Genesis GMP D Series User manual
GMP D Series
Mechanical Pulverizer
SAFETY, OPERATOR’S & PARTS MANUAL
© 2021 Genesis Attachments, LLC
Genesis GMP D
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CONTACT INFORMATION
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Asia Pacic Representative Oce
24 Upper Serangoon View #12-28
Singapore 534205
Phone: +65 9673 9730
E-mail:
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:
Central America & Colombia
Bogota, Colombia
Phone: +57 1 610 8160 / 795 8747
E-mail:
Genesis Attachments
1000 Genesis Drive
Superior, WI 54880 USA
Toll Free: 888-SHEAR-IT
(888-743-2748)
Phone: 715.395.5252
E-mail:
© 2021 Genesis Attachments, LLC Genesis GMP D 3
PREFACE
To ensure years of safe, dependable service, only trained and authorized persons should operate
and service your Genesis attachment. It is the responsibility of the product’s owner to ensure the
operator is trained in the safe operation of the product and has available this manual for review.
It is the responsibility of the operator and maintenance personnel to read, fully understand and
follow all operational and safety-related instructions in this manual. The attachment should not
be operated until you have read and fully understand these instructions. Always use good safety
practices to protect yourself and those around you.
Important
This operator’s manual must accompany the attachment at all times and be readily available to
the operator.
Manual Replacement
Should this manual become damaged or lost or if additional copies are required, immediately
contact any authorized Genesis dealer or the Genesis Service Department at 888-743-2748 or
715-395-5252 for a replacement.
Registration Form
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 you must satisfy yourself that the procedure,
application, work method or operating technique is safe for you and others before operating.
Public Notice
Genesis reserves the right to make changes and improvements to its products and technical
literature at any time without public notice or obligation. Genesis also reserves the right to
discontinue manufacturing any product at its discretion at any time.
Warranty
All work or repairs to be considered for warranty reimbursement must be pre-authorized by the
authorization by the Genesis Service Department will render all warranty reimbursement
consideration null and void without exception. See page 27 for Warranty Claim Procedures.
Improper operation or improperly performed maintenance may render any warranty null and void.
© 2021 Genesis Attachments, LLC
Genesis GMP D
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TABLE OF CONTENTS
CONTACT INFORMATION 2
PREFACE 3
Important 3
Manual Replacement 3
Registration Form 3
Possible Variations 3
Public Notice 3
Warranty 3
SAFETY STATEMENTS 6
OPERATIONAL SAFETY 7
Read Manual Before Operating or Maintaining the Attachment 7
Personal Protection 7
Know Your Equipment 7
Before Operating 7
Check the Equipment 8
Stability 8
Know the Work Area 9
Starting Procedure 9
Place the 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 Installation 16
Processor Installation 17
Removal 17
MAINTENANCE SAFETY 18
MAINTENANCE SCHEDULE 19
Eight-Hour Checklist 19
JAW MAINTENANCE 20
Pulverizing Teeth 20
GENERAL WELDING GUIDELINES 23
Welding Ground Clamp 23
Welding Rules 23
HARD-SURFACING 24
© 2021 Genesis Attachments, LLC Genesis GMP D 5
TABLE OF CONTENTS
HARD-SURFACING PATTERNS 25
TROUBLE-SHOOTING GUIDE 26
WARRANTY 27
Claim Procedure 27
Blade Warranty 27
PARTS ORDER POLICY AND PROCEDURE 28
Parts Orders Should Include 28
Placing Orders 28
Part Numbers 28
Shipping 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 TORQUE SPECIFICATIONS 38
BOLT DRIVE SPECIFICATIONS 39
CONTACT INFORMATION 40
© 2021 Genesis Attachments, LLC
Genesis GMP D
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SAFETY STATEMENTS
This symbol by itself or used with a safety signal word
throughout this manual is used to call attention to
instructions involving your personal safety or the safety
of others. Failure to follow these instructions 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 statement is used where serious injury or death will
result if the instructions are not followed properly.
© 2021 Genesis Attachments, LLC Genesis GMP D 7
!WARNING
Serious injury or death could result if appropriate
protective clothing and safety devices are not used.
