRICATION & MAINTENANCE CHART

* First 100 hours service only to be completed by your distributor.

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Break Fluid Reservoir

Radiator Fill

Grease Point: Tilt Cylinders

Forks

Fuel Fill

Engine Access

Grease Point: Front Axle

Grease Point: Rear Axle

Air Cleaner

TransmissionBattery

Hydraulic Oil Fill

Grease Point: Mast

Item Daily 50hrs 100hrs

500hrs

1000hrs

1500hrs

2000hrs

Pageinthis

manualTirePressure

Engine Refer to engine manual. Transmission 26

HydraulicOilLevel 42 SuctionStrainer 42

HydraulicOilChange HydraulicOilFilter 42 BrakeFluidLevel change 42 WheelNutTorque

FrontAxle 30 RearAxle 32 Mast 38 Forks 11

GreaseAllPoints below

Grease Point: Brake Pedal

Grease Point: Front Drive Shaft

Grease Point: Rear Drive Shaft

Grease Point: Hood Hinges

- LUBRICATION & MAINTENANCE 24 GVF Rough Terrain Forklift Manual

FIG. 34

INSTRUCTIONS FOR PRESSURE WASHING

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 harness and connections, and Safety decals

ENGINE – PLEASE REFER TO THE ENGINE MANUAL.

Part Number 9801/9310

A. Oil filter FIG. 32

B. Engine oil dipstick FIG. 32

C. Oil fill cap FIG. 32

D. Oil drain plug FIG. 33

FIG. 32

FIG. 33

FIG. 35

E. Fuel filters FIG. 34 & 35

F. Fuel lift pump FIG. 35

G. Fuel Tank FIG. 36 & 36 A

FIG. 36

Drain

Supply to Engine

FIG. 36 A

Primary Fuel Filter Secondary Fuel Filter

Fuel Fill Cap

Keep strainer clean and free of debris

H. Radiator Fill Tank FIG. 37 & 37 AB

D

CA

F

G

E E

E

G


I. Air Cleaner FIG. 38 & 39

J. Hydraulic Oil Fill FIG. 38 A

TRANSMISSION

FIG. 37

FIG. 38

Radiator Pressure Cap

FIG. 38 A

FIG. 37 A

H

I

J

FIG. 39

TIER III AIR CLEANER

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.com

/airc

lean

ers

Mill

ions

of

Pow

erC

ore

® F

ilter

s In

stal

led o

n O

rigin

al E

quip

men

t!Th

ree

times

mor

e ef

ficie

nt th

an a

vera

ge c

onve

ntio

nal p

leat

ed p

aper

filte

rs

This

new

air

clea

ner f

amily

of

fers

two-

stag

e fil

tratio

n in

a

sing

le, c

ompa

ct u

nit t

hat d

eliv

ers

supe

rior fi

ltrat

ion

perfo

rman

ce

usin

g ou

r Pow

erCo

re®

Filt

ratio

n Te

chno

logy

.

This

non

-met

al a

ir cl

eane

r (e

xcep

t for

cov

er c

lam

ps) i

s id

eal

for m

ediu

m- a

nd h

eavy

-dut

y eq

uipm

ent o

pera

ting

in li

ght t

o m

ediu

m d

ust e

nviro

nmen

ts.

Whe

n yo

u re

ques

t Po

wer

Core

Filt

ratio

n Te

chno

logy

, you

will

gai

n...

Equa

l or b

ette

r per

form

ance

in a

sm

all p

acka

ge –

the

freed

om to

de

sign

uni

que

confi

gura

tions

to

fit ti

ght s

pots

and

ove

rall

desi

gn

sim

plic

ity.

Don

alds

on re

liabi

lity

- bac

ked

by n

early

a c

entu

ry o

f inn

ovat

ion

and

expe

rienc

e. D

onal

dson

su

pplie

s ai

r filtr

atio

n pr

oduc

ts

to a

lmos

t eve

ry v

ehic

le

man

ufac

ture

r.

