Safety Manual - Genesis Attachments
Contents
1. 36 Guide Blades Guide Blade Shimming 2015 Genesis Attachments LLC Genesis Versi Pro 07 7 SHEAR JAW SET MAINTENANCE _ 37 Guide Blade Rotation Guide Blade Replacement Cutting Edges Blade Removal Blade Bolts SHEAR JAW SET MAINTENANCE 38 Blade Rotation CONCRETE CRACKER JAW SET MAINTENANCE 39 Tooth Replacement Procedure WIRE CUTTER JAW SET MAINTENANGE 40 45 Wire Cutter Jaw Removal Wire Cutter Jaw Installation GRAPPLE JAW SET MAINTENANCE 00000 46 Tip Replacement Procedure WELDING 47 General Welding Guidelines Welding Ground Clamp Welding Rules Before you begin During welding After welding maintenance is complete WELDING 48 Build Up WELDING 49 Hard surfacing WELDING 2 222 50 Hard surfacing Patterns HYDRAULIC ROTATION MAINTENANGE 51 Hydraulic Requirements Electrical Requirements TROUBLE SHOOTING _ 52 Jaw Set Troub2. Remove the blade bolts guide blade and shims Rotate the blade end for end or side to side rein stall and torque bolts Check gap shim if required If guide blade faces are worn excessively the blades cannot be rotated to place the uneven sur faces against the mating surface of the guide blade seats Uneven surfaces will not be supported and will break possibly resulting in damage to the guide blade seat Guide Blade Replacement Remove guide blade and shims Install new guide blade with no shims Check blade gap and shim as needed CUTTING EDGES Proper maintenance of the cutting edges is required for optimal performance Blade rotation extends blade life Dull blades make the carrier hydraulic system work harder and may cause structural damage to the Versi Pro Rotate blades to use all four cutting edges Always use Genesis approved blades Blades that do not meet Genesis specifications 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 Never strike a blade with a hardened steel tool The blade may fragment creating sharp flying objects BLADE REMOVAL Loosen the bolts enough to loosen the blades one blade at a time Carefully remove bolts and blades BLADE BOLTS Visually check for loose or broken bolts daily Re
3. To start v Make sure all controls in the center neutral position v Be properly seated V Slowly operate all functions to check for proper operation and to bleed air from the hydraulic system To shut down Y Return your Genesis attachment to a rest position on the ground Shut off the carrier engine Work controls in all directions to relieve hydraulic pressure 2015 Genesis Attachments LLC Genesis Versi Pro 07 HIGH VOLTAGE LINES MAY ARC 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 HIGH VOLTAGE OVERHEAD LINES 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 with any part of the excavator or skid steer Always contact the electrical power company when operating near power lines The lines should be moved insulated disconnected or de energized and grounded before operating in the area IF LOOSE BOLTS ARE FOUND DO NOT OPERATE THE ATTACHMENT CONTACT THE FACTORY STAND CLEAR WHEN THE ATTACHMENT IS BEING ROTATED ALWAYS STAY IN CLEAR VIEW OF THE OPERATOR WORKING OVERHEAD pm Avoid handling material overhead whenever possible Safety glass and wire mesh cab guarding must be installed to protect the opera
4. and the work area Practice safe working habits and be aware of hazardous conditions KNOW THE RULES Most employers have rules governing proper operation and maintenance of equipment Before starting work at a new location ask your supervisor or safety coordinator about rules you are expected to obey LIGHTING Do not operate without lights if conditions require them f lights are required and your machine is not so equipped contact your carrier dealer for a lighting package LOCKOUT TAGOUT Rotation systems are designed to position the attachment during operation not as a locking or supporting system during maintenance Always use proper blocking procedures during main tenance for operator safety Always practice lockout tagout procedures before performing maintenance USE LOCKOUT qe BEFORE WORKING 258 ON EQUIPMENT PROCESS MATERIAL SAFELY Using your Genesis Versi Pro in unauthorized applications may create an unsafe situation and will void the warranty Do not pull down structures with your Genesis Versi Pro Doing so may cause falling debris or material may break free and exceed the capacities of the carrier causing a tipping hazard The rotator should only be used for positioning your Genesis attachment Do not use the rotator to pry or break loose material HYDRAULIC SETTINGS The hydraulic system has been preset and tested by your dealer Do not alter hydraulic settings without consulting an authori
5. 33 Jaw Set Trouble Shooting 02 Lighting 18 Lockout Tag out 18 Long Term Maintenance 23 Maintenance Checks Daily 34 Maintenance Safety 21 Maintenance Schedule 23 Manual Replacement 3 Markings 2f Material Processing Areas 30 Mounting Bolts 25 Operation 30 Operational Concerns 31 Order Placement 55 Organize Work Area 30 Parts Order Form 50 Parts Order Policy 55 Parts Order Procedure 55 Piercing Tip Maintenance 34 Piercing Tip Replacement 34 Pivot Group Adjustment 39 Placing Orders 55 Possible Variations 3 Power Lines 20 Preheating Before Welding 46 Prioritized Oil Flow 20 Productive Operation 30 60 2015 Genesis Attachments LLC Genesis Versi Pro 07 Proper Bolts Public Notice Registration Form Restart After Maintenance Returns Returns Goods Authorization RGA Rotator Trouble Shooting oafety Statements Sanding Grinding Schedule Maintenance Settings Hydraulic Shear Jaw Stalls Shimming Guide Blades Shipping Standard Eight Pin Connection Start Up Starting Procedure Start Up Procedure Start Up Hydraulic Thermal Expansion Tip Replacement Procedure Tooth Replacement Torque Specs Trouble Shooting Jaw Set Trouble Shooting Rotator Warranty Warranty Claim Procedure Wear Plate Replacement Wedged Material Weld Build Up Welding Ground Clamp Welding Guidelines Welding Maintenance Welding Rules Wire Cutter Jaw Set Maintenance Wire Cutter Jaw Installation Wire Cutter Jaw Removal Worki
6. all operational and safety related instructions in this manual Do not operate the attachment until you have read and fully understand these instructions Always use good safety practices to protect yourself and those around you REGISTRATION FORM The Warranty Registration Form must be filled out by the dealer or customer and returned to Genesis indicating the date the machine went into service IMPORTANT This operator s manual must remain with the attachment at all times MANUAL REPLACEMENT Should this manual become damaged or lost immediately contact any authorized Genesis dealer or the Genesis Service Department at 888 743 2748 or 715 395 5252 for a replacement POSSIBLE VARIATIONS Genesis has made every effort to provide information as complete and accurate as possible for its attachments However because of owner requirements equipment and control variations may exist In addition due to Genesis policy of continually striving to improve its products occasional discrepancies may exist between individual attachments and the descriptions and information contained herein PUBLIC NOTICE Genesis reserves the right to make changes and improvements to its products 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 S
