Genesis Power Series, GRS, GLS, GCC, GMP Safety & Operators & Parts Manual

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Page 1

Power Series Linkage Tools

GLS, GRS, GCC, GMP

SAFETY, OPERATOR’S & PARTS MANUAL

Linkage Shear (GLS)

Concrete Cracker (GCC)

Rebar Shear (GRS)

Mechanical

Pulverizer (GMP)

Page 2

CONTACT INFORMATION

World Headquarters

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

Asia Pacic Representative Ofce

24 Upper Serangoon View #12-28

Singapore 534205

Phone: +65 9673 9730

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

E-mail:

Central America & Colombia

Cra 13A #89-38 / O 613

Bogota, Colombia

Phone: +57 1 610 8160 / 795 8747

E-mail:

contact@themsagroup.com

View and download all manuals: genesisattachments.com/manuals

Patents: genesisattachments.com/products/patents

Genesis Power Series Linkage Tools

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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 715395-5252 for a replacement.

Registration Form

The Warranty Registration Form must be lled 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 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 Genesis Service Department. Any alterations, modications or repairs performed before authorization by the Genesis Service Department will render all warranty reimbursement consideration null and void without exception. See page 46 for Warranty Claim Procedures.

Improper operation or improperly performed maintenance may render any warranty null and void.

Genesis Power Series Linkage Tools

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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 7 OPERATIONAL SAFETY 8

Read Manual Before Operating or Maintaining the Attachment 8 Personal Protection 8 Know Your Equipment 8 Before Operating 8 Check the Equipment 9 Stability 9 Know the Work 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 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

ATTACHMENT MARKINGS 15 PAD INSTALLATION 16 ATTACHMENT INSTALLATION 17

Removal 17

MAINTENANCE SAFETY 18 MAINTENANCE SCHEDULE 19

Eight-Hour Checklist 19 Grease 19

BOLT TORQUE SPECIFICATIONS 20

Visual Reference for GLS Bolt Torque 21 Visual Reference for GRS Bolt Torque 22 Visual Reference for GCC Bolt Torque 23 Visual Reference for GMP Bolt Torque 24

Genesis Power Series Linkage Tools

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TABLE OF CONTENTS

LINKAGE SHEAR MAINTENANCE 25

Blade Bolts 25 Piercing Blades 26 Piercing Blade Replacement 28 Guide Blade 29 Guide Blade Shimming 29 Guide Blade Rotation 29 Guide Blade Replacement 29 Primary and Secondary Blades 30 Primary and Secondary Blade Removal 30 Adjustment Plates 31 Primary and Secondary Blade Rotation 31 Primary and Secondary Blade Gap 32 Blade Gap Measuring Procedure 32 Blade Shimming 32 Razor Blade 33 Jaw Stop 33

REBAR SHEAR MAINTENANCE 34

Blade Bolts 34 Piercing Tips 34 Primary and Secondary Blades 35 Primary and Secondary Blade Removal 35 Primary and Secondary Blade Rotation 36 Primary and Secondary Blade Gap 36 Blade Gap Measuring Procedure 36 Blade Shimming 37 Jaw Stop 37

CONCRETE CRACKER MAINTENANCE 38

Concrete Cracking Blades 38 Blade Removal 38 Blade Rotation 39 Jaw Stop 39 Pulverizing Teeth 40

GENERAL WELDING GUIDELINES 41

Welding Ground Clamp 41 Welding Rules 41

BUILD-UP 42 HARD-SURFACING 43 HARD-SURFACING PATTERNS 44 TROUBLE-SHOOTING GUIDE 45 WARRANTY 46

Claim Procedure 46 Blade Warranty 46

Genesis Power Series Linkage Tools

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TABLE OF CONTENTS

PARTS ORDER POLICY AND PROCEDURE 47

Parts Orders Should Include 47 Placing Orders 47 Part Numbers 47 Shipping 47 Invoices 47 Returns 47 Return Goods Authorization 47

PARTS ORDER FORM 48 PARTS 49

GLS Blades and Wear Parts 50 GRS Blades and Wear Parts 51 GCC Blades and Wear Parts 52 GMP Blades and Wear Parts 53 Power Series Pivot Group 54

TOOL LIST 55 CONTACT INFORMATION 56

Genesis Power Series Linkage Tools

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SAFETY STATEMENTS

WARNING

CAUTION

DANGER

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 will result if the instructions are not followed properly.

