NPK Genesis GHG 16 Safety & Operator Manual Download Page 40 | Manualshive

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© 2022 Genesis Attachments, LLC

Genesis GHG 16 - GHG 50 Handling Grapple

40

Slow Cylinder Speed

The GHG cycle times are controlled by the flow provided by the carrier's hydraulic circuit and are a

direct result of the maximum published oil flow, see Hydraulic Flow and Pressure page 28.

If the arms will not open or close, be sure the right and left shut-off valves are open.

Checking Hydraulic Flow at Rated Pressure

Tools and equipment required:

Qty. 1 Pressure gauge: 0 – 5,000 psi (0 – 350 bar), for arm close circuit

Qty. 1 Test port adapter: to fit #4 SAE female port in the shut-off valve

Qty. 1 Test hose: rated for 5,000 psi (350 bar)

Qty. 1 Hydraulic flow meter: pressure loading type, 0 – 100 gpm (0 – 380 lpm) minimum

capacity

Checking Hydraulic Flow at Rated Pressure

Install a pressure gauge in the shut-off valve of the close side (left) of the hydraulic circuit.

Install a flow meter (t36) between the GHG (GZ) close

and open lines as shown.

Typically, the arm close line (m3) is on the left (from the

operator’s) seat and arm open (m4) is on the right.

To determine return line pressure (pressure drop) open

both shut-off valves (k4) and energize the arm close

circuit. Measure the pressure with the load valve (fm1) of

the flow meter in the full open position.

TROUBLE-SHOOTING GUIDE

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Summary of Contents for Genesis GHG 16

Page 1: ...Handling Grapple GHG Models GHG 16 GHG 50 SAFETY OPERATOR S MANUAL ...

Page 2: ...3 9730 E mail 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 5488...

Page 3: ...Form The Warranty 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 in...

Page 4: ...ork Area 10 Starting Procedure 10 Place the Load Safely 10 Safely Operate Equipment 11 Transporting the Attachment 12 Equipment Condition 12 Working Overhead 12 Power Lines 12 Use Care with Hydraulic Fluid Pressure 13 Prioritized Oil Flow 14 Emergency Situations 14 Unsafe Conditions 14 Crystalline Silica Dust 14 Process Material Safely 15 Lift the Load Safely 15 Place the Load Safely 15 SERIAL NUM...

Page 5: ... 31 Single Motor Hydraulic Circuit 32 Dual Motor Hydraulic Circuit 32 GRAPPLE INSTALLATION 33 Mounting to the Excavator 34 Removal from the Excavator 34 Grapple Storage 34 OPERATING TECHNIQUES AND PRECAUTIONS 35 TROUBLE SHOOTING GUIDE 36 Determine the Type of Problem 36 Determine the Cause of the Problem 36 Guide for Power Loss 36 Measuring Operating Pressures 36 Relief Valve Checking and Setting ...

Page 6: ...OR 50 Models GHG 20 GHG 40 50 COMPONENT KEYWORDS 51 WARRANTY 52 Claim Procedure 52 PARTS ORDER POLICY AND PROCEDURE 53 Parts Orders Should Include 53 Placing Orders 53 Part Numbers 53 Shipping 53 Invoices 53 Returns 53 Return Goods Authorization 53 PARTS ORDER FORM 54 CONTACT INFORMATION 55 TABLE OF CONTENTS ...

Page 7: ...s can result 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 stat...

Page 8: ...er Remove and 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 prop...

Page 9: ...r stability and compatibility warnings and instructions are not followed Stability Your Genesis attachment is sized for carrier stability However improper operation faulty maintenance or unauthorized modifications may cause instability The excavator weight ranges below are intended as a guideline only Other factors such as stick length counterweights and under carriage must be taken into considera...

Page 10: ...und the equipment to make certain no one is under it on it or close to it Keep all bystanders at least 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 i...

Page 11: ... 3 Do not exceed the lifting capacity of your carrier 3 Avoid conditions that can lead to tipping The carrier can tip when operated on hills ridges 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 person...

Page 12: ... handling Falling 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 ...

Page 13: ...red by injected 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 ...

Page 14: ...head operations 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 r...

Page 15: ...accidents or tipping Make sure the load is held securely in the tines Do not move a loaded attachment if load is loose or dangling Make sure the load is pinched between the tines never cradle a load Place the Load Safely Do not move the attachment or anything held in the tines over people equipment or buildings Place the load gently Do not throw or drop the contents Operate the controls smoothly a...

Page 16: ... 2022 Genesis Attachments LLC Genesis GHG 16 GHG 50 Handling Grapple 16 SERIAL NUMBER LOCATION ...