7. calibrated on an annual basis v When using a torque multiplier with a torque wrench incorrect settings will be multiplied by the ratio of the torque wrench v Never use an air wrench a torque multiplier Dry Torque Values Wet Torque Values 822 606 7 1008 1220 90 KN 9 es 27 _ Masa 72 55 C 12 175 125 92 wax ts 210 396 M14200 200 148 CL 109 I 5 14 8 365 27 53 92 148 0 2 M20 x 2 50 0 8 1 2 3 5 7 1 T 9 o 4280 24 2015 Genesis Attachments LLC Fastener Grade SizexPitch Wm Fei 358 383 a M20x2 50 458 338 CL 10 9 M27x3 00 1157 5 5 Apply grease or anti seize on threads and under bolt heads Visual Reference Genesis Versi Pro 07 MOUNTING BOLTS Visually check slewing ring rotation bearing bolts every eight hours of operation and replace every 2000 hours Do not reuse or re torque these bolts Immediately replace a loose or broken bolt and replace the bolts on either side of it Apply Loctite to the bolt threads and under the bolt head per Loctite instructions DO NOT SUBSTITUTE BOLT TORQUE k Aue Grade8 Class 10 9 The bolts that secure the slewing ring are critical to safe operation of the attach ment Improper bolt torques may cause the bolts to fail and allow the attachment to break free This may result in serious personal injury and damage to equip ment Improper
8. cylinder with the first cycles Use partial strokes extending and retracting slowly working to full strokes Stop and check the base machine hydraulic fluid level again to be sure there is still sufficient fluid Fill the reservoir as needed Note Hydraulic fluid level should be checked with the shear jaw open cylinder retracted v Cycle the jaws five or six strokes before increasing to full operating pressure 2015 Genesis Attachments LLC Genesis Versi 07 29 GENERAL OPERATION INSTRUCTIONS Follow all rules and procedures outlined in the Operation Safety section under General Safety in this manual Use the attachment only as intended in approved applications as set forth in this manual Do not allow attachment exposed cylinder rod or hoses to come into contact with any obstacles buildings or the excavator The attachment is not intended to crush or break objects or structures by swinging or dropping the attachment START UP INITIAL OPERATION amp RESTART AFTER MAINTENANCE During initial operation and any time jaw maintenance has been performed process thin and lighter material first to work harden wear areas developing a harder more durable edge This is also the most effective time to process materials such as sheet metal or wire The new or repaired edges will cut more efficiently and be less likely to get material jammed between the blades When operating in temperatures below freezing it is also
9. important to process light materials first This allows the jaw set s structural material to warm up preventing thermal cracking EFFICIENT AND PRODUCTIVE OPERATION Operators should become accustomed to performing work in the most proficient manner possible PROBLEMS WITH DIRT When cutting build up and cut out of small piles keeping the surfaces of the chin plate and upper jaw out of the dirt as much as possible Dirt is much more abrasive than steel and needlessly increases build up and hard surfacing time and intervals ORGANIZE WORK AREA It also helps to give yourself enough room to keep out of the way of other personnel and machines Material should be picked from a pile swung to the side and cut in a new area This prevents redundant cutting of the same pieces and allows for the newly prepared material to be loaded out with another material handling machine MATERIAL PROCESSING AREAS Material processing areas should be as close as safely possible to the location for loading materials for transportation Less time spent processing loading and transporting materials greatly affects operational costs and productivity and dramatically reduces man hours fuel costs and equipment wear ASSESSING MATERIALS Operators should develop the habit of assessing materials to be processed and visualizing a starting and finishing point to use the fewest cuts possible Excessive moving positioning and handling cost time and money Bringing t
10. of the stick toward the ground Set the tool firmly onto flat level ground Fully close the attachment jaw Remove the pin head retaining bolts from both the front cylinder pin and the jaw connection pin Fig 1 Remove the front cylinder pin Slowly retract the cylinder rod jaw open function If the upper jaw moves stop and pry the cylinder Fig 1 clevis away from the upper jaw Jaw Connection Pin CLOSE JAWS BEFORE ROTATING Close the jaws before rotating the Versi Pro back to the vertical position Failure to do so will allow the jaw to slam shut which may cause serious injury or damage to the machine Remove the jaw connection pin This can also be done by raising the attachment and carefully rotating the stick so the jaw connection pin head is facing downward then tapping the pin out With the pins removed and the attachment stick returned to a posi tion with the lower side of the stick facing the ground raise the stick up and tilt the jaw toward the ground until the lower jaw attachment pins clear the stick body attachment hooks the stick will be tilted about 30 or more when the jaws disconnect from the stick Fig 2 Lower Jaw JAW INSTALLATION Attachment Pins The jaw set to be installed should be placed on firm level ground with the cylinder connection facing upward Tilt the shear stick into a 30 position to connect the stick body Attaching attachment hooks onto the lower jaw attachment pins Once they
11. set in wire cutter position Wire Cutter Shear Breaker Fig 12 2015 Genesis Attachments LLC Genesis Versi Pro 07 45 Check grapple tine tips for wear and replace as needed following the procedure below Do not allow tips to wear down to the parent material Build up and hardsurfacing of grapple jaws is optional to prevent excessive wear Depending on the application it may or may not be necessary Use your discretion to determine whether it is war ranted by the severity of the application TIP REPLACEMENT PROCEDURE Follow all welding safety precautions found in this manual Preheat the area to 350 F 177 C six to eight inches around the tip Maintain this temperature throughout the procedure Do not exceed 400 F interpass temperature Air arc to remove the tip Clean the pocket and chamfer the perimeter at 5 8 x 45 angles Position and tack the new tip in place Weld with AWS E7018 electrode Begin with the sides filling in the chamfered area with single passes alternating sides and peening each pass Weld the back and front following the same method When welding is complete grind the welds flush on each side Cover with heat blanket or insulation and allow to cool slowly DO NOT put unit into operation until cool approximately eight hours 46 2015 Genesis Attachments LLC Genesis Versi Pro 07 GENERAL WELDING GUIDELINES Build up and hard surfacing are welding procedures
