Genesis GMP D Series Safety & Operators & Parts Manual Download Page 1 | Manualshive

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GMP D Series

Mechanical Pulverizer

SAFETY, OPERATOR’S & PARTS MANUAL

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Summary of Contents for GMP D Series

Page 1: ...GMP D Series Mechanical Pulverizer SAFETY OPERATOR S PARTS MANUAL ...

Page 2: ...l tchoo genesisattachments com Europe Africa Middle East Genesis GmbH Teramostrasse 23 87700 Memmingen Germany Phone 49 83 31 9 25 98 0 Fax 49 83 31 9 25 98 80 genesis europe com E mail info genesis europe com Central America Colombia Cra 13A 89 38 Ofi 613 Bogota Colombia Phone 57 1 610 8160 795 8747 E mail contact themsagroup com Genesis Attachments 1000 Genesis Drive Superior WI 54880 USA Toll F...

Page 3: ...ranty Registration Form must be filled out by the dealer or customer and returned to Genesis indicating the date the attachment went into service Possible Variations Genesis cannot anticipate every possible circumstance that might involve a potential hazard as the owner s requirements and equipment may vary Therefore the warnings in this publication and on the product may not be all inclusive and ...

Page 4: ... Load Safely 9 Safely Operate Equipment 10 Transporting the Attachment 11 Equipment Condition 11 Working Overhead 11 Power Lines 11 Use Care with Hydraulic Fluid Pressure 12 Prioritized Oil Flow 13 Emergency Situations 13 Unsafe Conditions 13 Crystalline Silica Dust 13 Process Material Safely 14 Lift the Load Safely 14 Place the Load Safely 14 PROCESSOR MARKINGS 15 PROCESSOR INSTALLATION 16 Pad In...

Page 5: ...ping 28 Invoices 28 Returns 28 Return Goods Authorization 28 PARTS ORDER FORM 29 PARTS 30 Welded Jaw Wear Parts 31 Bolt in Jaw Wear Parts 32 BOLT TORQUE SPECIFICATIONS 33 THREAD TREATMENT DIAGRAM 34 Linkage Tools 34 PROCEDURES 35 Cleaning 35 Threadlocker 35 Anti Seize 36 No Thread Treatment 36 BOLT TORQUE SPECIFICATIONS 37 Dry Torque Values 37 Wet Torque Values 37 O RING BOSS FLAT FACE O RING TORQ...

Page 6: ... in injury or death This statement is used where serious injury or death could result if the instructions are not followed properly WARNING This statement is used where minor or moderate injury could result if the instructions are not followed properly CAUTION This statement is used where property damage could result if the instructions are not followed properly NOTICE DANGER This statement is use...

Page 7: ...d replace any damaged or worn parts Before Operating 3 Warn all others in the area that you are about to start operation 3 Perform the Check the Equipment steps outlined in this manual 3 Check underneath and around the machine Make sure all personnel and equipment are clear from the area of operation and equipment movement Check clearances in all directions including overhead 3 Be properly seated ...

Page 8: ... death could result if warnings or instructions regarding carrier stability and the work area are not followed properly Stability Your Genesis attachment is sized for carrier stability However improper operation faulty maintenance or unauthorized modifications may cause instability 3 Know the working ranges and capacities of the carrier to avoid tipping 3 Use the recommended carrier counter weight...

Page 9: ... 75 feet away from the area of operation and equipment movement Let all other workers and bystanders know you are preparing to start DO NOT operate until everyone is clear Always be properly seated in the operator s seat before operating any carrier controls To start 3 Make sure all controls are in the center neutral position 3 Be properly seated 3 Slowly operate all functions to check for proper ...

Page 10: ...idges banks and slopes Avoid operating across a slope which could cause the carrier to overturn 3 Reduce speed when driving over rough terrain on a slope or when turning to avoid overturning the carrier 3 Never use the attachment as a work platform or personnel carrier 3 Keep all step plates grab bars pedals and controls free of dirt grease debris and oil 3 Never allow anyone to be around the equi...