Page 17: ...t GZ Follow the maintenance schedules in this manual Extreme conditions may dictate shorter maintenance intervals Do not exceed bolt torque specifications Do not weld on structural components without consulting Genesis Doing so may cause structural failure and void the warranty Do not operate an attachment without the case drain line properly installed if the attachment uses a rotation system that...

Page 18: ...nt Remove paint before welding or heating Hazardous fumes dust can be generated when paint is heated by welding soldering or using a torch Do all work outside or in a well ventilated area and dispose of paint and solvent properly When sanding or grinding paint avoid breathing the dust Wear an approved respirator If you use solvent or paint stripper remove stripper with soap and water before weldin...

Page 19: ...ationship including proper location position orientation and or alignment During assembly observe all markings made during disassembly and all corresponding features of mating parts to ensure proper location position orientation and alignment During disassembly of a sub assembly place removed components on a clean dry surface in proper relative position as an aid in re assembly Always inspect thre...

Page 20: ...on rod and all of the hoses and fittings Check all fasteners for looseness Retighten if necessary Inspect all welds and repair as necessary Inspect the hydraulic hoses for wear damage or oil leakage Arm Maintenance Check for wear of the replaceable cutters dg3 and dg4 If the cutters no longer touch they must be replaced The diagram below shows new CY and worn CZ cutters Frame Maintenance Inspect f...

Page 21: ...of the dial indicator onto the lower frame Indicate the other end of the dial onto the top bracket face as shown Using the excavator slightly rock the grapple back and forth using slight stick movement Note the movement shown by the dial Take this reading d59 in four places If your readings are greater than shown contact the Genesis Service Department at 715 395 5252 Model New Maximum inch mm All ...

Page 22: ...spected see below Testing the Rotary Joint Seals for Internal Leakage If internal seal leakage is suspected before disassembling the rotary joint assembly BN the counterbalance valve cartridge cb1 pressure setting should be checked Internal leakage will most likely prevent the unit from reaching relief pressure in the close function The relief cartridge is located below the rotary joint in a block...

Page 23: ...he joint fitting adapter fittings m44 from the spindle case manifold blocks Remove the hoses AO from the spindle base manifold Remove the bolt AF and spacer ZZ from the spindle base manifold Remove the four mounting bolts AF1 from the spindle case Pull the rotary joint assembly BN from the swivel flat top assembly Step 2 Remove the three flat head socket screws AF9 Remove the top plate CH and O ri...

Page 24: ...le and glide bearings Remove the main seals and glide rings with a seal pick note the proper placement of main seals and glide bearings Check the grooves 118 in the spindle case BZ for burrs or scoring damage Light grinding or polishing may be required Step 5 Rotary Joint Reassembly Lubricate the main seals dg8 glide bearings dg7 and O rings RR with grease Install the main seals into the spindle c...

Page 25: ...ft GR5 Motor pinion one lubrication point 5 strokes from grease gun once per shift GR6 Cylinder base end pin one lubrication point located at arm attachment end 10 strokes from grease gun every 4 hours GR9 Link plate pivot pins one lubrication point each end per link 10 strokes from grease gun every 4 hours Use a lithium based premium EP 2 in normal conditions above 32 F 0 C Use Grade 0 in tempera...

Page 26: ...ing welded without allowing cur rent to pass through the pivot pins cylinder pin cylinder swivel motor or slewing ring If you are welding on the frame connect weld clamp to the frame If you are welding on the arms connect to the arms 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 Befor...

Page 27: ...d pattern with the grain using E7018 electrode Peen each pass Do not apply a stringer directly on the edge Start the first pass 1 4 from the edge Stagger the ends of the stringer welds so they do not end in a straight line Cap each stringer bead with one pass of GenWire or GenRod to hard surface Do not apply more than two lay ers of hard surfacing Peen each pass Grind the ends of all stringer weld...

Page 28: ...ge may damage the attachment and its hydraulic components Main Jaws Model Oil Flow Pressure GPM LPM PSI BAR GHG 16 16 26 60 100 3 625 5 075 250 350 GHG 20 GHG 25 GHG 30 21 32 80 120 GHG 40 GHG 50 26 37 100 140 Rotation Model Oil Flow Pressure GPM LPM PSI BAR GHG 16 5 8 20 30 1 450 2 030 100 140 GHG 20 8 13 30 50 GHG 20 Optional Single Motor 5 8 20 30 GHG 25 8 13 30 50 GHG 25 Optional Single Motor ...

Page 29: ...en line is on the right side Shut Off Valves Some hydraulic installation kits use two shut off valves k4 on the dipper stick k1 of the carrier These valves control the hydraulic oil going to the close side m3 and the open side m4 from the grapple Pressure test ports k8 are in the shut off valves k4 Each shut off valve has an on k5 and an off k6 position HYDRAULIC INSTALLATION ...

