AIR2G2 AIR2G2-336 Page 1 Owner'S/Operator'S Manual Download

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GT AIRINJECT INC

“AIR2G2-336

”

OWNER/OPERATOR’S MANUAL

Summary of Contents for AIR2G2-336

Page 1: ...1 GT AIRINJECT INC AIR2G2 336 OWNER OPERATOR S MANUAL ...

Page 2: ...It is primarily designed for compaction relief and aeration of fine turf areas on professionally maintained park lawns athletic fields and golf courses You may contact GT AIRINJECT INC directly at www air2g2 com for parts information to find a dealer or register your machine To order parts please email parts air2g2 com Please include your machine s serial number as well as the needed part numbers ...

Page 3: ... FOR SAFE OPERATION 20 22 PRE OPERATION OF THE MACHINE 23 27 MACHINE TRANSPORT POSITION PRESSURE BEAM RETRACTED 28 MACHINE OPERATING POSITION PRESSURE BEAM EXTENDED 29 MACHINE CONTROLLER PROGRAMMING PLC FUNCTION KEYS 30 31 STANDARD OPERATIONS PROCEDURE FOR THE AERATION PROCESS 32 NEUTRAL ARM MECHANISM 32 MAINTENANCE AND STORAGE 33 34 TROUBLESHOOTING 35 WIRING DIAGRAM 36 DRIVE SYSTEM DIAGRAM 37 AIR...

Page 4: ...nted semi mounted and trailed machines Common safety requirements ANSI ASAE S338 5 Field Equipment for Agricultural Safety Chain for Towed Equipment ANSI OPEI B71 4 2012 Commercial Turf Care SafetySpecifications Full Name of Responsible Person GLEN BLACK TITLE PRESIDENT GT AIRINJECT INC Signature Date Full Name of AuthorizedRepresentative Signature Date Original must remain with machine owner Repr...

Page 5: ...tions please feel free to contact your distributor or email us at parts air2g2 com Distributor Information Name Address Telephone Fax Email Machine Information Purchase Date WARRANTY WILL BE DENIED IF THE WARRANTY REGISTRATION CERTIFICATE IS NOT RETURNED WITHIN 30 DAYS AFTER DELIVERY THIS FORM CAN BE FOUND IN THIS MANUAL Page 7 GT AIRINJECT INC 136 ELLIS ROAD N JACKSONVILLE FL 32254 USA T 904 379 ...

Page 6: ...s related to the return of the faulty product GT AIRINJECT INC will not be liable for any consequential loss damage or cost caused by the incidental failure of any new part supplied with the original purchase or any new part supplied as a replacement for any failed part Warranty Claims The final purchaser must provide the delivery date and serial number of the machine as well as written explanatio...

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Page 8: ...er each use for excessive wear Check for air leaks before and after each use Use soapy water to aid in finding any leaks Check all nuts and bolts on moving parts of machine to ensure they are properly tight After all air has been released remove each cylinder and move the rod up and down 2 3 times to expel any moisture build up in the cylinder Use the brush provided in the toolbox on the machine t...

Page 9: ...res and controls beforeuse ONLY qualified trained personnel should operate this machine For safe operation do not operate the machine when you are in poor physical condition tired sleepy or under the influence of drugs or alcohol IMPORTANT Turning the PLC Toggle Switch to the OFF position will send all moving parts to a HOME position Cable jumping the battery should never be done ONLY USE THE EMER...

Page 10: ...all safety Caution Warning or Note alert symbols The owner is responsible to train the operators and mechanics for safe operation of the machine Never allow children around or near the machine Never allow untrained people to operate or service the equipment Check local regulations regarding the minimum required age of persons operating this machine The owner user of this machine is responsible for...

Page 11: ... or fueling the machine NEVER add or drain gasoline indoors ALWAYS do so in a well ventilated area Fill the gas tank to within 2 inches 5 08 cm from the bottom of the fillerneck Operation NOTE THIS MACHINE IS NEVER TO BE TOWED Never run the engine in an enclosed area Operate the machine in good lighting keep away from holes and hidden hazards Ensure the shields covers and other guards are securely...