This statement is used where serious injury or death could result if the instructions are not followed properly.

This statement is used where minor or moderate injury could result if the instructions are not followed properly.

NOTICE

This statement is used where property damage could result if the instructions are not followed properly.

Genesis Power Series Linkage Tools

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WARNING

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.

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:

3 Hard hat 3 Safety glasses, goggles or face shield 3 Hearing protection 3 Safety shoes 3 Heavy gloves 3 Reective clothing 3 Respirator or lter mask

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

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 in the operator’s seat. 3 Do not attempt to operate until you have read and fully understand this manual and the

OEM manual for the carrier.

Genesis Power Series Linkage Tools

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WARNING

OPERATIONAL SAFETY

Check the Equipment

Before use, check the equipment to ensure it is in good operating condition.

Check the following:

3 Grease ttings. Pump grease at all tting locations, see page 19. 3 Blades and wear surfaces for wear or damage. 3 Hydraulic uid level. Add hydraulic uid as required. 3 Hydraulic hoses and hose connections for wear or leaks. Repair or

replace any damaged hoses or connections.

3 All control levers for proper operation.

Serious injury or death could result if warnings or instructions regarding carrier stability and the work area are not followed properly.

GOOD

CONDITION

Stability

Your Genesis attachment is sized for carrier stability. However, improper operation, faulty mainte-

nance or unauthorized modications may cause instability.

3 Know the working ranges and capacities of the carrier to avoid tipping. 3 Use the recommended carrier counter weight.

The following conditions affect stability:

• 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.

Genesis Power Series Linkage Tools

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WARNING

OPERATIONAL SAFETY

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.

Check ground conditions. Avoid unstable or slippery areas. Position the carrier on rm level

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:

3 Make sure all controls are in the center (neutral) position. 3 Be properly seated. 3 Slowly operate all functions to check for proper operation and to bleed air from the hydrau-

lic system.

To shut down:

3 Return your Genesis attachment to a rest position on the ground. 3 Shut off the carrier engine. 3 Work controls in all directions to relieve hydraulic pressure, per excavator manufacturer’s

instructions.

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.

Genesis Power Series Linkage Tools

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OPERATIONAL SAFETY

Safely Operate Equipment

Do not operate equipment until you are trained by a qualied operator in its use and capabilities.

See your carrier’s manual for these instructions.

3 Operate only from the operator’s seat. Check the seat belt daily and replace if frayed or

damaged.

3 Do not operate this or any other equipment under the inuence of drugs or alcohol. If you

are taking prescription medication or over-the-counter drugs ask your medical provider whether you can safely operate equipment.

3 Never leave equipment unattended with the engine running or with the attachment in a

raised position. Apply the brakes before exiting the equipment.

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 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 equipment when it is operating.

3 Do not operate poorly maintained or otherwise faulty equipment. Inform the proper authority

and DO NOT resume operation until the problem has been xed.

3 Do not alter or remove any safety features.

3 Know your work site safety rules as well as trafc rules and ow. When

in doubt on any safety issue, contact your supervisor or safety coordinator for an explanation.

3 A 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.

Genesis Power Series Linkage Tools

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WARNING

DANGER

OPERATIONAL SAFETY

Transporting the Attachment

3 Travel only with the attachment in a safe transport position to prevent uncontrolled move-

ment. Drive slowly over rough ground and on slopes.

3 When driving on public roads use safety lights, reectors, Slow Moving Vehicle signs, etc.,

to prevent accidents. Check local government regulations that may affect you.

3 Do not drive close to ditches, excavations, etc., as cave-in could result. 3 Do 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.

Serious injury or death could result if warnings or instructions regarding working overhead are not followed properly.

Working Overhead

Avoid handling material overhead whenever possible. Safety glass and wire mesh

cab guarding must be installed to protect the operator from ying debris that may be

created during handling. Falling Object Protection Structures, or FOPS, are necessary for any application where material is to be handled overhead.