Personal Protection
Use protective clothing and safety devices appropriate for the working conditions. These may
include but are not limited to:
3Hard hat
3Safety glasses, goggles or face shield
3Hearing protection
3Safety shoes
3Heavy gloves
3
3
Know Your Equipment
Know your attachment’s capabilities, dimensions and functions before
operating. Inspect your attachment before operating and never operate an
attachment that is not in proper working order. Remove and replace any
damaged or worn parts.
Before Operating
3Warn all others in the area that you are about to start operation.
3Perform the “Check the Equipment” steps outlined in this manual.
3Check 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.
3Be properly seated in the operator’s seat.
3Do not attempt to operate until you have read and fully understand this manual and the
OEM manual for the carrier.
OPERATIONAL SAFETY
Read Manual Before Operating or Maintaining the Attachment
Read this manual before attempting to operate the attachment. This operator’s
manual should be regarded as part of the attachment. For proper installation,
operation and maintenance of the attachment, operators and maintenance
personnel must read this manual.
© 2021 Genesis Attachments, LLC
Genesis GMP D
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Check the Equipment
Before use, check the equipment to ensure it is in good operating condition.
Check the following:
3
3
3Hydraulic hoses and hose connections for wear or leaks. Repair or replace any damaged
hoses or connections.
3All control levers for proper operation.
3Check for loose or missing pin retaining bolts.
GOOD
CONDITION
3
!WARNING
Serious injury or 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
3Know the working ranges and capacities of the carrier to avoid tipping.
3Use the recommended carrier counter weight.
• Ground conditions
• Grade
• Weight of attachment
• Contents of attachment
• Operator judgement
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 reaching to avoid tipping.
OPERATIONAL SAFETY
© 2021 Genesis Attachments, LLC Genesis GMP D 9
Know the Work Area
Check clearances in the work area. Keep all bystanders at a safe distance. Do not work under
obstacles. Always check your location for overhead and buried power lines or other utilities before
operation.
ground. If level ground is not possible, position the carrier to use the attachment to the front or
back of the carrier. Avoid working over the side of the carrier.
To reduce the risk of tipping and slipping, never park on a grade exceeding 10% (one-foot rise
over the span of a ten-foot run).
Starting Procedure
Before operating, walk completely around 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:
3Make sure all controls are in the center (neutral) position.
3Be properly seated.
3Slowly operate all functions to check for proper operation and to bleed air from the
hydraulic system.
To shut down:
3Return your Genesis attachment to a rest position on the ground.
3
3Work controls in all directions to relieve hydraulic pressure, per excavator manufacturer’s
instructions.
!WARNING
Serious injury or death could result if warnings or
instructions regarding safe operation are not followed
properly.
Place the Load Safely
Do not move the attachment, or anything held in the jaws, over people, equipment or buildings. Do
not throw or drop the contents. Operate the controls smoothly and gradually.
OPERATIONAL SAFETY
© 2021 Genesis Attachments, LLC
Genesis GMP D
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Safely Operate Equipment
See your carrier’s manual for these instructions.
3Operate only from the operator’s seat. Check the seat belt daily and replace if frayed or
damaged.
3
are taking prescription medication or over-the-counter drugs ask your medical provider
whether you can safely operate equipment.
3Never leave equipment unattended with the engine running or with the attachment in a
raised position. Apply the brakes before exiting the equipment.
3Do not exceed the lifting capacity of your carrier.
3Avoid 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.
3Reduce speed when driving over rough terrain, on a slope, or when
turning to avoid overturning the carrier.
3Never use the attachment as a work platform or personnel carrier.
3Keep all step plates, grab bars, pedals and controls free of dirt, grease,
debris and oil.
3Never allow anyone to be around the equipment when it is operating.
3Do not operate poorly maintained or otherwise faulty equipment. Inform the proper authority
3Do not alter or remove any safety features.
3
in doubt on any safety issue, contact your supervisor or safety
coordinator for an explanation.
3A heavy load can cause equipment instability. Use extreme care during travel. Slow down
on turns and watch out for bumps. The equipment may need additional counter-weights to
counterbalance the weight of the attachment.