12. that protect the parent material of the jaws and keep the blades in good adjustment Build up is the welding procedure that restores the jaws to their original shape Building up the jaws helps protect the blades and increases the life of the attachment Hard surfacing is the welding material added over the parent material or build up material to create a wear resistant surface Welding should not be performed until the jaws are work hardened Work hardening can take up to 80 hours However jaws must not wear lower than the height of a new blade If either jaw wears down lower than blade height immediately stop operating the shear and perform build up and hard surfacing as described in the following pages of this manual WELDING GROUND CLAMP Disconnect all battery ground cables or shut off master battery switch if equipped Failure to do so may cause carrier electrical problems including permanent damage to onboard computer systems Connect ground clamp as close as possible to the area being welded without allowing current to pass through the pivot group cylinder pin cylinder swivel motor gearbox or slewing ring If you are welding on the lower jaw connect weld 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 v Remove adja
13. torque loose bolts to the specifications listed in the torque chart in this manual Replace broken bolts immediately 2015 Genesis Attachments LLC Genesis Versi Pro 07 37 BLADE ROTATION Inspect blades every eight hours of operation Re torque Original Blade Configuration loose bolts and replace broken bolts Rotate blades when the cutting edges are worn to a 1 8 3 mm radius Recommended rotation intervals are approximately 20 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 an 1 8 3 mm radius First Rotation Rotate both blades end for end The following chart may be copied and used to track blade rotation Second Rotation Rotate both blades front to back and exchange seat positions BLADE GAP ADJUSTMENT amp SHIMMING After each blade rotation shim the lower blades to keep the gap within 005 to 010 Do not shim the upper blades Use Third Rotation only Genesis shim kits Rotate both blades end for end 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 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 v Loosen blade bolts Y Install shi
14. Do Not Use Your Hands See Illustration zA D V CARDBOARD HYDRAULIC HOSE OR FITTING MAGNIFYING GLASS 12 2015 Genesis Attachments LLC Genesis Versi Pro 07 SAFELY MAINTAIN AND REPAIR EQUIPMENT Do not wear loose clothing or any accessories that can catch in moving parts If you have long hair cover or secure it so it does not become entangled in the equipment Work on a level surface in a well lit area v Use properly grounded electrical outlets and tools v Use the correct tool for the job Make sure it is in good condition for the task required v Wear protective equipment specified by the tool manufacturer MAINTAINING THE ATTACHMENT THINK Before performing maintenance lower the attachment to the ground turn off the engine remove the key and SAFETY apply the brakes Perform appropriate Lockout Tagout FIRST procedures Y Never perform any work on the attachment unless you are authorized and qualified to do so Always read the operator s service manuals before making any repair After completing maintenance or repair check for correct functioning of the attachment If not functioning properly always tag DO NOT OPERATE until all problems are corrected v Never make hydraulic repairs while the system is under pressure Serious personal injury or death could result 2015 Genesis Attachments LLC Genesis Versi Pro 07 13 SAFELY OPERATE EQUIPMENT Do not operate e
15. GENESIS Versi Pro 07 GVP 07 SAFETY amp OPERATOR S MANUAL Division of map Genesis Attachments 1000 Genesis Drive Superior WI 54880 PH 715 395 5252 FX 715 395 5255 genesisattachments com nza INTERNATIONAL EQUIPMENT SOLUTIONS World Headquarters Genesis Attachments Europe Africa Middle East 1000 Genesis Drive Genesis GmbH Superior WI 54880 USA Alpenstrasse 71 D 87700 Memmingen Germany Toll Free 888 SHEAR IT 888 743 2748 Phone 49 83 31 9 25 98 0 Phone 715 395 5252 Fax 49 83 31 9 25 98 80 Fax 715 395 5255 Metis uen E mail info genesis europe com E mail info genesisattachments com Asia Pacific Representative Office 24 Upper Serangoon View 12 28 Singapore 534205 Phone 65 9673 9730 E mail tchoo genesisattachments com Central amp South America The Caribbean Cra 13A 89 38 Ofi 613 Bogota Colombia Phone 57 1 610 8160 795 8747 E mail contact themsagroup com Brazil Rua Jos Alves dos Santos 281 Sala 413 Sao Jos dos Campos SP Brazil Phone 55 12 3905 3405 E mail metalamericas metalamericas com View and download all manuals at genesisattachments com manuals asp 2 2015 Genesis Attachments LLC Genesis Versi Pro 07 To ensure years of safe dependable service only trained and authorized persons should operate and service your Genesis attachment lt is the responsibility of the operator to read fully under stand and follow
16. Hooks are connected tilt the shear stick back into a horizontal position making sure the attaching pins are firmly inside the attaching hooks Fig 2 Install the jaw connection pin and its retaining bolt If the jaw had been rotated to install the pin from the top rotate it back so the lower side of the stick is again facing the ground Fig 1 Extend the cylinder rod jaw close function until the cylinder con nection aligns itself to the jaw connection Install the front cylinder pin and its retaining bolt Slowly open and close the jaw checking for any interference Fig 2 32 2015 Genesis Attachments LLC Genesis Versi Pro 07 PIVOT GROUP ADJUSTMENT GVP 07 REVA Maintain proper pivot group adjustment to optimize cutting performance and maximize the life of the jaw set Use the following procedure along with the accompanying drawing for initial set up and to make adjustments as the bearings wear 1 Loosely assemble pivot group without end caps Set blade gap by pushing upper jaw blades against lower jaw blades with a 010 shim between them Ensure sleeve 1 is pressed tightly against upper jaw flange bearing 1 Measure the dimension D1 and install shims to eliminate this gap Fasten end cap 1 to the shaft on this side Measure the dimension D2 and install appropriate shims Ensure end cap 1 is pressed tightly against the lower jaw and measure dimension D3 Subtract D3 from 255 to determine t
17. ST v Operator judgement CHECK THE EQUIPMENT Before beginning each shift take the time to check the equipment and have all systems in good operating condition Check the following v Warning decals special instructions and owner s manual sure they are legible and in the proper location v Grease fittings Pump grease at all fitting locations See Page 26 v Hydraulic fluid level Add hydraulic fluid as required v Hydraulic hoses and hose connections for wear or leaks Repair replace any damaged hoses or connections V All control levers for proper operation v Rotation bearing Visually check for loose or damaged bolts If repair is required refer to qualified personnel GOOD v Grease rotation bearing and pinion gear CONDITION v Check for loose or missing pin retaining bolts POSITION THE ATTACHMENT Position the carrier on firm level ground Do not operate on slippery ground conditions 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 2015 Genesis Attachments LLC Genesis Versi Pro 07 17 OPERATION SAFETY oafe operation is the responsibility of the operator Improper use of the machine can lead to dangerous situations for yourself those around you the machine