Page 12: ...BE ENGAGED unless the handle bars are in a forward position away from operator position to move away from operator or the handle bars are pulled back towards the operator position to move towards operator NEVER APPLY PRESSURE TO THE HANDLE BARS IN AN ATTEMPT TO MOVE THE MACHINE WHEN IN A NEUTRAL POSITION DAMAGE MAY OCCUR TO THE CABLE OR TO THE CABLE CONNECTIONS If an object below the surface is st...

Page 13: ...y cause death or injury Seek shelter immediately Use extreme caution when loading or unloading the machine for transport Secure machine with straps at four points of tie downs pulling in straps in opposite directions Use extreme caution when approaching an area with blind corners shrubs trees or other objects that may obstruct your vision CAUTION BE AWARE OF THE PATH YOU ARE MOVING DURING OPERATIO...

Page 14: ...PROBES AND CYLINDERS When storing the Air2G2 336 release all air pressure from the system NEVER store the machine for any length of time with air pressure in the system i e air pressure in tank After one hour of use drain moisture from the water separator see page 15 item 10 ALWAYS Drain when machine is off of the playing surface On the upper left side of the frame above the air tubing bulkheads i...

Page 15: ...mmable Logic Computer PLC 13 Located on the dash you will see three 3 psi gauges The gauge on the left measures the air pressure used to push the probes into the ground The center gauge measures the total air pressure in the tank and should be no higher than 175 psi The gauge on the right measures the air pressure being injected into the subsurface The left and right gauges can be adjusted by the ...

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Page 17: ...POSITION OPERATE MACHINE ONLY WITH BOTH ARMS EXTENDED RETRACTED POSITION NOT FOR OPERATION TRANSPORT AND STORAGE ONLY ASSURE BOTH PINS ARE FULLY INSERTED BEFORE OPERATION OR TRANSPORT AIR2G2 336 PRESSURE BEAM 18 ...

Page 18: ...dth Length Cylinder height Handle height Ground clearance Forward speed Reverse speed Net weight 82 265 4cm 19 87 inches 221 cm 44 5 inches 113 cm 72 inches 183 cm 94 inches 238 76 cm 56 inches 142 24 cm 52 inches 104 cm 4 75 inches 12 1 cm 0 5 mph 0 8 kph 0 8 mph 0 13 kph 940 lb 426 37 kg 87 221 cm 44 5 1l3 Air2G2 336 ...

Page 19: ... manual NOTE An emergency shut off button is located on the steering bar 5 The AIR2G2 336 requires certain knowledge and expertise to operate You must be trained to use this machine Never permit inexperienced personnel to operate the machine Untrained persons can harm themselves and others if they operate themachine CAUTION THIS MACHINE IS NOT RIDEABLE INJURY OR DEATH MAYOCCUR 6 This machine canno...

Page 20: ...d CAUTION EAR PROTECTION IS REQUIRED 14 Parking the machine after use Check the probes 3 and probe tips for any damage With the beam locked in the UP position drain all air pressure When pressure is 0 manually push the cylinder rods downward You can now check the tips underneath the pressure pads for damage Loosen the 4 four 7 16 nuts underneath the cylinders ONLY LOOSEN Turn the cylinder clockwis...

Page 21: ...e the battery to deplete 17 For temporary or extended storage release all air pressure from the air tank drain all condensation build up from the air water separator and the air tank Check the machine for safe and efficient storage NOTE For extended storage treat the fuel with a fuel additive and then let the machine run 3 5 minutes before turning off the engine 18 If replacement parts are needed ...

Page 22: ...el system could be damaged Do not mix oil with gasoline WARNING GASOLINE IS HARMFUL AND FATAL IF SWALLOWED AND LONG TERM EXPOSURE TO VAPORS CAN CAUSE SERIOUS INJURY AND ILLNESS KEEP GAS AWAY FROM EYES AND SKIN AVOID PROLONGED BREATHING OF VAPORS KEEP FACE AWAY FROM NOZZLE AND GAS TANK NOTE Using stabilizers will help keep gasoline fresh during storage of 90 days or more Do not use fuel additives c...