OPERATIONAL SAFETY
© 2021 Genesis Attachments, LLC Genesis GMP D 11
Power Lines
Do not operate the machine near energized power lines. All local, state/provincial and federal
regulations must be met before approaching power lines, overhead or under-
ground cables, or power sources of any kind with any part of the carrier or
attachment. Always contact the appropriate utility when operating near power
lines. The lines should be moved, insulated, disconnected or de-energized
and grounded before operating in the area.
Current in high voltage lines may arc some distance from the wire to a nearby ground. Keep all parts
of the machine at least 50 feet (16m) away from power lines.
Working Overhead
Avoid handling material overhead whenever possible. Safety glass and wire mesh
created during handling. Falling Object Protection Structures, or FOPS, are
necessary for any application where material is to be handled overhead.
Transporting the Attachment
3Travel only with the attachment in a safe transport position to prevent uncontrolled
movement. Drive slowly over rough ground and on slopes.
3
3Do not drive close to ditches, excavations, etc., as cave-in could result.
3Do not smoke when refueling the prime mover. Allow room in the fuel tank for expansion.
Wipe up any spilled fuel. Secure cap tightly when done.
Equipment Condition
Never operate poorly maintained equipment. When maintenance is required, repair or replace
parts immediately.
!WARNING
Serious injury or death could result if warnings or
instructions regarding working overhead are not followed
properly.
!DANGER
Serious injury or death will result if warnings or instructions
regarding power lines are not followed properly.
OPERATIONAL SAFETY
© 2021 Genesis Attachments, LLC
Genesis GMP D
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Use Care with Hydraulic Fluid Pressure
Hydraulic leaks under pressure may not be visible.
3Keep unprotected body parts, such as face, eyes and arms as far away
develop gangrene or other permanent injuries.
3
3Wear 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.
3Hydraulic 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 protective
clothing and safety equipment. If burned, seek immediate medical attention.
!WARNING
Serious injury or death could result if warnings or
followed properly.
OPERATIONAL SAFETY
© 2021 Genesis Attachments, LLC Genesis GMP D 13
OPERATIONAL SAFETY
IMPORTANT: Concrete and masonry products contain silica sand.
Quartz, which is a form of silica and the most common mineral in the
Earth’s crust, is associated with many types of rock.
Some activities that may have silica dust present in the air include
demolition, sweeping, loading, sawing, hammering, drilling or planing of
rock, concrete or masonry.
It is recommended to use dust suppression (such as water) or dust
collection (such as a vacuum) along with personal protective equipment
if necessary during the operation of any attachment that may cause high
levels of silica dust.
Prioritized Oil Flow
operations or high reach conditions.
Emergency Situations
Unsafe Conditions
Do not operate if an unsafe condition exists. Stop operation immediately, shut down the machine
and report the unsafe condition to the proper authority. Equipment operation and maintenance
sense while operating and be alert to unsafe conditions.
Crystalline Silica Dust
It is recommended to use dust suppression, dust collection and if necessary, personal protective
equipment during the operation of any attachment that may cause high levels of dust.
!DANGER
Exposure to respirable crystalline silica dust along with
other hazardous dusts may cause serious or fatal
respiratory disease.
© 2021 Genesis Attachments, LLC
Genesis GMP D
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!WARNING
Using your Genesis attachment in unauthorized
applications may create an unsafe situation and will void
the warranty.
Process Material Safely
• Do not process hardened steel material such as tool steel, railroad rail, axles or machined
cause damaging decompression spikes to your Genesis attachment and base carrier
hydraulic systems.
• Do not operate any functions of the carrier while cutting or crushing with your Genesis attach-
ment, including boom and drive functions.
• Do not pull down structures with your Genesis attachment. Doing so may cause falling debris
or material may break free and exceed the capacities of the carrier, causing a tipping hazard.
Lift the Load Safely
• The hydraulic system has been preset and tested by your dealer. Do not alter hydraulic
settings without consulting an authorized Genesis dealer or the Genesis Service Department.
Doing so will void 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 reaching to avoid tipping.