Low

er s

hipp

ing

and

inve

ntor

y co

sts

– Po

wer

Core

filte

rs a

re

light

er a

nd ta

ke u

p le

ss s

helf

spac

e.

Prim

ary

filte

r with

Po

wer

Core

Filt

ratio

n Te

chno

logy

Cove

r ret

entio

n la

tche

s

Safe

ty fi

lter

(incl

uded

)Inje

ctio

n m

olde

d bo

dy

Filte

r ser

vice

in

dica

tor p

ort

Pre-

clea

ner d

rop

tube

Hous

ing

com

es w

ith a

Va

cuat

or™

Val

ve (P

1589

14).

Dr

op tu

be d

esig

ned

to b

e us

ed

as a

sca

veng

e lin

e or

with

a

Vacu

ator

Val

ve.H

igh

effic

ienc

y pr

e-cl

eane

r tu

bes

Inte

grat

edm

ount

ing

brac

kets

Prim

ary

filte

r with

Po

wer

Core

Filt

ratio

n Te

chno

logy

Cove

r ret

entio

n la

tche

s

Safe

ty fi

lter

serv

ice

hand

lein

clud

ed

Inje

ctio

n m

olde

d bo

dy

Avai

labl

e in

sta

ndar

d or

long

leng

ths

(Inle

t/ou

tlet e

nds

are

perm

anen

tly s

ecur

ed to

this

pi

ece

- sho

rter l

engt

h sh

own)

Filte

r ser

vice

in

dica

tor p

ort

Pre-

clea

ner d

rop

tube

Desi

gned

to b

e us

ed a

s a

scav

enge

line

or w

ith a

Va

cuat

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ve. M

odel

s av

aila

ble

with

tube

on

long

si

de o

f inl

et.

Hig

h ef

ficie

ncy

pre-

clea

ner t

ubes

Vacu

ator

™ V

alve

Inte

grat

ed m

ount

ing

brac

kets

on th

ree

side

s of

the

body

Rem

ovab

le

acce

ss c

over

Serv

ice

hand

le

atta

ched

to fi

lter

Atta

chm

ent p

oint

sfo

r you

r inl

et d

uctin

g

acce

ssor

ies

Serv

ice

Acc

ess

on In

let E

nd -

PSD

08

Serv

ice

Acc

ess

on S

ide

- PSD

09, P

SD10

and

PSD

12

Exp

lode

d vi

ew is

of

D08

0020

. Fo

r tu

be o

n lo

ng s

ide

of in

let

end

(opp

osit

e cl

amps

), c

onsi

der

D08

0026

.

Exp

lode

d vi

ew is

of

D09

0019

mod

el.

For

tube

on

long

sid

e of

inle

t en

d, c

onsi

der

D09

0020

or

D09

0022

.

Dona

ldso

n Po

wer

Core

® p

rodu

cts

are

prot

ecte

d in

tern

atio

nally

by

pate

nts,

trad

emar

ks, a

nd d

esig

n re

gist

ratio

ns, b

oth

issu

ed a

nd p

endi

ng.

GL

P776

033

GL

P601

735

GL

1227

0

- cov

er

GL

P122

90In

dica

tor,

air fi

lter r

estr

ictio

n

GL

1226

5

I


Health and Safety


Lubricants and Capacities - Transmission


Service Schedule - Transmission


Synchro Shuttle Transmission


PD70 FRONT AXLE

Axle Oil Level


Lubricants & Capacities - Front Axle

Service Schedules - Front Axle


SD55 REAR AXLE

Drive head Axles


Drive head Axles Cont. - Rear Axle


Greasing Axles - Rear Axle


Health & Safety - Rear Axle


Lubricants & Capacities - Rear Axle

Service Schedules - Rear Axle


Service Schedules Cont. - Rear Axle


MAST MAINTENANCE


Mast maintenance cont.


