Maxforce GH4030 AC Guide

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Operation & Parts
MAXFORCE GH4030 AC
Spray System
M10449-00-A
Gas powered spray system with integrated air compressor
2845 W Service Rd Eagan, MN 55121

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Table of Contents
Safety….………………………………………………….. 3
Component Identification……………………………….. 5
Setup……………………………………………………… 6
General setup
Flushing Procedure
Operation………………………………………………… 8
Pressure relief procedure………………………………………….8
Starting the sprayer………………………………………..…….. 8
Priming the coating pump……………………………………….. 8
Adjusting pressure……………………………………………… 9
Hose reel operations……………………………………………. 9
Cleaning a clogged tip………………………………………….. 9
Maintenance…………………………………………….. 10
Troubleshooting………………………………………… 11
Parts……………………………………………………... 13
Hydraulic Tank / Engine / Compressor…………………………13
Hydraulic Pump / Belt Drive / Cooler…………………………... 14
Air Tank / Control Panel…………………………………………. 15
Fuel Tank / Wheels…….……………………………………….. 16
Feed Pump / Coating Pump…………..……………………….. 17
Technical Data………………………………………….. 18
Sprayer Dimensions……………………………………………... 19
Warranty………………………………………………….20
For parts, service, and technical assistance,
contact your equipment distributer:

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Safety
General Safety Information
READ THE MANUAL
• Ensure any operator of this equipment has read and
understands the manual before operating.
• Do not attempt to repair or modify this equipment
EQUIPMENT MISUSE HAZARD
• Equipment misuse can cause the equipment to rupture
or malfunction and result in serious injury.
• This equipment is for professional use only.
• Read all instruction manuals, tags, and labels before
operating the equipment.
• Use the equipment only for its intended purpose. If you
are not sure, call your distributer.
• Do not alter or modify this equipment. Use only genuine
OEM parts.
• Check equipment daily. Repair or replace worn or
damaged parts immediately.
• Comply with all applicable local, state, and national fire,
electrical, and safety regulations
• Do not exceed the maximum working pressure of the
lowest rated system component. Refer to Technical
Data.
• Use fluids and solvents which are compatible with the
equipment wetted parts.
• Do not use hoses to pull equipment.
• Route hoses away from traffic areas, sharp edges,
moving parts, and hot surfaces. Do not expose hoses
to temperatures above 180 degrees F or below –20
degrees F.
• Do not lift pressurized equipment.
• Do not use 1, 1-trichloroethane, methylene chloride,
other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum
equipment Such use could result in a chemical
reaction, with the possibility of explosion.
FUEL HAZARD
• The fuel used in this unit is combustible and when
spilled on a hot surface can ignite and cause a fire.
• Do not fill the fuel tank while the engine is running or
hot.
EXHAUST HAZARD
• The exhaust contains poisonous carbon dioxide which
is colorless and odorless.
• Do not operate this equipment in a closed building.
NOISE HAZARD
• Wear hearing protection when operating this
equipment.
Equipment Hazards & Warnings
DANGER
FLUID INJECTION HAZARD
Spray from the gun, leaks or ruptured components can
inject fluid into your body and cause extremely serious
injury, including the need for amputation. Fluid splashed in
the eyes or on the skin can also cause serious injury.
• Fluid injected into the skin may look like just a cut, but it
is a serious injury. Get immediate medical attention.
• Do not point the gun at anyone or at any part of the
body.
• Do not put your hand or fingers over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove
or rag.
• Do not “blow back” fluid; this is not an air spray system.
• Always have the tip guard and the trigger guard on the
gun when spraying.
• Check the gun diffuser operation weekly. Refer to the
gun manual.
• Be sure the gun trigger safely operates before spraying.
• Lock the gun trigger safety when you stop spraying.
• Follow the Pressure Relief Procedure if the spray tip
clogs and before cleaning, checking, or servicing the
equipment.