Place the Load Safely
• Do not move the attachment, or anything held in the jaws, over people, equipment or
buildings. Place the load gently. Do not throw or drop the contents.
• Operate the controls smoothly and gradually. Jerky controls are hazardous and may cause
damage to the carrier.
•
• Never substitute pins or bolts. Use factory supplied pins. Replace all bolts with the same size
and grade. Failure to do so may cause serious injury or death.
• Use your Genesis attachment only as directed in this manual. Do not use the attachment to lift
and move other objects. Doing so may cause instability and tipping.
OPERATIONAL SAFETY
© 2021 Genesis Attachments, 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
© 2021 Genesis Attachments, LLC
Genesis GMP D
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PROCESSOR INSTALLATION
Preparation of the excavator prior to attachment delivery will make installation safer and
easier. Contact Genesis or your Genesis dealer for assistance.
Pad Installation
Curl the excavator stick under so the bottom of the stick is facing upward.
Use the mounting dimensions provided on your installation
drawing to 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, position the attachment on the
ground and properly support.
!WARNING
mallet when striking pins. Keep all personnel at a safe
distance.
© 2021 Genesis Attachments, LLC Genesis GMP D 17
PROCESSOR INSTALLATION
Processor Installation
Remove the bucket or other attachment following the
manufacturer’s procedure. Retract the bucket cylinder and
closed.
Position the excavator behind the attachment and carefully
line up the stick connection of the excavator and attachment.
Install pin.
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
Remove pin from pad. Move tool to storage position with
arm hanging.
Lower tool to ground. Close jaws to prevent tool movement
after link pin is removed.
Remove pins.
!WARNING
Lifting the attachment will cause the jaw to close and the
stabilizer bar to swing. Keep all personnel at a safe
distance.
© 2021 Genesis Attachments, LLC
Genesis GMP D
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MAINTENANCE SAFETY
Only trained and authorized persons should perform maintenance on the attachment. To be
rules and regulations of the job site.
Do not alter the physical, mechanical or hydraulic operation of the attachment. Doing so may
cause a dangerous situation for yourself and those around you and will void the warranty.
Do not attempt repairs you do not understand. If any questions arise regarding a safety or
maintenance procedure, contact Genesis or your Genesis dealer.
Read this entire manual. All personnel must understand the maintenance and safety procedures.
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 weld on structural components without consulting Genesis. Doing so may cause structural
failure and void the warranty.
Do not work on the attachment before ensuring it will not move. Completely lower the boom to the
ground or a rest position and relieve hydraulic pressure.
Never operate poorly maintained equipment. When maintenance is required, repair or replace
parts immediately.
Do not operate under unsafe conditions. If an unsafe condition arises during operation,
immediately shut down the equipment and report the situation to the proper authority.
© 2021 Genesis Attachments, LLC Genesis GMP D 19
MAINTENANCE SCHEDULE
Performing scheduled maintenance will promote safe, reliable operation of your attachment.
Inspect and grease components every eight hours of operation, as indicated on the following
checklist. Use maintenance procedures described in this manual. If you are not able to safely and
competently perform these procedures, have a Genesis dealer perform them.
Extreme operating conditions may require shortened
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 below freezing. Do not use grease containing Molybdenum (Moly).
Genesis anti-wear, extreme-pressure lithium grease, PN 6302601, is recommended.
Grease all locations until grease extrusion is visible.
Jaws and Teeth:
• Check teeth for wear
• Build-up and hard-surface as needed
© 2021 Genesis Attachments, LLC
Genesis GMP D
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the life of replaceable parts, follow all instructions for checks, adjustments and maintenance
described, at the intervals listed in this manual.
Before performing maintenance, read, fully understand and follow these safety rules.
Wear personal safety equipment including gloves, safety glasses, safety boots and proper
clothing.
Pulverizing Teeth
As teeth become worn, they need to be rotated,
built-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.
See the following pages for part numbers and contact your local Genesis dealer or the Genesis
Parts Department to order.
JAW MAINTENANCE
Line 3
Line 1 Line 2
Line 1
Line 2
Line 3
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