BRAKE FLUID

•Checklevelevery100hours

•Changefluidevery1500hours

• Use Brake Fluid Mobile 424

seeFIG.40

FIG. 40

Brake Fluid

HYDRAULIC SYSTEM

• Check hydraulic oil level daily FIG. 41

FIG. 41

•Change hydraulic oil filter every 500 hoursFIG. 42

FIG. 42

•Changehydraulicoilevery1000hoursFIG.43

•Cleansuctionstrainerevery1000hours

FIG. 43

Hydraulic Oil Fill

• keep strainer clean & free of debris

Hydraulic oil level

sight glass

Filter Head

GH11604 Dealer Part No.

GL11690


Hydraulic Diagram


FIG. 45

FIG. 12

ELECTRICAL

FUSES SEE FIG. 44

FIG. 44

Battery

SEE FIG. 45 & FIG.12

Fuse Access PanelBatteryBox


4 WD and Timing Advance Electrical Circuit

01 01

02 02

03 03

04 04

05 05

06 06

07 07

08 08

09 09

10 10

AA

BB

CC

DD

EE

FF

GG

A1

A2

-+

4DFW

D S

OLE

NO

IDA

-2C

7.5

AM

P F

US

E #

2

A1

A2

AD

VA

NC

E S

OLE

NO

ID

1314 t°

EN

GIN

E T

EM

P S

WIT

CH

AW

G16

BLU

E/G

RA

Y1

BLUE/GRAY 3

3087

A 87

6CR

NO

8685

7CR

FWD

REL

AY

BLUE/YELLOW 2

1

PA

NE

L G

RD

.AWG16 BLACK 5

1 GR

D.

AWG16 BLACK

A-3

C7.

5 A

MP

FU

SE

# 3

AWG16WHITE/BROWN

1

8 F

8 M

FCI 1

0 W

AY

9 M

9 F

AW

G16

BLU

E/G

RA

Y4

23

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

FWD

SW

ITC

H

AW

G16

BLU

E/W

HIT

E6

D-2

C-1D

-1B

-2

Dra

wn

by :

MA

TT G

ILLI

SO

NR

evis

ion

: 2G

L500

0_08

FWD

Dat

e : 1

2-19

-07

Pag

e 1/

1


01 01

02 02

03 03

04 04

05 05

06 06

07 07

08 08

09 09

10 10

AA

BB

CC

DD

EE

FF

GG

-+

Vol

tmet

er

1314

TRA

NS

PR

ES

. SW

ITC

H

1314 t°

TRA

NS

TE

MP

SW

ITC

H

1314

EN

G. O

IL S

WIT

CH

X1

X2

PA

RK

BR

AK

E

X1

X2

TRA

NS

PR

ES

SU

RE

X1

X2

1812

-1-1

2-20

340

FUE

L P

RE

SS

UR

E

X1

X2

EN

GIN

E O

IL

-+

HR

ME

TER

1112 14

PA

RK

SW

ITC

H

-

S

TEM

P S

EN

DE

R

S+

I

FUE

L G

UA

GE

S+

I

EN

GIN

E T

EM

P

S-

FUE

L LE

VE

L

X1

X2

TRA

NS

TE

MP

A-1

C7.

5 A

MP

FU

SE

# 1

1

PA

NE

L G

RD

.

BLACK 13

1

GR

D. #

2

1

GR

D. #

1

1 F

1 MFC

I 14

WA

Y

2 F

2 M

3 F

3 M

6 F

6 M

4 F

4 M

5 F

5 M

7 F

7 M

AWG16 PINK 3

AW

G16

PU

RP

LE4

AWG16 GRAY 6

AWG16 TAN 5

AW

G16

WH

ITE

7

AWG16 GREEN/ORANGE 8

17

RED 11

RED 12

RED 10

AWG16 RED 1

AW

G16

BLA

CK

9

BLACK 14

BLACK 15

1

9

9

GR

OU

ND

ALL

BU

LBS

13 F

13 M

AWG16ORANGE/WHITE

1314

FUE

L P

RE

S. S

WIT

CH

Dra

wn

by :