Serious injury or death will result if warnings or instructions regarding power lines are not followed properly.

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 underground 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.

Genesis Power Series Linkage Tools

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OPERATIONAL SAFETY

DANGER

Prioritized Oil Flow

Equipment operators must ensure there is prioritized oil ow to the main valves in overhead operations or high reach conditions.

Emergency Situations

Always be prepared for emergencies. Make sure a re extinguisher is available. Be familiar with its operation. Make sure to inspect and service the re extinguisher regularly. Make sure a rst 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 unsafe condition to the proper authority. Equipment operation and maintenance practices directly affect your safety and the safety of those around you. Always use common 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.

Exposure to respirable crystalline silica dust along with other hazardous dusts may cause serious or fatal respiratory disease.

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.

Genesis Power Series Linkage Tools

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WARNING

OPERATIONAL SAFETY

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

parts. Hardened material breaks, rather than shears, which may cause ying debris.

• Do not operate any functions of the carrier while cutting or crushing with your Genesis attachment, 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

• 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.

• 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.

• Avoid re hazards. Keep the area clean. Remove all ammable materials from the area during

any welding or heating process. Have a re extinguisher nearby and know how to use it.

• 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.

Genesis Power Series Linkage Tools

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ATTACHMENT MARKINGS

Decals are necessary for safe operation and maintenance. To reorder, contact your Genesis dealer or call 715-395-5252.

Logo

Model

Serial Number

(Weld-on)

Genesis Power Series Linkage Tools

Page 16

PAD INSTALLATION

WARNING

Preparation of the excavator prior to attachment delivery will make installation safer and

easier. Contact Genesis or your Genesis dealer for assistance.

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.

Removing any connecting pin may be hazardous. To remove a connecting pin, position the attachment on the ground and properly support.

Particles may y when a pin is struck. Use a drift pin or

mallet when striking pins. Keep all personnel at a safe distance.

Genesis Power Series Linkage Tools

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ATTACHMENT INSTALLATION

WARNING

Remove the bucket or other attachment following the manufacturer’s procedure. Retract the bucket cylinder and associated linkage. All Power Series Linkage Tools

are designed to sit at on the ground. The attachment must be on a rm, level surface with the jaws closed.

Position the excavator behind the attachment and carefully line up the stick connection of the excavator and attachment. Install pin.

Raise the tool slightly off the ground and extend the bucket cylinder.

Make sure all personnel stand clear. Lifting the attachment will cause the jaw to close and the stabilizer bar to swing.

Connect excavator power link 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 arm, set arm on heavy object. 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.

Genesis Power Series Linkage Tools

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MAINTENANCE SAFETY

Only trained and authorized persons should perform maintenance on the attachment. To be quali-

ed, you must understand the instructions in this manual, have training, and know the safety rules

and regulations of the job site.

Do not alter the physical or mechanical 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 exceed bolt torque specications.

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.

Genesis Power Series Linkage Tools

Page 19

MAINTENANCE SCHEDULE

Performing scheduled maintenance will ensure safe, reliable operation of your linkage attachment. Inspect and grease components every eight hours of operation, as indicated below. Use the 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.

Eight-Hour Checklist

Inspect:

• Bolts - replace loose or damaged

• Bracket pivot for wear and pin retainers

• Entire attachment for cracks (visual check)

• Jaw stop for cracking or damaged welds (GLS, GRS, GCC)

Grease:

• Bracket pivot

• Main shaft/pivot (both sides)

• Stick tip and linkage joints per excavator OEM instructions

Jaws:

• Check blade tolerance*

• Check blade edge radius*

• Check for loose or damaged bolts

• Check teeth or tines for wear

• Build-up and hard-surface as required

*See model-specic maintenance information in this manual for maximum tolerance and radius.

Grease

Use a lithium-based premium EP #2 in normal conditions above 32° F (0° C). Use Grade 0 in temperatures below freezing.

Grease all ttings every eight hours of operation. Grease until extrusion is visible.

Genesis Power Series Linkage Tools

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BOLT TORQUE SPECIFICATIONS

Genesis typically uses dry torque measurements.