18. aps of fatty glycerides as a base used for low temperature service Loctite A brand of among others bonding adhesives thread lockers and thread sealants Lockout Lock the only means to re energize equipment prior to servicing or maintenance Material Handler Vehicle on which the Versi Pro is mounted OEM Original Equipment Manufacturer O 2015 Genesis Attachments LLC Genesis Versi Pro 07 57 OSHA Occupational Safety and Health Administration OSHA An agency of the United States Department of Labor Its mission is to prevent work related injuries illnesses and occupational fatalities by issuing and enforcing standards for workplace safety and health Prime Mover Vehicle on which the Versi Pro is mounted RGA Return Goods Authorization ROPS Roll Over Protection Structure SAE Flat Face O Ring Adaptor Fitting For optimal leakage control in medium and high pressure hydraulic systems The male fitting has a straight thread and O ring The female port has a straight thread a machined surface minimum spot face and a chamfer to accept the O ring The seal takes place by compressing the O ring in the chamfer The threads hold the connection mechanically Slewing Ring or Slewing Bearing or Rotation Bearing A rotational rolling element bearing that typically supports a heavy but slow turning load Tagout Remove the lock so the equipment can be re energized Torque Multiplier Enables small amounts of input torqu
19. aulic lines to supply hydraulic fluid to the shear jaw and rotation circuits Hydraulic connections Note This option will require that the machine is equipped with two 2 bi directional flow hydraulic circuits equipped with port reliefs and anti cavitation valves Control system inside cab No electrical connection 28 2015 Genesis Attachments LLC Genesis Versi Pro 07 HYDRAULIC START UP The Genesis Versi Pro 07 Processor is designed to operate up to 3650 PSI Due to these high pressures it is important that air is bled from the attachment cylinder after installation Failure to follow these procedures could result in cylinder seal damage and or base machine hydraulic system damage START UP PROCEDURE v Check the base machine hydraulic reservoir for proper fluid level Prior to hooking up the attachment the base machine hydraulic oil should be warmed up per the OEM procedures for starting and warm up in cold weather v Do not operate the attachment circuit during the warm up period v After the base machine has reached normal operating temperature set the engine to idle speed v Attachment must be vertical to bleed air from the cylinder v Slowly fill the bore end of the attachment cylinder to partially close the jaws Do not allow the tank to run low have someone watch the oil level gauge Slowly fill the rod end of the attachment cylinder to open the jaws Note Do not fully extend or retract attachment
20. cent blades as preheating and welding may cause blade damage v Wearing an approved respirator grind the area to clean it removing all existing hard surfacing v Preheat area to 350 F 177 C Maintain this temperature throughout the procedure Do not exceed 450 F interpass temperature During welding v Always grind and weld with the grain of the material v Peen each weld pass to relieve stress and harden the welds Do not undercut the ends of the welds Do not start or stop welds directly above a bolt hole or in the apex of the jaw After welding maintenance is complete v Cover the area with a heat blanket and allow it to cool slowly approximately eight hours Y Do not put the jaw set into operation until the welds have been allowed to cool 2015 Genesis Attachments LLC Genesis Versi Pro 07 47 BUILD UP Procedure Follow the General Welding Guidelines and Rules v Determine the area to build up using a straight edge or square Jaws must not wear lower than the height of a new blade Use a new blade to help determine build up height for the jaw v Build up the jaw to slightly higher than the original parent material profile with E7018 Apply single passes in each line with the grain of the steel peening after each pass v Protection strips or raised areas under or around blade seats must be built up and maintained during build up procedure using E7018 or equivalent v These areas should be maintained b
21. de optional 2015 Genesis Attachments LLC Genesis Versi Pro 07 51 JAW SET TROUBLE SHOOTING oymptom Possible Cause Possible Solution Circuit not getting full pressure from Check hydraulic pressure at port block excavator Check for bypass and replace seals if Lacks power Shear cylinder or swivel bypass needed GenFlow valve has faulty cartridge or Contact Genesis Service Department seal bypass Check valve seals replace as needed Material size is beyond shear appetite range Consult the factory Worn blades Refer to Jaw and Blade Maintenance in this manual Poor cutting Excess blade gap o Refer to Jaw and Blade Maintenance in Poor piercing Piercing tip or chin is worn incen mi Excess blade gap Material jamming Wor blades Refer to Jaw pus in Worn piercing tip chin or guide block Slow jaw cycle in Excess back pressure on return side of Check excavator main control valve or open direction cylinder hydraulic line size Excavator control valve Check excavator main control valve Jaw drifts closed or can Check for bypass and replace seals if Processor cylinder or swivel bypass be pushed closed needed GenFlow valve seal bypass Replace seal as necessary 52 02015 Genesis Attachments LLC Genesis Versi Pro 07 ROTATOR TROUBLE SHOOTING Symptom Possible Cause Possible Solution Blown fuse Electrical problem Does not rotate Incorrect pressure settings Faulty components No electr
22. e pulling to produce large amounts of output torque turning efficiently and safely Wet Torque Any bolt that is lubricated or coated with an anti seize compound 58 2015 Genesis Attachments LLC Genesis Versi Pro 07 Assessing Materials 30 Attachment Installation 20 Attachment Markings 27 Authorized Parts 21 Blade Bolts 37 Blade Removal 37 Blade Rotation 38 Bolt Torque Specs 24 Chatter While Cutting 31 Check List Eight Hour 23 Connection Eight Pin 28 Cracker Jaw Maintenance 39 Cutting Edges 37 Daily Maintenance Checks 34 Dirt Problems with 30 Efficient Operation 30 Eight Hour Check List 23 Eight Pin Connection 28 Electric Installation 28 Electrical Requirements 51 Fastener Identification 19 General Operation Instructions 30 General Safety 11 General Welding Guidelines 4T Glossary of Grapple Jaw Maintenance 46 Grease Locations 26 Grease Temperatures 25 Ground Clamp Welding 47 Guide Blade Replacement 37 Guide Blade Rotation 3 Guide Blade Shimming 36 Guide Blades 36 Guidelines General Welding 47 Hard surfacing 49 Hard surfacing Patterns 50 Hydraulic Rotation Maintenance 25 Hydraulic Rotation Maintenance 51 2015 Genesis Attachments LLC Genesis VersiPro07 59 Hydraulic Installation 28 Hydraulic Requirements 51 Hydraulic Settings 18 Hydraulic Start Up 29 Initial Operation 30 Installation Attachment 20 Invoices 29 Jamming Conditions 31 Jaw Installation 32 Jaw Removal 32 Jaw Set Maintenance