Page 30: ...rapple 30 Port Connection Diagram HYDRAULIC INSTALLATION m3 Hose arm close m4 Hose arm open m39a Rotation Hose for clockwise movement m39b Rotation Hose for counterclockwise movement Model Open Close Rotation GHG 16 12 JIC 8 JIC GHG 20 GHG 25 GHG 30 GHG 40 GHG 50 ...

Page 31: ...enesis Attachments LLC Genesis GHG 16 GHG 50 Handling Grapple 31 HYDRAULIC CIRCUITS Cylinder Hydraulic Circuit BN Rotary Joint Assembly c11 Cylinder cb1 Counterbalance Valve m3 Arm Close Port m4 Arm Open Port ...

Page 32: ...Single Motor Hydraulic Circuit BQ4 Hydraulic Motor fr Flow Regulator ma4 Cross port Relief m39a Clockwise Rotation Port m39b Counter Clockwise Rotation Port Dual Motor Hydraulic Circuit BQ4 Hydraulic Motor ma4 Cross port Relief m39a Clockwise Rotation Port m39b Counter Clockwise Rotation Port ...

Page 33: ...pt the GHG to the excavator stick or arm The kits include all necessary stick and link pins bolts etc GRAPPLE INSTALLATION m1 Stick Pin optional m2 Link Pin optional m3 Whip Hose Close optional m4 Whip Hose Open optional m7 Top Bracket m11 Bracket Bolt m12 Hex Nut m13 Washer m27 Swivel Top m39 Rotation Hose optional m42 Hex Nut m43 Pin Bolt ...

Page 34: ...andled carefully to prevent contamination from entering the grapple or the carrier hydraulic system NOTICE Removal from the Excavator Retract the cylinder to open jaws fully Position the GHG horizontally on wood blocks t20 as shown above Install safety bar Close the shut off valves Shut off engine and relieve all hydraulic pressure Disconnect the hydraulic hoses before setting the GHG down Install...

Page 35: ...cavator cylinders fully extended 96 or retracted 97 Do not strike push pull or scrape material with the GHG DO1 Do not pry twist or pull with the excavator The excavator should only be used to position and supply hydraulic power to the GHG For most efficient operation open the jaw only wide enough to grasp the material Grasp the material to be grabbed as deep into the throat of the GHG as possible...

Page 36: ...ill determine if the problem is in the grapple or the carrier If the pressures and flow available to the GHG are correct the problem is in the grapple Guide for Power Loss Power loss can be caused by a low carrier relief valve setting or a low grapple relief setting Verify the correct relief valve settings of the carrier and the GHG See the Relief Valve Checking and Setting section and troubleshoo...

Page 37: ...350 bar pressure gauge g8b in the 4 SAE test port on the arm open side located in both shut off valves k4 at the end of the stick Turn the shut off valves k4 to the off position Start the carrier and set the throttle to the full position Actuate the hydraulic circuit to close the GHG arms The pressure reading on the gauge should be a minimum of 500 psi 34 bar above the GHG s relief valve setting s...

Page 38: ...er Set the throttle to the full position then close the arms completely and hold for ten seconds Check the psi bar reading on the gauge and compare to the GHG s specified counterbalance valve setting If the reading is not per specification see Hydraulic Flow and Pressure page 28 and reset the counterbalance valve cartridge If you are unable to reset the counterbalance refer to the trouble shooting...

Page 39: ...place the attachment relief valve Check the relief valve cartridge for tightness Tighten the relief valve cartridge Check the relief valve cartridge for mis adjustment Re adjust the relief cartridge Check the O rings and backup rings of the relief valve cartridge Replace the O rings and backup rings of the relief valve cartridge Check the seals between the open and close passages of the swivel man...

Page 40: ...dapter to fit 4 SAE female port in the shut off valve Qty 1 Test hose rated for 5 000 psi 350 bar Qty 1 Hydraulic flow meter pressure loading type 0 100 gpm 0 380 lpm minimum capacity Checking Hydraulic Flow at Rated Pressure Install a pressure gauge in the shut off valve of the close side left of the hydraulic circuit Install a flow meter t36 between the GHG GZ close and open lines as shown Typic...

Page 41: ...erature With the engine at full throttle and the flow meter set at zero pressure energize the close circuit Turn in the loading valve adjustment knob and record pressure and flow at regular intervals on graph paper Record pressure on one axis of the graph and flow on the other Increase pressure until the relief valve setting of the carrier is reached This is the circuit flow chart Set the flow met...

Page 42: ...Tighten the counter balance valve cartridge Check the O rings and backup rings of the counterbalance valve cartridge Replace the O rings and backup rings of the counterbalance valve cartridge If additional assistance is required call the Genesis Service Department at 715 395 5252 Jaw Drift Some drift may be experienced depending on the GHG s position Acceptable drift may occur over a number of min...