MA

TT G

ILLI

SO

NR

evis

ion

: 3G

L500

0_08

GA

UG

ES

Dat

e : 7

/29/

10P

age

1/1

Gauges and Indicator Lights Electrical Circuit


01 01

02 02

03 03

04 04

05 05

06 06

07 07

08 08

09 09

10 10

AA

BB

CC

DD

EE

FF

GG

-+

BA

TTE

RY

12V

STU

DA

WG

1R

ED

A1

A2 PE

DC

STA

RTE

R

GR

D. #

1

1314

STA

RTE

R S

WIT

CH

1314

IGN

ITIO

NS

WIT

CH

AW

G1

BLA

CK

YE

LLO

W/R

ED

2

1314

SD

-SW

ITC

H

12

BA

CK

UP

ALA

RM

12

HO

RN

A1

A2

PU

MP

SO

LEN

OID

+ -

12 V

DC

PO

WE

R

ALT

INA

TOR

3087

a 87

S/D

RE

LAY

8685

13/N

O14

4CR

NO

8685

5CR

ST. R

ELA

Y

6 F

5 F

4 F

3 F

2 F

1 F

1

4 5 6

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

3

23

HO

RN

SW

ITC

H

FNR

SW

ITC

H

DE

UTS

CH

6 W

AY

AW

G16

RE

D

AW

G16

RE

D

AW

G16

GR

EY

/GR

EE

N

AW

G16

GR

EE

N

AW

G16

GR

EY

/BLA

CK

AW

G16

BLU

E

A-9

C15

AM

P F

US

E #

9

GR

EY

/GR

EE

N12

A-8

C10

AM

P F

US

E #

8

D +

B+

AWG12 RED/GREEN

RED/GREEN

AWG8 RED

RED/BLACK

RED/GREEN

AW

G16

RE

D/B

LAC

K19

AW

G16

RE

D/G

RE

EN

20

3

YELLOW/RED

BROWN 6

AW

G16

BR

OW

N

9

AWG16 ORANGE

ORANGE8

11

AWG16 RED 10

RE

D7

GREY/BLACK 15

GREEN 13

BLUE 16

14

AWG16 RED/PURPLE

1 F

1 M

FCI 1

0 W

AY

4 F

4 M

5 F

5 M

2 F

2 M

3 F

3 M

6 F

6 M

7 F

7 M

3087

a 87

8685

N-S

-S R

ELA

Y

LIG

HT

BLU

E18

AWG16 LIGHT BLUE

A-6

C10

AM

P F

US

E #

6

AWG16 YELLOW/RED 1

AWG8 RED

1

PA

NE

L G

RD

.A

WG

16B

LAC

K17

11 F

11 M

FCI 1

4 W

AY

12 F

12 M

31

GR

D.

A-7

C20

AM

P F

US

E #

7

AWG16 RED 4

AWG16 BLACK 5

AW

G10

RE

D

1G

RD

. # 1

AWG16 GREEN

AWG16 BLUE

BLA

CK

BLA

CK

ORANGE/WHITE

1G

RD

. # 2

BLA

CK

AWG16 BLACK

AWG1 BLACK

B-6

D-5

B-5

D-6

D-3

B-4

C-3

D-4

A2

A1

-+

1DFOW

AR

D S

OLE

NO

ID

RE

VE

RS

E S

OLE

NO

ID

A2

A1

-+

2D

1 M

1 FFC

I 6 W

AY

2 M

2 F

3 M

3 F

4 M

4 F

5 M

5 F

6 M

6 F

A1

A2

13/N

O14

1/L1

2/T1

1/L1 2/T1

FUS

E 2

0 A

MP

FUS

E 5

0 A

MP

PS

S

PS

RPO

WER

REL

AY

MO

DU

LE

Dra

wn

by :