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Safety — Cont.
Equipment Hazards & Warnings—Cont.
DANGER
FLUID INJECTION HAZARD—Continued
• Tighten all fluid connections before operating the
equipment.
• Check the hoses, tubes, and couplings daily. Replace
worn or damaged parts immediately. Do not repair high
pressure couplings; you must replace the entire hose
• Fluid hoses must have spring guards on both ends, to
help protect them from rupture caused by kinks or
bends near the couplings.
TOXIC FLUID HAZARD
• Hazardous fluid or toxic fumes can cause serious injury
or death if splashed in the eyes or on the skin, inhaled,
or swallowed.
• Know the specific hazards of the fluid you are using.
• Store hazardous fluid in an approved container.
Dispose of hazardous fluid according to all local, state
and national guidelines.
• Always wear protective eyewear, gloves, clothing and
respirator as recommended by the fluid and solvent
manufacturer. Check the hoses, tubes, and couplings
daily. Replace worn or damaged parts immediately. Do
not repair high pressure couplings; you must replace
the entire hose
• Check the hoses tubes, and couplings, daily. Replace
worn or damaged parts immediately. Do not repair high
pressure couplings; you must replace the entire hose.
• Fluid hoses must have spring guards on both ends, to
help protect them from rupture caused by kinks or
bends near the couplings.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks
can cause a hazardous condition and result in a fire or
explosion and serious injury.
• If there is any static sparking or you feel and electric
shock while using this equipment, stop spraying
immediately. Do not use the equipment until you
identify and correct the problem.
• Provide fresh air ventilation to avoid the buildup of
flammable fumes from solvents or fluid being sprayed.
• Keep the spray area free of debris, including solvent,
rags and gasoline.
DANGER
FIRE AND EXPLOSION HAZARD
• Disconnect all electric equipment in the spray area.
• Extinguish all open flames or pilot lights in the spray
area.
• Do not smoke in the spray area.
• Do not turn on or off any light switch in the spray area
while operating or if fumes are present.
• Do not operate a gasoline engine in the spray area.
• Ground the sprayer to a true earth ground with the
ground wire and clamp (supplied).
• Use only electrically conductive hoses.
MOVING PARTS HAZARD
• Moving parts can pinch or amputate your fingers.
• Keep clear of all moving parts when starting or
operating the sprayer.
• Before servicing the equipment, follow the Pressure
Relief Procedure to prevent the equipment from starting
unexpectedly.
WARNING
• Read the operators manual before starting this unit.
Failure to adhere to instructions can result in severe
personal injury.
• Drive belts in rotation. Switch off engine and disconnect
battery before attempting to work or perform
maintenance on the equipment.
• Hoses under pressure. Relieve system pressure before
disconnecting or replacing air and oil hoses.
CAUTION
• To avoid electrical shock, disconnect battery prior to
electrical system service

M10449-00-A(888) 257-7729 | maxforce.com 5
Component Identification
B
N
ACoating pump IGasoline Fuel Fill
BHydraulic Pump JCoating Transfer Pump
CKohler Engine KEngine Temp and Hour Meter
DAir Compressor LCoating Pump ON/OFF Valve
EPowered Hose Reel MOil Coalescing Filter / Water Separator
FHydraulic Oil Filter NAir Tank Drain
GControl Panel OAir Pressure Gauge
HCoating Prime Valve PHydraulic Pressure Gauge
A
C
D
E
G
H
L
MOP
F
I
J
K

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Setup
1. Remove packaging and remove pump from pallet.
2. Fill coating pump wet cup with throat seal liquid
(Fig 1.)
3. Check hydraulic oil level by removing the oil fill
cap and inspecting inside the tank. The oil level
should be within 1 in of the tank opening. Add oil
as needed to fill to proper level.
4. Check engine oil level. Remove dipstick. Be sure
oil is up to the full mark on the dipstick. If oil is
needed, add oil to full mark on the dipstick.
5. Fill the fuel tank with clean, fresh unleaded regular
grade gasoline.
6. Flush the sprayer to remove the oil which was left
in the pump after factory testing. See Flushing
procedure.
7. When transporting pump, be sure to prevent
pump from rolling. Immobilize pump using wheel
chocks and tie-downs.
Figure 1
Wet Cup
WARNING
INJECTION HAZARD
To reduce the risk of a fluid injection injury NEVER
hold your hand, body or a rag in front of the spray tip.
NEVER point gun toward body.
Flushing Procedure
1. Engage the gun safety latch. Remove the spray
tip from the gun.
2. Pour enough recommended flushing agent (refer
to material manufacturers recommendations) into
a large, grounded metal pail. You will need
approximately 10 to 15 gallons.
3. Place the transfer pump into the pail.
4. Turn the Pump Spray Pressure control knob
counterclockwise until all spring tension is
relieved. The sprayer is now set at the lowest
pressure setting.
5. Open the choke by moving the choke lever. See
Fig 4.
Figure 4
Choke
Throttle
NOTICE
When to Flush the Coatings Pump
• Your new sprayer was factory tested with
lightweight oil which was left in the pump to
protect from corrosion. Flush the oil from the
pump prior to spraying a coating. Before using oil-
based coatings, flush with mineral spirits.
• When preparing for storage, flush with
manufactures recommended solvent, then mineral
spirits. Leave mineral spirits in the pump, hose,
and gun.