23. ectrode Begin with the area between the wear plate and piercing tip Fill in the area with single passes peening each pass Weld the back and front following the same method When welding is complete grind the welds flush with the wear plate and piercing tip Cycle the jaw slowly to check for interference Cover with heat blanket and allow to cool slowly DO NOT put unit into operation until cool 2015 Genesis Attachments LLC Genesis Versi Pro 07 35 GUIDE BLADES After performing piercing tip maintenance check guide blade tolerances When necessary shim the guide blade to keep the gap within 0 005 0 010 Rotate the guide blades when worn to a 1 8 3 mm radius Replace the guide blade when more than 075 2 mm of shims are required to keep the blade gap within the tolerances Gap 005 010 Guide Blade Shimming Slowly close the jaw so the upper piercing tip begins to bypass the guide blades Stop the jaw and check the gap between the guide blades and piercing tip Cycle the jaws slowly stopping at several points along the piercing tip to check the gap each time Shim the guide blades as needed to keep the gap within a 0 005 0 010 tolerance To install shims loosen blade bolts and slide shims between the guide blade and guide blade seat Re torque bolts and recheck the gap cude Bade Guide Blade 36 2015 Genesis Attachments LLC Genesis Versi Pro 07 GUIDE BLADE ROTATION
24. ents LLC Genesis Versi Pro 07 24 Bolt Torque Specifications HYDRAULIC ROTATION MAINTENANCE 25 Mounting Bolts Bolt Torque Grease Slewing Ring Rotate After Greasing Yoke Greasing Grease Temperatures MAINTENANCE 26 ATTACHMENT 5 27 INSTALLATION _ 28 Attachment Installation Electric Installation Versi Pro Standard Eight Pin Connection Hydraulic Installation INSTALLATION RR 29 Hydraulic Start Up Start Up Procedure OPERATION 30 General Operation Instructions Start Up Efficient and Productive Operation OPERATION 1 RR eene 31 Common Operational Concerns 32 Jaw Set Change Over Jaw Removal Jaw Installation JAW SET MAINTENANCE 33 Pivot Group Adjustment GVP07 Rev A SHEAR JAW SET MAINTENANCE _ 34 Piercing Tip Piercing Tip Replacement SHEAR JAW SET 35 Wear Plate Replacement SHEAR JAW SET MAINTENANCE _
25. er bead with one pass of GenWire or GenRod to hard surface Do not apply more than two layers of hard surfacing Peen each pass v Grind the ends of all stringer welds with the grain to taper 1 to 1 1 2 31 38 mm to the parent material 1 4 from edge See the following page for hard surfacing illustrations and instructions specific to each area of the tines 2015 Genesis Attachments LLC Genesis Versi 07 49 HARD SURFACING PATTERNS Where parallel lines are shown apply single passes approximately 3 4 apart Where crosshatch is shown apply stringer beads at 45 angles to form 3 4 squares Hard surfacing patterns are indicated by red lines in the drawings Do not crosshatch the curved areas of the jaws near the pivot Use only straight stringers on these areas Follow hard surfacing instructions on Page 43 Staggered stringers GVP 07 Cracker Jaw Set 50 2015 Genesis Attachments LLC Genesis Versi Pro 07 HYDRAULIC REQUIREMENTS GVP 07 15 25 GPM 57 95 LPM 2500 3650 PSI 172 252 BAR Rotate Circuit GVP 07 poemas CHR OPERATING ABOVE RECOMMENDED FLOW AND OR PRESSURE MAY CAUSE DAMAGE AND OR CREATE A DANGEROUS SITUATION 44 DANGER ELECTRICAL REQUIREMENTS v 12 VDC keyed power 10 amps v quick disconnect on boom for joystick button signals v 2 rocker type switches in joystick handles for close rotate v 1 momentary toggle switch for regen overri
26. ervice Department Any alterations modifications or repairs performed before authoriza tion by the Genesis Service Department will render all warranty reimbursement consideration null and void without exception See page 48 for Warranty Claim Procedures A lack of or improperly performed maintenance and procedures as set forth in this manual as well as operator abuse may render warranty consideration null and void 2015 Genesis Attachments LLC Genesis Versi Pro 07 3 4 2015 Genesis Attachments LLC Genesis Versi Pro 07 SAFETY 10 GENERAL 11 Read Manual Before Installation Read and Understand All Safety Statements Know Your Equipment Lower or Support Raised Equipment Do Not Modify Machine or Attachment Protect Against Flying Debris GENERAL SAFETY dod vba eoe Den ERA 12 Use Care with Hydraulic Fluid Pressure GENERAL 13 oafely Maintain and Repair Equipment Maintaining the Attachment GENERAL SAFETY Safely 14 GENERAL SAFETY Safely Operate 15 Know Where Utilities Are Operator Qua
27. etween blade height and 010 lower than blade height These areas protect the bottom unused edges of the blades as well as reduce the chance for material to catch on the bottom of the blade during jaw open functions which cause blades to move in their seats v Denting deformation or build up higher than blades in these areas may cause upper jaw deflection excessive blade gaps wear to blade faces and undue stress to upper and lower jaws v After build up is complete grind material to be flush with a new blade Note Closely monitor areas above guide blade bolt countersinks and below front two upper blade bolt countersinks These are high wear areas If allowed to wear too far parent material starts to fold into the countersinks and it becomes time consuming to clean out this area when access is needed for blade rotation and replacement 48 2015 Genesis Attachments LLC Genesis Versi Pro 07 HARD SURFACING Do not apply hard surfacing directly to the parent material as this could cause toe cracking and the hard surfacing will G enRod Procedure GenWire Follow these general welding guidelines and rules v Apply a single pass stringer bead 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 v Stagger the ends of the stringer welds so they do not end in a straight line v Cap each string
28. g 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 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 Service Department will provide the necessary forms Your account will be credited when the warranty claim is accepted Please direct any questions to the Genesis Service Department 715 395 5252 54 2015 Genesis Attachments LLC Genesis Versi Pro 07 ORDER PLACEMENT PARTS ORDERS SHOULD INCLUDE THE FOLLOWING LJ Purchase order number Model and serial number of attachment LJ Part number and quantity needed Shipping and billing address Method of shipment or required delivery date PLACING ORDERS Orders may be placed by phone e mail or fax To fax an order use the form on the following page Contact information is located at the front of this manual PART NUMBERS Part numbers are listed in the Parts Manual Contact the Genesis Parts Department with questions regarding part numbers availability and pricing PARTS POLICY SHIPPING All orders will be shipped best way surface unless an alternate shipping method is
29. garded as part of the attach ment For proper installation operation or maintenance opera tors and maintenance personnel should read this manual along with the manuals of the material handler or serious injury or death could result READ AND UNDERSTAND ALL SAFETY STATEMENTS Read all safety statements in this manual prior to operating or working on this attachment Know and obey all OSHA regulations local laws and other pro fessional guidelines for your operation Know and follow good work practices when assembling maintaining repairing mounting removing or operating this attachment KNOW YOUR EQUIPMENT Know your attachments capabilities dimensions and operations before operating Visually inspect your attachment before you start and never operate an attachment that is not in proper working order with all safety devices in place Remove and replace any damaged or excessively worn parts LOWER OR SUPPORT RAISED EQUIPMENT Do not work under raised booms without supporting them Do not use support material made of concrete blocks logs buckets barrels or any other material that could suddenly collapse or shift positions Make sure support material is solid not decayed warped twisted or tapered Lower boom and attachment to the ground before leaving the cab or operator s station DO NOT MODIFY MACHINE OR ATTACHMENT Modifications may weaken an attachment s integrity and impair its function life and performance When making