Page 23: ...s located in the HOME position Raise the aluminum clamp rings to the top of each rod and tighten With the beam in a LOCKED position push down the rods until they meet the ground You will now be able to look at all 3 probe tips to make sure they are not bent or dull and you will be able to check the aeration holes to make sure they are clear of any debris If probe tips are worn or dull replace imme...

Page 24: ... begin the aerationprocess WARNING DO NOT RIDE THIS MACHINE TO AVOID ACCIDENTS A QUALIFIED OPERATOR MUST BE AWARE OF THEIR SURROUNDINGS AND REMEMBER THAT IT IS YOUR RESPONSIBILITY TO THINK AND OPERATE SAFELY NOTE Wear proper clothing footwear and eye protection Ear protection isrequired 5 After the motor is running Above the beam see picture release the chain from the side one on the left and one ...

Page 25: ...E 1 AUTO 2 MANUAL SEE FUNCTION KEYS FOR THE PLC ON THE FOLLOWING PAGE Press 6 and hold The screen will read RESET TO FACTORY 1 YES 3 NO Press 1 YES FACTORY DEFAULT SETTING HAVE BEEN RESET 10 Press 1 AUTO PLC will read TRIGGER TO START Once in position to begin the aeration process slide the throttle lever completely to the left Trigger buttons at each end of the handle bars must be depressed simul...

Page 26: ...0 48 cm in 5 13mm outside diameter If a depth of less than 10 to 12 inches 25 4 to 30 48 cm is desired then we suggest using 7 inch 17 780 cm probes NOTE 3 Depth of ALL probes may vary by up to 1 inch 2 54cm depending on tire pressure pad assemblies properly adjusted and or height of the turf to be aerated The manufacturer suggests that before each use operate the machine one time normally move th...

Page 27: ...FOR TRANSPORTATION OR STORAGE ONLY RETRACTED POSITION NOT FOR OPERATION ENSURE BOTH LOCK PINS ARE FULLY INSERTED BEFORE TRANSPORT ENSURE BOTH LOCK PINS ARE FULLY INSERTED BEFORE TRANSPORT 28 ...

Page 28: ...EXTENDED POSITION OPERATE MACHINE ONLY WITH BOTH ARMS EXTENDED ENSURE BOTH LOCK PINS ARE FULLY INSERTED BEFORE OPERATION ENSURE BOTH LOCK PINS ARE FULLY INSERTED BEFORE OPERATION 29 ...

Page 29: ...ASE OF EMERGENCY PUSH THE EMERGENCY STOP BUTTON OR TURN THE TOGGLE SWITCH DOWN TO OFF THE MACHINE WILL RETURN ALL FUNCTIONS TO THE HOME POSITION ALL SETTINGS ARE FACTORY SET OTHER PLC FUNCTION KEYS There are two 2 function keys for the operator touse With the PLC in 1 AUTO 2 MANUAL Press 5 and HOLD for 3 seconds Screen will read AIR2G2 REVISION 6 2 Press 7 9 and HOLD SIMULTANEOUSLY Screen will rea...

Page 30: ...l Screen will read MANUAL MODE 1 Motion 2 Timer timer pre set Press 1 Motion This is used to ensure the probes are moving UP and DOWN and to ensure the pressure from the beam is being applied to the pressure pads Screen will read MANUAL MOVE 1 Probe 2 Beam DO NOT OPERATE ON A HARD SURFACE I E CONCRETE ORPAVEMENT Press 1 Probe Screen will read MANUAL PROBE 1 Toggle Press BACK Screen will read MANUA...

Page 31: ...e handle bars in front of the left tire you will see the neutral arm See LEFT PIC Looking at the Neutral Arm turn it Counter Clockwise Anti Clockwise from the top point Pull the arm towards you At this point the Neutral should be engaged In order to move the machine while in the neutral position you must make sure the machine and PLC are off and the motor is no longer running Also the handle bars ...

Page 32: ...l movement to stop on the machine before adjusting cleaning or repairing The beam must be in the upward and secured position the brake will be engaged with the handle bars in the neutral position stop the engine and put the PLC in the OFF position Clean the machine from all grass Clean all debris from the probes mufflers and engine to help prevent fires DO NOT PRESSURE WASH Use low pressure water ...