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Setup — Cont.
6. Turn the Compressor Unloader knob to Start. See
Fig 5.
7. Set Throttle to Half—After Engine Starts Move to
full throttle after engine starts
Figure 5
Transfer
pump air
regulator
Compressor
Unloader
Spray pump pressure
control knob Transfer Pump
Pressure Gauge
8. Turn Ignition Key until engine starts
9. Close the choke after the engine is warm.
10. Open the spray pump hydraulic ball valve. See
Fig 6.
Coating pump ON/OFF valve
Figure 6 CLOSEDOPEN
11. Turn the Transfer Pump Air Regulator clockwise
until the Air Pressure gauge reads 60 psi. See Fig
5.
12. Place bucket under Prime Valve (fig 7)
13. Open prime valve (fig 7) and wait for fluid to begin
steadily coming from valve. Once fluid has begun
steadily leaving valve, close the valve.
Figure 7
Prime
Valve
14. Point the gun into the grounded metal pail and
hold a metal part of the gun firmly against the pail.
15. Making firm metal-to-metal contact, hold the gun
firmly to the side of the grounded waste pail.
Trigger the gun. At the same time, slowly turn the
Pump Spray Pressure control knob clockwise just
enough to start the pump.
16. Circulate until both systems are fully flushed.
17. Release the trigger and engage the gun safety
latch.
WARNING
INJECTION HAZARD
The system pressure must be manually relieved to
prevent the system from starting or spraying
accidentally. Fluid under high pressure can be
injected through the skin and cause serious injury. To
reduce the risk of an injury from injection, splashing
fluid, or moving parts, follow the Pressure Relief
Procedure whenever you:
• Are instructed to relieve the pressure
• Stop spraying
• Check or service any of the system equipment
• Install or clean the spray tip
FIRE AND EXPLOSION HAZARD
To reduce the risk of static sparking and splashing
when flushing, always remove the spray tip from the
gun and hold a metal part of the gun firmly to the side
of a grounded metal pail.

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Operation
Pressure Relief Procedure
1. Engage the gun safety latch.
2. Close spray pump hydraulic ball valve
3. Turn the Pump Spray Pressure knob counter-
clockwise until there is no more tension (Fig 5.)
4. Turn the Transfer Pump Air Regulator counter-
clockwise until the pressure gauge reads 0 (Fig 5.)
5. Turn the gas engine off .
6. Disengage the gun safety latch. Hold a metal part
of the gun firmly to the side of a grounded metal
pail, and trigger the gun until all pressure is
relieved.
7. Engage the gun safety latch.
Prepare the Fluid
1. Place the transfer pump in first drum of coating to
be sprayed. Turn the transfer pump air regulator
until the air motor begins to engage. See Fig 8
Starting the Sprayer
1. Be sure the gun safety latch is engaged.
2. Turn the Pump Spray Pressure knob
counterclockwise until all tension is relieved. See
Fig 5. You will be able to feel it. The sprayer is
now set at the lowest pressure setting.
3. Turn the gas engine ON/OFF switch to ON. See
Fig 3.
4. Open the choke by moving the choke lever. See
Fig 4.
5. Open the gas throttle. See Fig 4.
6. Turn the Compressor Unloader knob to Start. See
Fig 5.
7. Use the key-switch to start the engine.
8. Close the choke after the engine is warm.
Prime the Coating Pump
1. Be sure the gun safety latch is engaged.
2. Don’t install the spray tip yet.
3. Prepare fluid using the above procedure.
4. Start the sprayer using the above procedure.
5. Disengage the gun safety latch.
6. Turn Compressor Unloader switch to Run. See
Fig 5.
7. Turn the Transfer Pump Air Regulator clockwise
until the Air Pressure gauge reads the 60 PSI See
Fig 5.
8. Place bucket under Prime Valve (fig 6a)
9. Open the spray pump hydraulic ball valve. See Fig
6.
10. Turn Pump Spray pressure knob slowly until main
pump begins to engage up and down. See Fig 5
11. Open prime valve (fig 6a) and wait for fluid to
begin steadily coming from valve. Once fluid has
begun steadily leaving valve, close the valve
12. Point the gun into a grounded metal pail and hold
a metal part of the gun firmly against the pail.
WARNING
INJECTION HAZARD
To reduce the risk of a fluid injection injury NEVER
hold your hand, body or a rag in front of the spray tip.
NEVER point gun toward body.
Figure 8
Air Motor