30. he jaws to full open when only partial jaw open is needed for a cut wastes time and fuel slows other excavator functions as well as causes needless wear to hydraulic components hoses and O rings More efficient processing will extend the attachment life 30 02015 Genesis Attachments LLC Genesis Versi Pro 07 COMMON OPERATIONAL CONCERNS SHEAR JAW STALLS When cutting larger materials and the shear jaw stalls just before cutting suspend the material on the prepared pile open the jaw and position the material as close to the throat as possible Without pushing down on the material with excavator or skid steer force rapidly close the jaw on the material Using the speed of regeneration can improve performance when cutting larger materials CHATTER WHILE CUTTING PIERCING TIPS amp GUIDE BLADES If the attachment starts to chatter while cutting back out of the cut and reposition at a different spot Chattering is an indication that material is jamming between the piercing tips and guide blades or between upper and lower cutting blades This indicates that blade maintenance needs to be performed immediately Worn blades and improper blade gaps are usually the cause CHATTER WHILE CUTTING THERMAL EXPANSION Insufficient piercing tip gaps will also cause this as the blades and parent material of the jaws are subject to thermal expansion from cutting friction The tighter the blades run the hotter they get and the more they expand Pierc
31. he shim thickness required under the end cap Use a 3 8 dowel pin or a light film of grease to hold shims in place Tighten end cap 2 Verify a 005 clearance in the pivot group with a feeler gage between the sleeve and the flange bearing on either side of the upper jaw Grease pivot group as described in this manual End cap 2 Sleeve 2 D2 9 Flange Bn bearing 2 Tee TT xh Flange AN NI bearing 1 di HAH AAR Sleeve 1 Set blade gap at 010 Lower jaw End cap 1 2015 Genesis Attachments LLC Genesis Versi Pro 07 33 DAILY MAINTENANCE CHECKS Perform the following daily maintenance checks to keep Wear Plate the equipment in good operating condition vV Ensure proper pivot group adjustment Y Check blades guide block and piercing tip for ex cess wear Rotate or replace as needed Y Inspect jaw for wear including the chin where the Piercing piercing tip meets the lower jaw Perform build up Tip and hardsurfacing as needed PIERCING TIP Proper maintenance of the piercing tip boosts productivity and prevents material jams Inspect the piercing tip daily for wear and perform maintenance every 20 40 hours depending on the application Slowly cycle the shear until the piercing tip is flush with the top edge of the chin Check the gap with a tape measure Acceptable gap is 1 4 3 8 6 9 5 mm Check the condition of the piercing tip with a straigh
32. ical power to one side Does not rotate in one direction Faulty directional control valve Faulty cartridge Electrical short Rotator chatters Power to both rotation solenoids at the same time Rotates too fast or too slow Flow control out of adjustment Replace fuse Test for proper voltage at plugs on directional valve while depressing foot switch Set pressures Contact Genesis to replace valve Test for 12V at plugs on directional valve while operating controller Check if directional control valve shifts both ways while actuating foot switch in both directions Contact Genesis to replace valve Check on VOM meter Test for 12V at plugs on directional valve while operating controller Set flow control 2015 Genesis Attachments LLC Genesis Versi Pro 07 53 Notify the Genesis Service Department of the potential warranty claim prior to making the repair Digital pictures are very helpful for diagnosing problems and recommending repairs Contact the Genesis Service Department before making alterations changes or repairs to any component that is going to be considered for warranty Not doing so will void all Genesis warranty consideration The Genesis Service Department will issue an authorization number to track the repair costs out going parts and or defective parts returning to the factory Replacement parts must be ordered using a purchase order number Shipping is standard ground Overnight shippin
33. 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 EMERGENCY SITUATIONS Always know where to get assistance in case of an emergency Know where to locate and how to use safety equipment such as a first aid kit and fire extinguisher 391 all injuries to your supervisor or as directed 2015 Genesis Attachments LLC Genesis Versi Pro 07 15 PERSONAL SAFETY Use all protective clothing and safety devices dictated by the working conditions These may include but are not limited to v Hard hat v Safety glasses goggles or face shield v Hearing protection v Safety shoes v Heavy gloves Y Reflective clothing Safety matters v Respirator or filter mask BEFORE OPERATING Warn all others in the area that you are about to start operation Perform the Check the Equipment Page 17 steps outlined in this manual Check underneath and around the machine Make sure all personnel and equip ment are clear from the area of operation and equipment movement Check clearances in all directions including overhead Be properly seated in the operator s seat Do not attempt to operate the controls until you have read and fully understand the safety sta
34. ing tips and guide blades are the most susceptible to this and will show blue streaking on their corresponding faces In some cases they will get so hot that surface cracks and spidering occur As this happens it will spread the lower jaw and increase gaps between the primary and secondary blades causing thin material to jam between them CHATTER WHILE CUTTING WEDGED MATERIAL Another key area to watch is the opening between the guide blades Be aware of material that may get into this opening before the piercing tip moves into this space as it will be wedged between the piercing tip and guide blades JAMMING CONDITIONS Most jamming conditions can be prevented if the operator pays attention to the sound and vibration that is associated with a jam Remember that because of the rod to bore ratios of displacement on the attachments hydraulic cylinder piston the shear has half the force on jaw open compared to jaw close Therefore it will not have enough cylinder force to open if material gets jammed into the cutting blade area Please contact the Genesis Service Department for advice on removing jammed material 2015 Genesis Attachments LLC Genesis Versi Pro 07 31 JAW SET CHANGE OVER Pin Head Front Cylinder JAW REMOVAL Retaining Bolts It is safer easier and quicker to change the jaw sets with two people one person to remove the attaching pins and the other to operate the machine Position the Versi Pro with the lower side
