Gillison's variety fabrication Tier iv gvf 4000 User manual

Tier IV GVF 4000

Rough Terrain Forklift

Owners Manual

Model Number:

GVF 4000

Manual Part Number: GL 11498

3033 B

enzie

. B

enzonia

, Mi 49616 231-882-5921

Fax 231-882-5637 800-392-6059

Gillison’sVariet y

Fabrication, Inc.

email: [email protected]

online: www.gillisons.com

GVF

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INDEX

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

Modications 10

OwnershipRecords 10

RecordRetention 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

Display Screen Information 18

Display Screen - Pop Up Warning Lights 21

Instrument Panel Diagram 17

Various Controls Of The Forklift 25

OPERATION 29

Cold Weather Starting 29

Forklift Shutdown 29

Operating The GVF Forklift 29

Pre Start Up 29

Starting The Engine 29

Troubleshooting 32

LUBRICATION & MAINTENANCE 36

Electrical 53

Engine 49

Factory Fill For Oil, Fluid and Grease 37

Filter Part Numbers 37

FrontAxle111DualBrake 60

Grease Point and Maintenance Locations Diagram 38

Grease Point Locations 39

Hydraulic Diagram 44

HydraulicSpecications 45

Hydraulic System 42

Instructions for Pressure Washing 36

Lubrication & Maintenance Chart 36

Mast Maintenance 66

Rear Axle 211 63

Reference Documents 37

T120006SpdTransmissionMaintenance 47

Transmission 46

WARRANTY 70

GVF Warranty 72

KohlerEngineWarranty70

6/2018

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GVF 4000 Rough Terrain Forklift Manual INTRODUCTION - 1

INTRODUCTION

The information in this publication describes the safety

requirements, operation, maintenance and servicing of

theGVFForklift.Everyeort hasbeenmade topro-

vide correct and concise information to you, the oper-

ator, as available at the date of publication. Your GVF

dealer is available should items in this book or details of

your machine not be understood.

This book is supplied with each machine to familiarize

the operator with proper instructions needed for opera-

tion and maintenance. Studying and adhering to these

instructions will insure optimum machine performance

and longevity. A machine that is maintained properly

and operated in the intended manner will provide great-

er dividends than one that is neglected and/or operated

in a manner other than as intended. Design and servic-

ing of this machine has been kept as simple as possible

to permit maintenance operations to be carried out with

tools normally available.

This book should be thoroughly read and understood

prior to operation of this machine. Inexperienced op-

erators should study contents of this publication and

receive instruction from an experienced operator when

possible. Your GVF dealer can assist in areas concern-

ing machine operation and provide details concerning

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/GVF dealer in regards to acquiring a re-

placement.

Customers are strongly advised to use an authorized

Gillison/GVF 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/GVF dealer for repairs

and/or replacement.

GVF4000,TierIVRoughTerrainForklift

Location of Owner’s Manual

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- SAFETY2GVF 4000 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.

SAFETYALERT SYMBOL

FIG. 1: This is the safety alert symbol. It means AT-

TENTION! BECOMEALERT! 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.

SIGNALWORDS

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,

may result in minor or moderate injury.

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-

edlaterinthissectionofthemanual.

FIG. 1

FIG. 2

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SAFETY - 3

GVF 4000 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 o engine and remove key.

WARNING: An operator should not use

alcohol or drugs which can aect their

alertnessorcoordination.Anoperatoron

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otheenginerst.

Keep all shields and guards in place.

FIG. 3

FIG. 4

FIG. 5

Location of Owner’s Manual

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- SAFETY4GVF 4000 Rough Terrain Forklift Manual

FIG. 6: Additional equipment: A re extinguisher

andrstaidkitshouldbecarriedwiththemachineor

be kept readily available at all times.

Have emergency telephone numbers for immediate ac-

cess.

GENERALSAFETY 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

manual 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

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.

FIG. 6

FIG. 7

FIG. 8

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GVF 4000 Rough Terrain Forklift Manual

FIG. 9: Do not use starting uid.Startinguidmust

onlybeusedwhenanether-startaidistted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 uid or

ether aid.

Useofstartinguid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.

SAFETYWHILE 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 existing coolant.

FIG. 9

FIG.10

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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(see1)rsttopreventshortcircuits.