MA

TT G

ILLI

SO

NR

evis

ion

: 2G

L500

0_08

PO

WE

R_S

UP

PLY

Dat

e : 1

2-26

-07

Pag

e 1/

1

Ignition Switch and Power Supply Relay

Electrical Circuit


01 01

02 02

03 03

04 04

05 05

06 06

07 07

08 08

09 09

10 10

AA

BB

CC

DD

EE

FF

GG

CA

-420

AM

P F

US

E #

42

1 3

5

4 6

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

WO

RK

LIG

HTS

X1

X2

RE

AR

WO

RK

LIG

HT

X1

X2

FRO

NT

WO

RK

LIG

HT

X1

X2

FRO

NT

WO

RK

LIG

HT

X1

X2

RE

AR

WO

RK

LIG

HT

RE

D/G

RE

EN

1

2

3

3

AW

G16

BLU

E/G

RE

EN

4

AW

G16

BLU

E/R

ED

AW

G16

BLU

E/R

EDA

WG

16B

LUE

/GR

EE

N

5

1G

RD

.A

WG

16B

LAC

K

CA

-510

AM

P F

US

E #

52

3

5

6

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

FLA

SH

ER

SW

ITC

H

2

1 3

5

4 6

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

12

31

23

TUR

N S

IGN

AL

SW

ITC

H

T/S

TAIL

GR

D.

R-R

LIG

HT

T/S

TAIL

GR

D.

R-L

LIG

HT

T/S

TAIL

GR

D.

F-R

LIG

HT

T/S

TAIL

GR

D.

F-L

LIG

HT

L+

I

B-8

D-8

C-9

FLA

SH

ER

AWG16 WHITE 12

AWG16 WHITE/YELLOW 14

1 2

5D1 2

6DAWG16 WHITE/BROWN 16

20

WH

ITE

/BLU

E22

WH

ITE

/RE

D18

1 GR

D.

AWG16 BLACK

WH

ITE

/RE

D19

WHITE/YELLOW 15

1

PA

NE

L G

RD

.A

WG

16B

LAC

K17

1 M

1 FFC

I 2 W

AY

2 M

2 F

1 M

1 FFC

I 2 W

AY

2 M

2 F

8 F

8 M

FCI 1

4 W

AY

9 F

9 M

10 F

10 M

1 M

1 FFC

I 2 W

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REFERENCE DOCUMENTS:

GVF5000ForkliftPartsManual

Part Number: GL11485

GVF5000ForkliftServiceManual

PartNumber:GL11490

TransmissionSS700ServiceManual

PartNumber:9803/9070

FrontAxlePD70ServiceManual


RearAxleSD55ServiceManual


JCB 444 Engine Service Manual


FILTER PART NUMBERS

Engine Oil Filter

PartNumber:GL11670

TierIIIFuelPrefilterandWaterTrap

Part Number: GL 12535

Fuel Filter 5 Micron

PartNumber:GL11680

Transmission Oil Filter


Hydraulic Oil Filter

PartNumber:GL11690

Tier III Engine Air Filters:

Primary Filter


Safety Filter

PartNumber:GL12270

WARRANTY - 51GVF Rough Terrain Forklift Manual

GVF WARRANTY

Gillison’s Variety Fabrication, Inc. will replace or repair at GVF option, any GVF manufactured item that is, intheopinionofGVF,defectiveinmaterialorworkmanshipforaperiodof1yearor1,000hours,whichevercomesfirst,fromthedateofpurchase,andisreturnedtotheGVFplantorservicecenterattheexpenseofthecustomer. Thiswarranty ismadeexpressly in lieuofallotherwarrantiesexpressedor 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.

Theownerisspecificallyresponsiblefortheoperationandserviceofthemachine.Thiswarrantyshallnotapply 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 notresponsibleforlosttimeoranyotherexpensesincurredduetolosttime.

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 orreplacedwhencontinuedoperationwouldcausedamageorexcessiveweartootherpartsorcauseasafetyhazard.

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.