35. le Shooting TROUBLE SHOOTING 53 Rotator Trouble Shooting WARRANTY CLAIM 54 PARTS ORDER POLICY AND PROCEDURE 55 PARTS ORDER 56 CESI TIPA FT ROUEN MIRI ed ERU 57 58 E E E A AEE 59 61 8 2015 Genesis Attachments LLC Genesis Versi Pro 07 2015 Genesis Attachments LLC Genesis Versi Pro 07 9 Death Will Result This statement is used where serious injury or death will D AN G result if the instructions are not followed properly Death Could Result This statement is used where serious injury or death could result if the instructions are not followed properly Damage Could Result This statement is used where minor injury or property damage could result if the instructions are not followed properly Call Attention To This symbol by itself or used with a safety signal word throughout this manual is used to call attention to instruc tions involving your personal safety or the safety of others Failure to follow these instructions can result in injury or death 10 2015 Genesis Attachments LLC Genesis Versi Pro 07 READ MANUAL BEFORE INSTALLATION Read this manual before attempting to operate the attachment 7 tu This operator s manual should be re
36. lifications Unsafe Conditions Emergency Situations GENERAL SAFETY Personal 16 Before Operating Know the Work Area GENERAL SAFETY Machine 17 Check the Equipment Position the Attachment GENERAL SAFETY Operation 18 Know the Rules Lighting Lockout Tagout Process Material Safely Hydraulic Settings 2015 Genesis Attachments LLC Genesis Versi Pro07 5 GENERAL 19 Fire Hazards otability Place the Load Safely Fastener Identification Starting Procedure To Start To Shut Down GENERAL SAFETY 17 20 High Voltage Lines May Arc Power Lines Working Overhead Prioritized Oil Flow MAINTENANCE SAFETY 21 Trained and Authorized Repairs Authorized Parts Schedules Torque Specs Welding Maintenance Equipment Conditions MAINTENANCE 22 Pressurized System Medical Assistance Burns Ventilate the Area Sanding Grinding Prevent Fires Proper Bolts MAINTENANCE SAFETY 1 RR 23 Performing Maintenance Unsafe Condition Equipment Condition Maintenance Schedule Eight Hour Checklist Inspect Grease Long Term Maintenance 6 02015 Genesis Attachm
37. ms between the blades and blade seat as needed to bring into tolerance v Torque bolts to spec and recheck the tolerances 38 2015 Genesis Attachments LLC Genesis Versi Pro 07 Replace teeth when points are worn down and can no longer process concrete efficiently Weld new teeth in place using the following procedure If desired points may also be rebuilt and hard surfaced Q when 1 2 has worn away as shown in the illustration However rebuilt points on the teeth will wear down faster than the original teeth REPLACEMENT PROCEDURE 7 Follow all welding safety precautions found in this manual 1 2 Preheat the jaws surrounding the teeth to 350 F 177 C being cautious to stay away from the pivot group Maintain this temperature throughout the procedure Do not exceed 400 F interpass temperature Air arc to remove worn teeth using a template available from the Genesis Parts Department Grind jaw surfaces smooth to accept new teeth Position and tack the new teeth in place as shown Weld with AWS E7018 electrode or equivalent Begin with the sides filling in the chamfered area with single passes alternating sides and peening each pass Weld the back and front of each piece following the same method When welding is complete grind the welds flush on the sides of the upper jaw Failure to grind these surfaces flat may prevent the teeth from bypassing the lower teeth Cycle the jaw slowly
38. ng Overhead 2015 Genesis Attachments LLC Genesis Versi Pro 07 61 lt GENESIS World Headquarters Genesis Attachments Europe Africa Middle East 1000 Genesis Drive Genesis GmbH Superior WI 54880 USA Alpenstrasse 71 D 87700 Memmingen Germany Toll Free 888 SHEAR IT 888 743 2748 Phone 49 83 31 9 25 98 0 Phone 715 395 5252 Fax 49 83 31 9 25 98 80 Fax 715 395 5255 AEI PEREZ E mall info genesis europe com E mail info genesisattachments com Asia Pacific Representative Office 24 Upper Serangoon View 12 28 Singapore 534205 Phone 65 9673 9730 E mail tchoo genesisattachments com Central amp South America The Caribbean Cra 13A 89 38 Ofi 613 Bogota Colombia Phone 57 1 610 8160 795 8747 E mail contact themsagroup com Brazil Rua Jos Alves dos Santos 281 Sala 413 Sao Jos dos Campos SP Brazil Phone 55 12 3905 3405 E mail metalamericas metalamericas com View and download all manuals at genesisattachments com manuals asp Rev E 1 20 15
39. od Model serial Number Fax to the Genesis Parts Department at 15 395 3411 For assistance call 715 395 5252 or e mail genesisparts paladinbrands com 56 2015 Genesis Attachments LLC Genesis Versi Pro 07 TERMS USED IN THIS MANUAL Anti seize A material used to prevent cohesion of parts moving relative to each other Attachment Shear Grapple Cracker or Wire Cutter Authorized Employee An employee who can lockout or tagout machines or equipment in order to perform servicing or maintenance on that machine or equipment An affected employee becomes an authorized employee when that employee s duties include performing servicing or maintenance Dry Torque Any bolt that is not lubricated or coated with an anti seize compound Energized Connected to any source of stored or live energy of electrical mechanical hydraulic pneumatic chemical or thermal natures FOPS Falling Object Protective Structure Good Work Practices Examples Practicing good housekeeping Wearing personal protective equipment Applying first aid procedures if trained Using good ergonomic principles Wearing respiratory protection Using and following lockout tagout procedures Using and following confined space entry Using hazard communication Avoiding blood borne pathogens if applicable Oe S CN Lithium based Grease Heat stable water resistant lubricating grease with lithium salts of higher fatty acids or lithium so
40. one to be around the equipment when it is operating Do not allow riders on the attachment or the prime mover NO RIDERS 14 2015 Genesis Attachments LLC Genesis Versi Pro 07 SAFELY OPERATE EQUIPMENT v Do not alter or remove any safety feature from the prime mover or this attachment Y Know your work site safety rules as well as traffic rules and flow When in doubt on any safety issue contact your supervisor or safety coordinator for an explanation Do not remove guards v A heavy load can cause instability of the prime mover Use extreme care during travel Slow down on turns and watch out for bumps The prime mover may need additional counter weights to counter balance the weight of the attachment KNOW WHERE UTILITIES ARE Observe overhead electrical and other utility lines Be sure equipment will clear them When digging call your local utilities for the location of buried utility lines gas water and sewer lines as well as any other hazards OPERATOR QUALIFICATIONS Only trained and authorized persons should operate this machine and attachment To be qualified you must understand the written instructions in this manual and know all safety rules and NOTICE regulations of the job site AUTHORIZED PERSONS ONLY SHALL OPERATE mis equipment Do not operate the machine until you fully understand the function of all controls indicators and instruments UNSAFE CONDITIONS Do not operate