Keepsparks,amesandcigarettes away. Useaash-

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

if battery temperature exceeds 52°.

Wash hands after handling battery.

Hydraulic System

FIG. 13: High pressure uid 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.

Alluidsshouldbehandled with care. If you are in-

juredbyorswallowanyuid, 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uids under high pressure.When

FIG. 11

FIG. 12

FIG. 13

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SAFETY - 7

GVF 4000 Rough Terrain Forklift Manual

checking for leaks always use a piece of cardboard or

wood.Neveruseyourhandstondapressureleak.

IfANYuidisinjectedintotheskin,itmustbeattend-

ed to by a doctor immediately.

Fuel System

FIG. 14: Diesel fuel is ammable and must be han-

dled with care.

Never refuel or service the fuel system on the machine

whilesmokingorwhennearopenames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

qualied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inationpressurespeciedon

thetire.Inationbeyondthismaximumpressuremay

break the bead, or even the rim, with dangerous, explo-

sive force.

When preparing a calcium chloride solution for uid

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akestowaterandstirringun-

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

tooriginalspecications.

FIG. 14

FIG. 15

refueling.

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- SAFETY8GVF 4000 Rough Terrain Forklift Manual

A A

B B

C C

D D

SHEET 1 OF 1

DRAWN

CHECKED

MFG

APPROVED

Matt 9/8/2016

DWG NO

GVF9400_DECALS

TITLE

GVF 4000 DECAL LOCATIONS

SIZE

SCALE

GILLISON'S VARIETY FAB.

REV

A A

B B

C C

D D

SHEET 1 OF 1

DRAWN

CHECKED

MFG

APPROVED

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DWG NO

GVF9400_DECALS

TITLE

GVF 4000 DECAL LOCATIONS

SIZE

SCALE

GILLISON'S VARIETY FAB.

REV

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.SP6260 3.SP6210

4.SP6207 5. SP 6285

7.SP6208 8. SP 6211

9. SP 6265

10.SP6290 11.SP6250

12.SP6270 13. SP 6221 14. SP 6275

16. SP 6325

Decal Locations

If proof is not approved within 30 DAYS, we will invoice you for the artwork only.

SHEET of

INDIVIDUAL ROLL of

COPY DIRECTION SHOWN BELOW:

PRINTING

READS

This Way

PRINTING

READS

This Way

PRINTING

READS

This Way

PRINTING

READS

This Way

PRINTING

READS

This Way

PRINTING

READS

This Way

PRINTING

READS

This Way

PRINTING

READS

This Way

STRIP of

JOB #:

DECAL SIZE:

PART #:

MATERIAL:

ADHESIVE:

DIE/I-CUT:

OTHER:

COLORS:

LAMINATION:

EMBOSS DIE:

THERMO DIE:

SERIALIZING

N/A

REV:

Prefix: Size:

# of Digits: Typestyle:

Start#: End#:

Code: # of Digits:

CUSTOMER TOLERANCE

Approval

CUL

Approval

RoHS

Compliant

INDIGO HEAD STAMP MCLOONE'S

BARCODE

Prefix: Barcode #:

Sequential Barcodes

Start#: End#:

N/A

2D 3D (QR Code)

Include

INTERNAL #: MASTER INT #:

N/A

V H

PER

SPLIT DECAL:

Form 7.2_10 Rev. N/A Is sue Date: 05.11.15

Code 128

223456789123

N/A

Comp. Paper Email Epson Composite

Digital: ___Indigo ___Gandi ___Mimaki ___Gerber

COLOR(S) SHOWN REPRESENT COLOR LAYOUT ONLY.

THIS PROOF IS NOT A TRUE COLOR MATCH.

354328 : AH

105100

6.50" x 4.25" w/ 0.125" rad.

SP 6306

01/18/163

PROOF

Die Cut: ±

Print to Die Cut Registration: ±

(#) (#)

(#)

Job out to Mcloone's

1-White 2-Orange 3-Black DIELINE

Gillison's Variety Fabrication, Inc.

CUSTOMER:

WARNING

Made In U.S.A.

TRUCK CONFORMS TO ASME B56.6

MODEL SERIAL NO. TYPE

CAPACITY WITH MAST VERTICAL AND EQUIPPED AS SHOWN

TIRE

SIZE

DEGREES MAX BACK TILT

DATE OF MANUFACTURE:

MAST TYPE

DRIVE IN

A B C CAPACITYTRUCK WT.