Page 43: ...HG 50 8 13 30 50 1 450 2 320 100 160 TROUBLE SHOOTING GUIDE Slow Rotation Speed The rotation speed is a direct result of the amount of flow gpm lpm supplied by the carrier rotation circuit The chart below lists the approximate flow required Adjust the rotation flow so that it is within the guidelines shown for the model being tested Flows are checked at a normal operating pressure of 1 000 psi 70 ...

Page 44: ...ad 2 000 psi 138 bar Rotation Problem Cause Check Remedy Unit will not rotate Low or no flow Check hydraulic flow Adjust the carrier s flow to the attachment Pressure setting of cross port relief valves ma4 Check cross port relief valve settings Adjust the cross port relief valves on the rotation holding valve Replace cross port relief valves Broken pinion gear or hydraulic motor shaft Check pinio...

Page 45: ...ntly from each other 1 Remove both covers s9 from the side of the swivel top m27 2 When the covers are removed two flow regulators fr will be visible 3 These regulators are locked with a 3 32 locking screw c6 The screw must be loosened before the flow regulators can be adjusted 4 By turning the adjustment knobs you can either slow down or accelerate the rotation speed Be sure to tighten the lockin...

Page 46: ...less otherwise noted Top Cover HHCS Model Part Number Bolt Diameter ft lbs Nm GHG 16 GHG 50 N71008020 M8 19 25 Cover Plate HHCS Model Part Number Bolt Diameter ft lbs Nm GHG 16 GHG 50 N71010020 M10 37 50 Safety Bar HHCS Model Part Number Bolt Diameter ft lbs Nm GHG 16 GHG 40 N71020040 M20 406 550 GHG 50 N71020045 Support Bracket HHCS Model Part Number Bolt Diameter ft lbs Nm GHG 16 GHG 50 N7101202...

Page 47: ...er ft lbs Nm GHG 16 GHG 50 N98500647 M10 7 10 Medium strength Loctite must be used Slewing Ring Model Part Number Bolt Diameter ft lbs Nm GHG 16 N74016075 M16 258 350 GHG 20 GHG 25 N74016075 N74016070 GHG 30 GHG 50 N74016080 N74016090 Do not use Loctite on slewing ring bolts Top Bracket Model Bolt Diameter ft lbs Nm GHG 16 GHG 20 1 750 1015 GHG 25 GHG 50 1 1 4 1500 2030 Swivel Manifold Model Part ...

Page 48: ...pple 48 PINION GEAR INSTALLATION Insert the key c7 into the slot on the motor shaft Slide the pinion gear BR onto the shaft Apply a medium strength Loctite on the set screw c6 and torque the set screw c6 using the chart in the fastener torque section of this manual ...

Page 49: ...torques listed below are for the rod nut c1 and piston c2 used in the GHG cylinder assembly When assembling during rebuild it is also recommended that thread adhesive is used to ensure complete clamping Torque ft lbs Nm Piston c2 1106 1500 Rod Nut c1 29 5 40 Apply a small amount of thread adhesive to the set screw c6 before installing ...

Page 50: ...s GHG 20 GHG 40 Parts to Remove AO N98500849 Hose Assembly BQ4 N9850201 Hydraulic Motor BR N98600640 Pinion Gear DE N98601199 Motor Plate f3 N98500155 Tee g24 N97600055 Swivel Elbow Parts to Add EC N98601233 Cover f1 N97600043 Adaptor Fitting f4 N97600046 90 Adaptor f5 N97600044 Adaptor Fitting fr N98500241 Flow Valve ...

Page 51: ...y dg5 Support Bracket BQ4 Hydraulic Motor dg6 Arm Pin BR Pinion Gear dg9 Frame Bushing BT Slewing Ring g14 Pin cylinder rod end c11 Cylinder hm21 Motor Mounting Flange c13 Pin Lock Plate m2 Link Pin c49 Pin cylinder m18a Joint Fitting close dg1 Drive Arm m18b Joint Fitting open dg10 Link Bushing m27 Swivel Flat Top dg2 Arm m30 Link dg3 Cutter sharp s9 Cover ...

Page 52: ...g to the factory Replacement parts must be ordered using a purchase order number Shipping is standard ground Overnight shipping is available by request and Genesis will not cover the shipping charge When the repair is complete submit an invoice to the Genesis Service Department within 30 days Include itemized internal labor reporting parts lists and invoices for outside contractors Reference the a...

Page 53: ...nts with invoices 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...

Page 54: ...TSORDERFORM E mail to the Genesis Parts Department genesisparts genesisattachments com For assistance call 715 395 5252 Customer Phone Shipping Address Purchase Order Model Date Contact E mail Billing Address Shipping Method Serial Number Quantity Part Number Description Price ...

Page 55: ... 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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