Prior to using the chart below, clean all bolt holes, bolts and nuts to remove dirt, grease and oil. See the Visual Reference below or Part Lists to 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 multiplier with a torque wrench, incorrect settings will be multiplied by the ratio of the torque wrench.

Never use an air wrench on a torque multiplier.

Dry Torque Values

Hex Head Flat Head

Fastener

Grade

CL 10.9

L9 1.00-8 1152 850 922 680

Size x

Pitch

M8 x 1.25 36 27 29 22

M10 x 1.50 72 53 58 42

M12 x 1.75 125 92 100 74

M14 x 1.50 210 154 168 123

M14 x 2.00 200 148 160 118

M16 x 2.00 313 230 250 184

M20 x 1.50 640 472 512 378

M20 x 2.50 610 450 488 360

M24 x 3.00 1055 778 844 622

M27 x 3.00 1543 1138 1234 910

M30 x 3.50 2095 1545 1676 1236

1/2-13 145 107 11 6 86

1/2-20 163 120 130 96

5/8-11 286 2 11 229 169

3/4-10 510 376 408 301

7/8-9 822 606 658 485

1.00-8 1220 900 976 720

1.00-14 1345 992 1076 794

1.25-7 2464 1817 1971 1454

1.50-6 4280 3160 3424 2528

Nm Ft-lb Nm Ft-lb

Wet Torque Values

Fastener

Grade

CL 10.9

Hex Head

Size x

Pitch

M20 x 2.50 458 338 366 270

M24 x 3.00 790 583 632 466

M27 x 3.00 1157 850 926 680

M30 x 3.50 1572 1160 1258 928

3/4-10 383 282 306 226

7/8-9 617 455 494 364

1.00-8 916 675 733 540

1.25-7 1847 1362 1478 1090

1.50-12 4067 3000 3254 2400

Nm Ft-lb Nm Ft-lb

Flat Head

Apply grease or anti-seize on threads and under bolt heads

Visual Reference

Genesis Power Series Linkage Tools

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BOLT TORQUE SPECIFICATIONS

Visual Reference for GLS Bolt Torque

Item Description GLS 50 GLS 70 & 90

A Tip Blade Bolts, Lubricated

B Cutting Blade Bolts

C Guide Blade Bolts

D Razor Blade Bolts

282 Ft-lbs

(383 Nm)

376 Ft-lbs

(510 Nm)

376 Ft-lbs

(510 Nm)

376 Ft-lbs

(510 Nm)

675 Ft-lbs

(916 Nm)

606 Ft-lbs

(822 Nm)

606 Ft-lbs

(822 Nm)

606 Ft-lbs

(822 Nm)

E End Cap Bolts

1545 Ft-lbs

(2095 Nm)

Genesis Power Series Linkage Tools

1545 Ft-lbs

(2095 Nm)

Page 22

BOLT TORQUE SPECIFICATIONS

Visual Reference for GRS Bolt Torque

Item Description GRS 70 & 90

A Cutting Blade Bolts

B End Cap Bolts

Genesis Power Series Linkage Tools

900 Ft-lbs

(1220 Nm)

1545 Ft-lbs

(2095 Nm)

Page 23

BOLT TORQUE SPECIFICATIONS

Visual Reference for GCC Bolt Torque

Item Description GCC 50 GCC 70 & 90

A Blade Bolts

B End Cap Bolts

606 Ft-lbs

(822 Nm)

1545 Ft-lbs

(2095 Nm)

900 Ft-lbs

(1220 Nm)

1545 Ft-lbs

(2095 Nm)

Genesis Power Series Linkage Tools

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BOLT TORQUE SPECIFICATIONS

Visual Reference for GMP Bolt Torque

Item Description GMP 50 GMP 70 & 90

A Tooth Bed Bolts

450 Ft-lbs

(610 Nm)

778 Ft-lbs

(1055 Nm)

B End Cap Bolts

Genesis Power Series Linkage Tools

1545 Ft-lbs

(2095 Nm)

1545 Ft-lbs

(2095 Nm)

Page 25

LINKAGE SHEAR MAINTENANCE

Blade and jaw maintenance greatly affects performance. To maximize cutting performance and optimize replaceable part life, follow this specic sequence of checks, adjustments and maintenance.