Page 11: ...ling Object Protection Structures or FOPS are necessary for any application where material is to be handled overhead Transporting the Attachment 3 Travel only with the attachment in a safe transport position to prevent uncontrolled movement Drive slowly over rough ground and on slopes 3 When driving on public roads use safety lights reflectors Slow Moving Vehicle signs etc to prevent accidents Che...

Page 12: ...ed fluid see a doctor immediately 3 Wear safety glasses and protective clothing and use a piece of cardboard or wood when searching for hydraulic leaks Do Not Use Your Hands See illustration below 3 Hydraulic oil becomes hot during operation Do not let hydraulic oil or components contact skin as it could cause severe burns Allow hydraulic components to cool before working on them Use appropriate p...

Page 13: ...ons or high reach conditions Emergency Situations Always be prepared for emergencies Make sure a fire extinguisher is available Be familiar with its operation Make sure to inspect and service the fire extinguisher regularly Make sure a first aid kit is readily available Unsafe Conditions Do not operate if an unsafe condition exists Stop operation immediately shut down the machine and report the un...

Page 14: ...id the warranty and may cause structural damage accidents or tipping Make sure the load is held securely in the jaws Do not move a loaded attachment if load is loose or dangling Make sure the load is pinched between the jaws never cradle a load For greater stability knuckle the attachment to bring the load closer to the center of rotation center of gravity while lifting Use extra caution during re...

Page 15: ...ments LLC Genesis GMP D 15 PROCESSOR MARKINGS Decals are necessary for safe operation and maintenance To reorder contact your Genesis dealer or call 715 395 5252 Model Number Serial Number Welded on back of upper jaw Logo ...

Page 16: ...locate the correct placement of the stabilizer pad on the bottom of the stick The stabilizer pad must be centered on and parallel to the stick Weld the pad to the stick using E7018 low hydrogen electrode or equivalent Weld per instructions provided on your installation drawing Install the stabilizer arm to the pad WARNING Removing any connecting pin may be hazardous To remove a connecting pin posi...

Page 17: ... bucket cylinder Make sure all personnel stand clear Lifting the tool will cause the jaw to close and stabilizer bar to swing Connect power link of excavator to upper jaw Align the stabilizer arm with the stationary jaw by moving the stick and operating the bucket cylinder Pin the arm to the jaw Check all connections to ensure mounting pins are properly retained Removal To remove tool with stiff a...

Page 18: ...s Use factory authorized parts The use of unauthorized parts may compromise safety performance and durability of the attachment and may void the warranty Follow the daily checklist and maintenance schedules in this manual Extreme conditions may dictate shorter maintenance intervals Do not exceed bolt torque specifications See the Genesis Fastener Manual Do not weld on structural components without...

Page 19: ...tened maintenance intervals NOTICE Eight Hour Checklist Inspect Bolts check for loose bolts replace if damaged Bracket pivot for wear and pin retainers Entire attachment for cracks visual check Grease Bracket pivot Main shaft pivot both sides Stick tip and linkage joints per excavator OEM instructions Use a lithium based premium EP 2 in normal conditions above 32 F 0 C Use Grade 0 in temperatures ...

Page 20: ...up or replaced To help customers determine and monitor how far processor teeth have worn from their original shape Genesis has created tooth build up templates Each template is sized and formed to that tooth s original shape and features three lines that indicate wear level Simply place the template over the tooth to determine the amount of wear and build up required or if replacement is needed Se...

Page 21: ...Genesis Attachments LLC Genesis GMP D 21 JAW MAINTENANCE Model Part Number Template 50 C D Weld on 9103759 9103760 50 C D Bolt on 9103761 9103762 70 C D Weld on 9103755 9103756 70 C D Bolt on 9103757 9103758 ...