IN IN LB LB

TREAD

FRONT PSI

PRESS.

GVF 4000 GL- DIESEL

14-17.5 10 PLY

60 24 4000

120 9140

ES40

6 PLY28X8.5-15

IMPROPER OPERATION OR

MAINTENANCE COULD RESULT

IN INJURY OR DEATH. READ

AND UNDERSTAND THE

OPERATION AND MAINTENANCE

MANUAL BEFORE OPERATING.

6.500"

4.250"

0.125" rad. (4x) 0.188" (typ.)

0.188" (typ.)

0.125" diam. hole (4x)

Serialized numbers here

White (prints behind graphics)

1. Enter comments/issues here.

17.FOPSdecalSP6301

Nameplate - SP6306

Includes important information such as: Warning, Model,

Serial Number, Type, Tire Pressure & Size, Mast Type,

Degrees Max Back Tilt, Date of Manufacture, Drive Tread,

Truck Wt., Capacity

Nameplate 2

16 13

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SAFETY - 9

GVF 4000 Rough Terrain Forklift Manual

SERIALNUMBER

Location of serial number is on the nameplate and is

provided as a reference. See FIG. 16

SAFETYWHILE 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 and personal protective equip-

ment:

a. No baggy clothing.

b. Use eye protection.

c. Use a hard hat.

FIG. 17

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inuence ofany

kind of drugs or alcohol that impair judgment or per-

formance.

Do not operate the forklift without overhead guard in place.

Lower forks completely to the ground when adjusting

and when work is completed.

Do not allow anyone to stand under or work under

raised forks.

Never raise persons with the forks.

Never leave forklift running unattended. Always set the

parkingbrake,shifttoNeutral,shuto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o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 dierent rat-

ing.

Do not add or subtract weight from the counterweight

box.

RULES OFTHE ROAD

Before operating your forklift on a public road, a num-

ber of precautions must be taken.

Familiarize yourself with, and obey, all

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- SAFETY10 GVF 4000 Rough Terrain Forklift Manual

laws appropriate to your machine.

Disengage FWD.

Make sure any required clearance ags

orhazardlightsarein placeandinwork-

ing order.

Clean o all reectors 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 ashing 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 trac to clear before entering

a public road.

Bewareof blindintersections.Slowdown

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-

c.

Drive defensively. Anticipate what other

drivers might do.

Watch out for overhead obstructions.

MODIFICATIONS

Modication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 trained upon de-

livery of the GVF Forklift

C. Written records of frequent inspec-

tions, maintenance performed and parts

replaced

OWNERSHIPRECORDS

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

within60daysofthesale:

A. Serial number of machine

B. Name & address of new owner

FIG.18

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SAFETY - 11

GVF 4000 Rough Terrain Forklift Manual

FORK SAFETY

Fork Inspection

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- SAFETY12 GVF 4000 Rough Terrain Forklift Manual

Fork Inspection Cont.

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SAFETY - 13

GVF 4000 Rough Terrain Forklift Manual

Fork Inspection Poster

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Fork Maintenance

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SAFETY - 15

GVF 4000 Rough Terrain Forklift Manual

Fork Maintenance Cont.

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- SAFETY16 GVF 4000 Rough Terrain Forklift Manual

FORKLIFT MAST SAFETY

Refer to the following illustrations for mast safety:

255222 R5 05/19/11 Page 3

Contents

Cover..............................................................................................................................................................................1

Introduction.....................................................................................................................................................................2

Safety Decals .................................................................................................................................................................3

Main Lift Cylinders ..........................................................................................................................................................4

Weldments......................................................................................................................................................................8

Common Parts ...............................................................................................................................................................9

Hoist Chains .................................................................................................................................................................10

InstallationComponents ...............................................................................................................................................11

Load Backrest ..............................................................................................................................................................12

Lowering ControlValve .................................................................................................................................................13

4 Roller Carriages.........................................................................................................................................................14

6 Roller Carriages.........................................................................................................................................................15

Single Internal Hose Reeving .......................................................................................................................................16

Recommended Spare Parts List ...................................................................................................................................20

Safety Decals

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