1. Piercing Blades - replace when edges are worn.

2. Guide Blade - rotate, shim to tolerance and replace when worn.

3. Upper and Lower Cutting Blades - rotate; replace when all edges are worn. Shim lower blades to tolerance.

4. Razor Blade - rotate and replace when all edges are worn.

5. Welding Maintenance - perform jaw build-up and hardsurface as needed.

Blade Bolts

Torque blade bolts every eight hours to the specications

listed in the torque chart in this manual. Check for broken bolts daily and replace them immediately.

3 5

Genesis Power Series Linkage Tools

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LINKAGE SHEAR MAINTENANCE

Piercing Blades

Piercing blade maintenance is crucial to productivity and safe operation. An improper blade gap may cause material jamming and/or blade breakage.

Use the following procedure to check for wear.

• Slowly close jaws until the piercing blades are ush with the

top edge of the razor blade.

• Check gap with a tape measure. Acceptable gap is 5/8”.

• Check the condition of the piercing blades with a straight edge or square.

• Check the prole along the blades.

• Badly worn blades must be replaced. However, slightly worn blades may be squared up with a grinder and a square. This may be repeated until a maximum of 1/2” of material is removed from the lower piercing edge.

Check gap

• Typical use requires blade replacement at approximately 200 hours; heavy piercing requires replacement at approximately 40 hours. These are general guidelines only. Replace blades based on wear, not based on hours of operation.

• Width of blades, top to bottom, may taper 0.060” (2mm) total. Bottom edges may be worn to a maximum radius of 3/16”.

3/16” Maximum radius

↓

1/2”

↓

Genesis Power Series Linkage Tools

Page 27

LINKAGE SHEAR MAINTENANCE

Piercing blades must t tightly in some areas while having clearance in others. Piercing blades

are made from the same material as the cutting blades to withstand the friction caused by piercing hard materials.

Areas Highlighted in Blue require contact t to the upper jaw and tang to prevent shattering.

Areas Highlighted in Red require an air gap, and blades may occasionally need to be ground down to provide clearance.

Piercing blade contact with the clearance areas (red) will cause abnormal stresses to the blade and the piercing blades and/or guide blades to shatter.

Tang

When necessary, build up the front lower edge of the tang and the front vertical surface of the upper (areas highlighted in yellow), following the procedures given in this manual. After welding, surfaces should be squared

with a grinder and nished with a le and a machinist’s straight edge.

It is critical that the piercing blade pocket and tang surfaces are straight and true, without dings, deformations, high or low spots, or areas that are worn away.

Piercing blade bolts must not make hard contact with the bolt holes in the upper tang. In rare cases it has been noted that improper alignment of piercing blade bolt holes and the bolt holes in the tang can cause the piercing blades to break through the bolt holes.

When installing the piercing blades, the bolts must be freely installed by hand, not with an air impact wrench.

The bolts may start freely, but when the bolt shank, which is larger in diameter than the threads, enters the hole in the tang, the interference can cause side loading to the piercing blades. This can cause the tips to break as they try to force the holes apart, or it may force the tips to seat improperly on the tang which can also cause tip failure. This is not a common issue, but one that should be noted as part of routine tip maintenance to prevent unnecessary costs and downtime. If this situation is encountered, contact the Genesis Parts or Service Departments for further instructions.

Genesis Power Series Linkage Tools

Page 28

LINKAGE SHEAR MAINTENANCE

Piercing Blade Replacement

1. Remove blades using an air-impact wrench or breaker bar and multiplier.

2. Remove dust and debris from blade seats; wipe down with a rag and solvent.

3. Lightly le deformities from blade seat edges. Do not sand or grind face of blade seats.

4. Install new, clean blades. Lubricate the threaded holes in the blade and on the bottom of the bolt head where it will contact the blade.

5. Snug lubricated blade bolts by hand to hold them in place; push blades up and into the upper and rear surfaces of the seats.

6. Torque bolts to 1/3 of the nal torque value.

7. Check for rm contact against blade seats.

8. With a feeler gauge, conrm gap of 0.002” to 0.010” where blades meet at piercing surface. A very narrow gap may

be conrmed by shining a ashlight from below the blades

and seeing light pass through. If gap exceeds 0.010”, call the Genesis Service Department. If no gap exists, remove blades, lightly grind facing surfaces and repeat steps 5-8.