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Operation — Cont.
13. Squeeze the trigger and slowly turn the pressure
control knob clockwise just enough to start the
pump.
14. Operate the pump until all air is purged from the
pump and hoses and the fluid is flowing freely
from the gun.
15. Release the trigger and engage the safety latch.
16. Install the spray tip in the gun.
Adjusting Pressure
1. Turn the Pump Spray Pressure knob (Fig 5.)
clockwise to increase pressure and
counterclockwise to decrease pressure. The
coating pressure gauge displays spray pressure
(Fig 9.)
2. Always use the lowest pressure necessary to
completely atomize fluid.
WARNING
INJECTION HAZARD
To reduce the risk of a fluid injection injury NEVER
hold your hand, body or a rag in front of the spray tip.
NEVER point gun toward body.
AA Coating Pressure
BB Hose Reel Motor
CC Hose Reel Pushbutton
AA
BB
CC
Figure 9
Hose Reel Operations
1. Hold down push button to activate hose reel
rewind only. Make sure to deplete pressure from
hose before rewinding.
Cleaning a Clogged Tip
1. To clear the coating tip, rotate the tip 180 degrees.
Pull trigger and spray product into waste bucket.
Rotate tip 180 degrees into original position
WARNING
INJECTION HAZARD
To reduce the risk of a fluid injection injury NEVER
hold your hand, body or a rag in front of the spray tip.
NEVER point gun toward body.

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Maintenance
• Always stop the pump at the bottom of its stroke
when taking a break and at the end of the day.
This helps keep fluid from drying on the rod and
damaging the packings.
• Keep the coatings pump wet cup filled with TSL at
all times.
• Check hydraulic oil level regularly. Refer to
maintenance schedule table for service intervals.
If low, fill reservoir with clean hydraulic oil.
• Check engine oil level regularly. Refer to
maintenance schedule table for service intervals.
The oil must be up to the FULL mark on the
dipstick.
• Drain excess moisture from the air tank daily.
• Inspect the return hydraulic line filter regularly for
clogging. Refer to maintenance schedule table for
service intervals.
• Refer to the Kohler engine manual included with
the pump for additional engine maintenance and
service items.
Changing the Hydraulic Oil
1. Follow the Pressure Relief Procedures.
2. Place a waste container under the drain plug of
the hydraulic reservoir.
3. Unscrew the plug and drain the reservoir.
Reinstall the plug before proceeding (Fig 14.)
AA Hydraulic Return Line Filter
BB Hydraulic Reservoir Fill Cap
CC Hydraulic Reservoir Drain Plug
Figure 14
BB AA
CC
Item Frequency Part Number
Hydraulic Oil 2000 hrs / 12 Months
(>85° F, 1000 hrs / 6 Months) (3-4 Gal.) Synthetic AW-46
Hydraulic Return Line Filter 500 hrs / 6 Months V11722-00
Engine Oil 100 hrs 2 Quarts SAE 10W-30
Engine Oil Filter 200 hrs 12 050 01-S1
Engine Air Filter 100 hrs 47 083 03-S
Engine Fuel Filter 200 hrs 24 050 13-S1
Air Compressor Oil 3 Months 1.0 Quart Royal Purple (Synfilm 100)
Air Compressor Air Filter 3 Months 19-0253
Oil Coalescing Filter 6 Months 21999-0394
TSL for Wet Cup As necessary 238049
Maintenance Schedule Table
4. Remove the return line filter and install a new filter
assembly (Fig 14.)
5. Remove the hydraulic reservoir cap. Pour new,
clean hydraulic oil into the reservoir until the oil
level reaches to within 1 inch of the tank opening.
Replace the hydraulic reservoir cap (Fig 14.)
6. The hydraulic system typically requires additional
hydraulic oil to fill the hoses and pump. Running
the machine will circulate the oil through the
hoses. Start up the sprayer and run for 3-5
minutes.
7. Shut the sprayer down and check the hydraulic oil
level.
8. Open the hydraulic reservoir cap, and top off the
hydraulic oil level. Replace the cap. The sprayer is
now ready for normal operation.