Page 22: ... or flat Dull teeth will process concrete less efficiently Teeth may be built up and hard surfaced to extend their life The bypass of the outside rows of teeth is tight enough to cut rebar front teeth Maintaining square edges in these areas both upper and lower will allow continued cutting Model Part Number Template 90 C D Weld on 9103763 9103764 90 C D Bolt on 9103765 9103766 ...

Page 23: ...d clamp to the lower If you are welding on the upper jaw connect to the upper but not to the cylinder clevis If needed weld a piece of steel to the area for the grounding clamp and cut the piece off when welding is completed Welding Rules Before you begin Wearing an approved respirator grind the area to clean it removing all existing hard surfacing Preheat area to 350 F 177 C Maintain this tempera...

Page 24: ... pass stringer bead pattern using E7018 electrode Peen each pass Do not apply a stringer directly on the edge Start the first pass 1 4 from the edge Cap each stringer bead with one pass of GenWire or GenRod to hard surface Do not apply more than two layers of hard surfacing Peen each pass Grind the ends of all stringer welds with the grain to taper 1 to 1 1 2 25 38 mm to the parent material See th...

Page 25: ...sis Attachments LLC Genesis GMP D 25 HARD SURFACING PATTERNS Where parallel lines are shown apply single passes approximately 1 apart Where crosshatch is shown apply stringer beads at 45 angles to form 1 squares ...

Page 26: ...e closer to the tool decreasing jaw opening but yielding more power See warning below Poor cutting crushing Material size is beyond attachment appetite range Consult the factory Worn pulverizing teeth Replace component or build up and hard surface TROUBLE SHOOTING GUIDE Moving stiff arm back one hole farther from the tool from factory recommended position may result in linkage toggle and damage to...

Page 27: ...an invoice to the Genesis Service Department within 30 days Include itemized internal labor reporting parts lists and invoices for outside contractors Reference the authorization number on all invoices When returning parts for warranty consideration include a copy of any related Genesis paperwork along with any other necessary documentation to ensure proper processing and credit The Genesis Servic...

Page 28: ...oices open beyond 60 days are subject to review and may be placed on C O D status without further notice Returns Unused Genesis parts may be returned with proper documentation Return shipping is the responsibility of the purchaser Credit will be issued upon return less a 20 restocking fee Documentation is required for credit of returned parts Contact the Genesis Parts Department at 715 395 5252 fo...

Page 29: ...ustomer Phone Shipping Address Purchase Order Model Date Contact E mail Billing Address Shipping Method Serial Number Quantity Part Number Description Price E mail to the Genesis Parts Department genesisparts genesisattachments com For assistance call 715 395 5252 ...

Page 30: ...ded to aid in operation and maintenance If further information is required contact the Genesis Parts Department for a breakdown and parts list specific to your attachment model and serial number Part numbers listed are those currently used These may differ from the part numbers of the components originally installed in your attachment To ensure use of the correct internal components always indicat...

Page 31: ...60 5 Nylock Hex Nut M16 X 2 0 1 F1016200 1 F1016200 1 F1016200 6 Socket Head Capscrew M20 X 2 50 X 130 1 F0620130 1 F0620130 1 F0620130 7 Nylock Hex Nut M20 X 2 50 1 F1020250 1 F1020250 1 F1020250 8 Mach Washer M20 X 2 00 X 0 25 1 2101497 1 2101497 1 2101497 9 Hex Head Capscrew M20 X 2 50 X 50 1 F0120050 1 F0120050 1 F0120050 10 Socket Head Capscrew M16 X 2 0 X 40 4 F0616040 5 F0616040 5 F0616040 ...

Page 32: ...621 4 4502752 3 Mach Lower Tooth Plate 1 4502965 4502850 1 4502899 4 Mach Upper Tooth Plate 1 4502963 4502848 1 4502902 5 Front Plate Puck 4 4502620 4502620 4 4502620 6 Hex Head Capscrew M30 X 3 5 X 90 12 F0130090 F0130090 14 F0130090 7 Flat Washer M30 12 F1203056 F1203056 14 F1203056 8 Nylock Hex Nut M30 X 3 5 12 F1030350 F1030350 14 F1030350 Bolt in Jaw Wear Parts 1 1 8 5 7 6 4 2 2 8 5 3 7 6 ...