Check gap

9. Torque bolts to 2/3 nal value, and then to nal value, using a cross bolt pattern.

Piercing blade bolts must be lubricated and torqued as

NOTICE

Description GLS 50 GLS 70 & 90

Blade Bolts, Lub.

Correct clamping force is required to keep tips from moving on their seats. Over-tightening can cause bolt shanks to stretch, losing their clamping force. Loose bolts will cause the seating areas to erode.

specied below.

282 Ft-lbs

(382 Nm)

675 Ft-lbs

(915 Nm)

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LINKAGE SHEAR MAINTENANCE

Guide Blade

Check guide blade tolerance every eight hours. When necessary, shim the guide blade to keep

the gap within the specications listed in the blade gap table.

Rotate the guide blade when worn to a 1/8” (3 mm) radius. Replace the guide blade when more than 0.075” (2 mm) of shims are required to keep the blade gap within the tolerances listed in the following table.

Guide Blade to Piercing Blade Gap

Model Minimum Maximum

GLS 50 0.005” 0.020”

GLS 70 0.005” 0.020”

GLS 90 0.010” 0.025”

Guide Blade Shimming

Slowly close the jaws so the upper piercing tip begins to bypass the guide blade. Stop the jaw and check the gap between the guide blade and piercing tip. Cycle the jaws slowly, stopping at several points along the piercing tip to check the gap each time.

Shim the guide blade as needed to keep the gap within the tolerances listed in the blade gap table.

To install shims, loosen the blade bolts and slide shims between the guide blade and guide blade seat. Retorque bolts and recheck the gap.

Guide Blade Rotation

Remove the bolts, guide blade and shims. Rotate the blade endfor-end or side-to-side; reinstall and torque bolts. Check gap; shim if required.

If guide blade faces are worn excessively, the blade cannot be rotated to place the uneven surface against the mating surface of the guide blade seat. Uneven surfaces will not be supported and will break, possibly resulting in guide blade seat damage.

Guide Blade Replacement

Remove guide blade and shims. Install new guide blade with no shims. Check blade gap and shim as needed.

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LINKAGE SHEAR MAINTENANCE

Primary and Secondary Blades

Proper maintenance of the primary and secondary blades, or cutting blades, is required for optimal performance. Blade rotation extends blade life and improves cutting performance. Shimming to maintain blade tolerances helps prevent jamming. Dull blades make the excavator hydraulic system work harder and may cause structural damage to the attachment.

Inspect blades every eight hours of operation. Re-torque loose bolts and replace broken bolts. Grind away dents or mushrooming of blade edges at the end of each day to prevent upper jaw

deection, excessive blade wear and undue stress to upper and lower jaws.

Rotate blades to use all four cutting edges. Always use Genesis-approved blades. Blades that do not meet Genesis specications can cause major problems, and using them may void the warranty.

Before performing any blade maintenance, read, fully understand and follow these safety rules.

• Wear personal safety equipment including gloves, safety glasses, safety boots and proper clothing.

• Safe blade maintenance requires two people - one to steady the blade while the other loosens the bolts.

• Blades are heavy and may fall out of the blade seat if not adequately supported. Bystanders must stand clear.

• Never strike a blade with a hardened steel tool. The blade may fragment, creat-

ing sharp ying debris.

Primary and Secondary Blade Removal

Loosen the bolts on one blade at a time, enough to loosen the blades.

If blades remain tight, insert a 7/16” brass drift pin into the throughhole on the lower jaw. Tap the drift pin with a hammer until the blade is loose.

Carefully remove bolts and blades.

Insert drift pin

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LINKAGE SHEAR MAINTENANCE

Adjustment Plates

Do not remove the adjustment plates from the lower jaw during routine blade rotation or replacement. These plates are custom-machined for each attachment and need only be replaced when lost, damaged or extremely worn.

Inspect the top of each adjustment plate and seat for burrs, nicks or other imperfections that may prevent proper seating of the blades and cause errant blade gap readings. Clean the adjustment plates as necessary.