Page 33: ...nd lift up and out of the cylinder tubes You will now be able to either change or inspect the probe When changing probes be sure to manually move the cylinder rod up and down 2 3 times to push any excess moisture from the cylinder before installing After inspection replace the cylinder by setting the cylinder flat on the cylinder flange Rotate counter clockwise and tighten the nuts securely When t...

Page 34: ...ect connections i e from the machine top tube to top connector center tube to center connector and bottom tube to bottom connector Condition Probes go down but no air injects Solution Check probes i e tips and aeration holes make sure these are not plugged Check tubing for injection of the air going into the cylinders Press 8 make sure air is released Check 6 valve and solenoid for proper operatio...

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Page 41: ...RA 2105 complete right wing assembly 3FRA 2104 complete left wing assembly 3FRA 2007 complete center beam assembly 3FPCLG0 53 5 5 X 3 5 Pin 3FPCLG0 53 5 Air2G2 336 Pressure Beam Assembly parts numbers 42 ...

Page 42: ...ssist 10 12 VALVES cylinder actuation 2 AS 14 015 2 STATION ALUMINUM VALVE MANIFOLD 10 12 VALVE BANK MANIFOLD 1 AS 14 016 100 PSI PRESSURE GAUGE 2 AIR INJECTION PRESSURE GAUGE 1 AS 14 017 200 PSI PRESSURE GAUGE 2 PROBE INJECTION PRESSURE GAUGE 1 AS 14 018 300 PSI PRESSURE GAUGE 2 SYSTEM PRESSURE GAUGE 1 AS 14 019 1 4 BLACK TUBING per foot AIR GAUGE TUBING 8 AS 14 020 BK 1 2 BLACK TUBING per foot A...

Page 43: ...GS 1 AS 14 040 1 2 TUBE UNION CENTER PROBE CYLINDER COILED TUBING UNION 1 AS 14 044 SPEED CONTROL AIR EXHAUST MUFFLER PROBE CYLINDER TOP QE MUFFLER 3 AS 14 045 AIR EXHAUST MUFFLER PROBE CYLINDER BOTTOM QE VALVE MUFFLER 3 AS 14 048 3 8 MNPT x 1 4 INDUSTRIAL QD AIR COUPLING AUXILIARY HOSE PORT 1 AS 14 049 UNLOADER VALVE HIGH FLOW EXHAUST MUFFLER UNLOADER VALVE EXHAUST MUFFLER 1 AS 14 051 BEAM CYLIND...

Page 44: ... 1 8 MNPT x 1 4 TUBE ELBOW FITTING CYLINDER AIR PLATE SUPPLY FITTING 6 AS 16 060 3 8 MNPT x 1 4 TUBE ELBOW FITTING QE VALVE TOP FITTING 6 AS 16 061 1 4 TUBE PLUG IN ELBOW QE VALVE FITTING EXTENDER ELBOWS 3 AS 17 052 3 8 MNPT x 3 8 FNPT STEEL ELBOW PROBE CYLINDER FITTING 3 AS 18 023 BASE PROBE CYLINDER w INTEGRATED WIPER PLATE WITH SMALLER ID SHAFT HOLE PROBE CYLINDER 3 AS 18 041 120 PSI SAFETY POP...

Page 45: ...EMBLY 1 ASA 18 023 PROBE CYLINDER ASSEMBLY PROBE CYLINDER ASSEMBLY 3 ASA 1881 VALVE PLATE COMPLETE ASSEMBLY INSTALL READY VALVE PLATE ASSEMBLY 1 ASA 19 007 B NORGREN FILTER SEPARATOR MOUNT BRACKET ASSEMBLY FILTER MOUNT 1 ASA 19 007 CA FILTER SEPARATOR COMPLETE ASSEMBLY INSTALL READY 1 ASA 310078 BLUE AIR TANK ASSEMBLY BLUE AIR TANK ASSEMBLY 1 LSS 212 5B PROBE CYLINDER REPLACEMENT PISTON AND ROD AS...