Page 33: ...nd identify bolt type Never re torque bolts that use Loctite If a bolt becomes loose or damaged after the initial use when Loctite was applied and the bolt was torqued the bolt must be replaced Never break tightened bolts loose with a torque wrench Doing so may break the torque wrench or take it out of calibration Torque wrenches should be calibrated on an annual basis When using a torque multipli...

Page 34: ...is GMP D 34 THREAD TREATMENT DIAGRAM Linkage Tools Use this diagram to determine what thread treatment if any is required for each fastener For thread treatment application procedures see page 35 For prescribed torque values see page 37 ...

Page 35: ...g threadlocker use Loctite 263 or equivalent applied using the following procedure Clean and degrease all threads For thru holes or nuts apply threadlocker to bolt threads For blind holes apply stripe of threadlocker along the length of the hole applying to the bolt can cause escaping air to remove threadlocker as the bolt is inserted Torque bolt to specified Wet Torque Value see page 37 For threa...

Page 36: ... or equivalent using the following procedure Clean and degrease all threads Apply thin coat of anti seize to internal and external threads and under bolt head and or nut ensuring complete coverage Torque bolt to specified Wet Torque Value see page 37 No Thread Treatment Clean and degrease all threads Torque bolt to specified Dry Torque Value see page 37 DRY ...

Page 37: ...376 415 300 7 8 9 821 606 670 484 1 00 8 1232 909 1007 727 1 00 14 1383 1020 1130 816 1 25 7 2463 1817 2013 1453 L9 1 50 6 4287 3162 3504 2529 Wet Torque Values Hex Socket Head Flat Head Fastener Grade Size x Pitch Nm Ft lb Nm Ft lb CL 10 9 M8 x 1 25 29 22 23 17 M10 x 1 50 61 45 49 36 M12 x 1 75 105 78 85 62 M14 x 1 50 150 111 121 88 M14 x 2 00 170 126 138 100 M16 x 2 00 265 196 216 156 M20 x 1 50...

Page 38: ...IFICATIONS O Ring Boss Torque Values Size Dash Nm Ft lb 4 22 16 5 27 20 6 36 26 8 83 60 10 110 80 12 187 135 14 249 180 16 304 220 20 387 280 24 498 360 Flat Face O Ring Torque Values Size Dash Nm Ft lb 4 18 13 6 30 22 8 60 44 10 85 62 12 121 88 14 121 88 16 160 116 20 213 154 24 274 198 ...

Page 39: ... 22mm 12mm 10mm M16 x 2 00 24mm 14mm 10mm M20 x 1 50 30mm 17mm 12mm M20 x 2 50 30mm 17mm 12mm M24 x 3 00 36mm 19mm 14mm M27 x 3 00 41mm 19mm M30 x 3 50 46mm 22mm M36 x 4 00 55mm 27mm 1 4 20 7 16 3 16 5 32 5 16 18 1 2 1 4 3 16 3 8 16 9 16 5 16 7 32 7 16 14 5 8 3 8 1 4 1 2 13 3 4 3 8 5 16 1 2 20 3 4 3 8 5 16 5 8 11 15 16 1 2 3 8 3 4 10 1 1 8 5 8 1 2 7 8 9 1 5 16 3 4 9 16 1 00 8 1 1 2 3 4 5 8 1 00 14...

Page 40: ... genesis europe com E mail info genesis europe com Central America Colombia Cra 13A 89 38 Ofi 613 Bogota Colombia Phone 57 1 610 8160 795 8747 E mail contact themsagroup com Genesis Attachments 1000 Genesis Drive Superior WI 54880 USA Toll Free 888 SHEAR IT 888 743 2748 Phone 715 395 5252 E mail info genesisattachments com CONTACT INFORMATION View and download all manuals genesisattachments com ma...

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