Replacement plates can be ordered from your Genesis dealer or the Genesis Parts Department with the serial number of your attachment.

Offset dowel or fastener holes are located in each adjustment plate. When replacing adjustment plates, make sure these holes are aligned with the corresponding holes in the blade seat.

Do not grind blade seat areas.

Primary and Secondary Blade Rotation

Rotate blades when the cutting edges are worn to a 1/8” (3 mm) radius.

Recommended rotation intervals are approximately 40-80 hours, depending on the material being processed. Thin materials may require shorter rotation intervals. Blades must be replaced when all four edges are worn to 1/8” (3 mm) radius.

Second Rotation Rotate both blades frontto-back and exchange seat positions

Third Rotation Rotate both blades end-for-end

Original Blade Conguration

First Rotation Rotate both blades end-for-end

The following chart may be copied and used to track blade rotation.

40 - 80 Hours Date Hour Meter Performed By Installed Rotation 1 Rotation 2 Rotation 3

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LINKAGE SHEAR MAINTENANCE

Primary and Secondary Blade Gap

After each blade rotation, shim the lower blades to keep the gap within the specications listed in

the table below. Do not shim the upper blades. Use only Genesis shim kits.

Primary and Secondary Blade Gap

Model Minimum Maximum

GLS 50 0.005” 0.015”

GLS 70 0.005” 0.015”

GLS 90 0.010” 0.020”

Blade Gap Measuring Procedure

Slowly close jaws until blades begin to bypass. Stop the jaw and check the gap with a feeler gauge.

Cycle the jaws slowly and continue checking the gap at several points along the entire length of the blades.

Note: The gap will be consistent along the entire length of the blades if they have been rotated and shimmed correctly.

If the blade gap exceeds the maximum listed on the table above, shim the lower blades. Blades must be replaced when shims exceed 0.060”.

Blade Shimming

Loosen blade bolts.

Install shims between the blades and adjustment plates as needed to bring into tolerance.

Torque bolts to spec and recheck the tolerances.

Adjustment

Do not use more than 0.060” of shims.

plates

Install shims

Genesis Power Series Linkage Tools

Blades

Page 33

LINKAGE SHEAR MAINTENANCE

CAUTION

Razor Blade

Check the razor blade for wear every eight hours of operation. Rotate when worn, using the edges in the sequence indicated by the illustration.

After rotation, check the gap between the razor blade and piercing blades. If the gap exceeds the maximum tolerance after new piercing blades have been installed, the razor blade must be replaced. Do not shim the razor blade.

Set screws should be installed in unused bolt holes to prevent thread and hole damage. Replace set screws when lost or damaged.

Jaw Stop

The Linkage Shear features a jaw stop welded in the lower jaw.

The jaw stop is positioned well beyond blade bypass and designed to prevent the excavator bucket linkage from toggling over. Toggling over can jam the linkage and bend the bucket cylinder rod.

To extend the life of the jaw stop and reduce maintenance, avoid extending the bucket cylinder beyond the point where material is cut.

Inspect the jaw stop every eight hours of operation, checking for cracked or damaged welds.

To prevent serious excavator damage, replace the stop immediately if cracked or damaged welds are found.

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REBAR SHEAR MAINTENANCE

Blade and jaw maintenance greatly affects performance. To maximize cutting performance and optimize replacement part life, follow this specic sequence of checks, adjustments and maintenance.

1. Piercing Tips - replace or build up when edges are worn.

2. Upper and Lower Blades - rotate; replace when all edges are worn. Shim lower blades to tolerance.

3. Welding Maintenance - perform jaw build-up and hardsurface as needed.

Blade Bolts

Torque blade bolts every eight hours, to the specications

listed in the torque chart in this manual. Check for broken bolts daily and replace them immediately.

Piercing Tips

Piercing tips are highly susceptible to wear from cutting and digging in rebar piles. Excessive wear will cause material jamming and parent material erosion.

Piercing tips should be replaced when 1/2” radius is worn from the front edge of the tip and 1/4” is worn from the sides. Tips may be

built up and ground ush with blades to extend tip life.

1 2

1/2” Radius1/4” Radius

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