Page 46: ...AF 8 FEMALE SWIVEL JIC TO 6 MALE O RING BOSS 90 DEGREE ELBOW AXLE RESERVOIR HOSE ADAPTER FITTING 1 DS 18 011HA 30 HOSE ASSEMBLY w 8 FEMALE SWIVEL JIC x OPEN END G7 AXLE RESERVOIR HOSE ASSEMBLY 1 DS 18 037 CLEVIS ROD END 1 4 PIN 2 LONG 1 4 28 FEMALE SHANK ZINC PLATED G7 BRAKE CONNECTOR 1 DS 18 038 SEALED BALL BEARING 3 8 SHAFT DIAMETER G7 LINKAGE CONNECTOR BEARING 1 DS 18 039 5 16 18 SHOULDER BOLT ...

Page 47: ...DING CABLE ASSY 1 ES 14 019 HANDLEBAR WIRING HARNESS HANDLE BAR WIRING HARNESS 1 ES 14 020 BLACK FRAME GROUNDING CABLE 9 BATTERY GROUND CABLE COMPLETE 1 ES 14 021 RED BATTERY CABLE BATTERY POSITIVE CABLE COMPLETE 1 ES 16 007 E STOP ENCLOSURE SYSTEM EMERGENCY STOP ENCLOSURE 1 ES 16 025 DC HOUR METER 2 HOLE RECTANGULAR DASH MOUNT HOUR METER 1 ES 16 027 1 AMP 600V RECTIFIER DIODES RECTIFIER DIODES 3 ...

Page 48: ...OMPLETE ASSY 1 FRA 14 015 PRESSURE BEAM ASSEMBLY PRESSURE BEAM ASSEMBLY 1 FRA 14 018 PAD ASSEMBLY COMPLETE PAD ASSEMBLY 3 FRA 14 023 UPRIGHT SPINDLE HUB 5 LUG ASSEMBLY UPRIGHT MOUNT HUB COMPLETE ASSEMBLY 1 FRA 1418 L LEFT POWER STRUT ASSEMBLY w BUSHINGS POWER STRUT COMPLETE ASSY LEFT 1 FRA 1418 R RIGHT POWER STRUT ASSEMBLY w BUSHINGS POWER STRUT COMPLETE ASSY RIGHT 1 FRA 1420 SHORT LINK TUBE ASSEM...

Page 49: ...E 20 LONG w ONE FJIC FITTING ENGINE FUEL FILTER TO FRAME FUEL HOSE 1 FS 14 010 ENGINE VENT TO FRAME HOSE 23 ENGINE VENT TO FRAME HOSE 1 FS 14 013 FUEL LINE QD MALE CONNECTOR VALVE FUEL LINE QD VALVE 1 FS 14 014 FUEL LINE QD FEMALE COUPLER VALVE FUEL LINE QD VALVE 1 FS 14 016 1 4 JIC MALE x 1 4 JIC MALE BULKHEAD 90 DEGREE ELBOW w LOCKNUT FRAME FUEL LINE BULKHEAD FITTINGS 2 FS 14 017 3 16 x 1 4 SING...

Page 50: ...IM COMPRESSOR SHIELD CUT OUT HOLE 22 5 PLA 14 001 OWNER S MANUAL CANISTER OWNER S MANUAL CANISTER TRIMMED 1 PLA 14 007H DASH ASSEMBLY w HOUR METER COMPLETE DASH ASSEMBLY 1 PLA 14 011 TOOL BOX ASSEMBLY TOOL BOX ASSEMBLY 1 PROBE ITEMS PR 14 002 OVERSIZE PROBE TIPS HARDENED OVERSIZE PROBE TIPS PR 14 004 PROBE SPRING PROBE SPRINGS 9 PR 14 007 7 PROBE ASSEMBLY w PR 14 002 OS TIP 7 PROBE ASSEMBLY 3 PR 1...

Page 51: ... AIR2G2 Risk Assessment By John Ross MG CMIosh March 2020 Page Significant Risks 1 Noise 2 Vibration 5 Maneuvering 7 Moving Parts 7 Hot Parts 8 Exhaust Fumes 9 Compressed Air 9 Petrol Fire 10 Site Specific Risks 52 ...

Page 52: ...he loudest recorded sound that may only be for a very brief period of 1 millisecond a c refers to sound filters built into the noise meter The A filter measures exposure at the human ear The C filter measures single loud brief sounds Noise exposure measured in March 2020 with Svantek SV971 Class 1 sound meter instrument standard IEC 61672 1 2002 BS4142 for environmental noise Operative Controls No...

Page 53: ...lation Control of Vibration at Work Regulations 2005 The regulations place a duty on the employer to manage employee s exposure to handheld vibrating equipment Where that exposure is 2 5M S 2 to do all that is reasonably practicable to reduce it In situations where this is not possible not to expose employees to a vibration magnitude 5M S 2 In any single day In situations where a piece of equipmen...

Page 54: ...0 sq Metres with approx 200 injections 14 points 90 minutes for 2 X Greens at 1000 sq metres with approx 400 injections 28 points 4 hours of continuous exposure while injecting 75 points 6 hours of continuous exposure while injecting 112 points 30 minutes traversing between areas without injecting 6 points 45 minutes traversing between areas without injecting 9 points Vibration measured in March 2...

Page 55: ...so u 71l5 1lOO 515 5 1150 Maximum total points expoS ure in 24 u 110 11 120 615 1000 5 1lOO hou r period 400 1 0 50 32 1 25 s s 15 30 s 13 25 45 10 20 8 16 35 12 2 5 3 400 12 0 so 100 32 13 25 255 215 130 150 38 1000 SlO 305 SO 2 5 100 00 245 150 2 2 8 15 2 s 2 16 24 14 4 32 0 16 2l 8 10 27 36 S 12 16 20 m b p lsare till e Chart Legend Likety to be a bove the ELY Above the ELV Above the ALV Likoly...

Page 56: ...Below AlV no actionneeded AI r2G injecting M 2G Traversing AL V Action limit val ue of 2 5M S Sq Daily Point total S M S Sq 57 ELY EXposure Limit value of S M S Sq ...

Page 57: ...le rear type pivot giving a quick change of direction Operative Controls Injection patterns are planned to avoid turning in the direction of hazards When maneuvering in close proximity to hazards revs are lowered and sudden changes in direction avoided The operator is aware that sudden changes in the direction on the steering bar can result in increased forces in the momentum of the AIR2G2 Sudden ...

Page 58: ...nned to avoid steep slopes A steep slope is one where gravitational forces exert directional momentum on to the GT Air Inject in addition to that from the power unit The maximum slope for traversing or injection cycles on the AIR2G2 is Degrees Gradient Percent 15 0 1 3 75 26 8 When planning work the chosen direction of travel on a slope is always directly up or down in preference to horizontal tra...

Page 59: ...ne in injection mode all other persons other than the operative are kept clear of the process by a distance of at least 1 metre Moving Parts Risk Using AIR2G2 At Risk Operatives others in close proximity service mechanic Without controls Extremely High High Moderate Low Negligible With controls Extremely High High Moderate Low Negligible 5 Hot Parts a Exhaust system Contact with exhaust system Des...

Page 60: ...Engine exhaust emissions Inhalation of fumes Designed Controls The engine exhaust is located at the front of the AIR2G2 separating the operator by distance from the fumes The equipment is designed to be used outdoors in a well ventilated environment b Operative Controls When the engine has to be run indoors the time is limited to no more than a few minutes When the engine is run in a workshop for ...

Page 61: ... The compressor has two drain points that prevent moisture from building up inside the chamber which would create internal rusting and weakening of the chamber Air pressure within the tank can be monitored using a highly visible gauge on the control panel Operative Controls There is a maintenance programmed for the pressure system which includes a recorded examination by a competent person on an a...

Page 62: ...ill nozzle is used for filling At no time is petrol stored on the AIR2G2 other than that which is held within the fuel tank Fire Petrol Risk Using AIR2G2 At Risk All in close proximity Without controls Extremely High High Moderate Low Negligible With controls Extremely High High Moderate Low Negligible 9 Site Specific Risks Where is the hazard What is the hazard What is the risk without controls W...

Page 63: ...64 Signed Date ...

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AIR2G2 AIR2G2-336, Owner'S/Operator'S Manual

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