41. peration until the problem has been fixed MAINTENANCE SCHEDULE Performing scheduled maintenance will promote safe reliable operation of your Versi Pro 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 Eight Hour Checklist INSPECT Bolts Check for loose bolts replace if damaged 1 Fittings and hoses for damage or leaks Cylinders for damage or leaks Hydraulic swivel for damage or leaks GREASE Slewing Ring and Drive Gear Long Term Maintenance Check all bolts for loose washers including slewing ring bolts after the first 80 hours of operation LJ Reseal cylinder every 2000 hours 2015 Genesis Attachments LLC Genesis Versi 07 23 BOLT TORQUE SPECIFICATIONS Y Genesis typically uses dry torque measurements v 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 Parts Manual to identify bolt type Never re torque bolts that use Loctite If a bolt becomes loose or damaged after the initial use when Loctie 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 v Torque wrenches should be
42. pproved res pirator If you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable materials from area Allow fumes to disperse at least 15 minutes before welding or heating PREVENT FIRES Avoid fire hazards Keep the area clean Remove all flammable materials from the area during any welding or heating process Have a fire extinguisher nearby and know how to use it PROPER BOLTS 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 22 02015 Genesis Attachments LLC Genesis Versi Pro 07 MAINTENANCE SAFETY PERFORMING MAINTENANCE If maintenance or service is to be performed on your Genesis attachment make sure it is properly blocked to prevent accidental rotation of the attachment onto the operator or mechanic Do not rely on the rotation motor or other rotation com ponents to inhibit movement of the attachment during maintenance or servicing Always perform appropriate Lockout Tagout procedures UNSAFE CONDITION 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 EQUIPMENT CONDITION Do not operate poorly maintained or otherwise faulty equipment Inform the proper authority and DO NOT resume o
43. quipment until you are completely trained by a qualified opera tor in how to use the controls and know its capabilities dimensions and all safety requirements See your machine s manual for these instructions v Operate only from the operator s seat Check the seat belt daily and replace if frayed or damaged Y An operator must not be under the influence of drugs or alcohol which can change their alertness or coordination An operator taking prescription or over the counter drugs should seek medical advice on whether or not they can safely operate equipment v Never leave equipment unattended with the engine running or with the attachment in a raised position v Before exiting the prime mover lower the attachment to the ground turn off the prime mover s engine remove the key and apply the brakes Do not exceed the lifting capacity of your prime mover v When operating on slopes drive up and down not across Avoid steep hillside operation which could cause the prime mover to overturn v Reduce speed when driving over rough terrain or on a slope or when turning to avoid overturning the vehicle v Never heap load heavy material where the combined weight of the bucket and material could exceed the rated lifting capacity of the loader v Never use the attachment for a work platform or personnel carrier v Keep all step plates grab bars pedals and controls free of dirt grease debris and oil v Never allow any
44. repairs use only the manufacturer s genuine parts following authorized instructions Other parts may be substandard in fit and quality Never modify any ROPS Roll Over Protection Structure or FOPS Falling Object Protective Structure equipment or device Any modifications must be authorized in writing by the manufacturer PROTECT AGAINST FLYING DEBRIS Always wear proper safety glasses or a face shield 35 when driving pins in or out or when an operation causes dust JY flying debris or any other hazardous material 2015 Genesis Attachments LLC Genesis Versi Pro 07 11 USE CARE WITH HYDRAULIC FLUID PRESSURE Hydraulic fluid under pressure can penetrate the skin and cause serious injury or death Hydraulic leaks under pressure may not be visible Before connect ing or disconnecting hydraulic hoses read your material handler s operator s manual for detailed instructions on connecting and disconnecting hydraulic hoses or fittings v Keep unprotected body parts such as face eyes and arms as far away as possible from a suspected leak Flesh injected with hydraulic fluid may develop gangrene or other permanent disabilities v f injured by injected fluid see a doctor at once If your doctor is not familiar with this type of injury ask him to research it immediately to determine the proper treatment v Wear safety glasses and protective clothing and use piece of cardboard or wood when searching for hydraulic leaks
45. requested Shipping charges are not included in the purchase price of parts INVOICES All invoices are due upon receipt Any accounts 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 respon sibility of the purchasing party 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 for a RGA Return Goods Authorization number and form RETURN GOODS AUTHORIZATION All parts returned to Genesis for warranty consideration must be returned with a completed RGA Return Goods Authorization provided by the Genesis Parts Department The form needs to be completed in its entirety including any additional information requested by the Parts or Service Department Return freight is the responsibility of the shipper and will be credited upon claim approval A determination to accept or deny the claim will be made based on the information avail able to Genesis Warranty on purchased parts other than wear components is 6 months There is no warranty period on wear parts or components O 2015 Genesis Attachments LLC Genesis Versi Pro 07 55 lt GENESIS PARTS ORDER FORM Date Customer Contact Phone Fax Shipping Address Billing Address Purchase Order Shipping Meth
46. ring 5 Gear teeth inside bearing shroud 1 2 4 5 26 2015 Genesis Attachments LLC Genesis Versi Pro 07 Decals are necessary for safe operation and maintenance To reorder contact your Genesis dealer or call 715 395 5252 Versi Pro 07 Markings Model Number Serial Number weld on Logo Viewing Distance 2015 Genesis Attachments LLC Genesis Versi Pro 07 27 ATTACHMENT INSTALLATION Install the Versi Pro according to your carrier skid steer or mini excavator OEM s standard bucket attachment installation instructions ELECTRIC INSTALLATION For Electric Over Hydraulic Option OEM electrical I connector The Versi Pro 07 requires an electrical connection to the carrier skid steer or mini excavator Carrier OEMs often provide an electrical connector near the hydraulic quick couplers Genesis provides a wiring harness to connect the Versi Pro to the carrier OR In the absence of an OEM provided electrical connection Control system Genesis provides a complete control system including joy Joystick with buttons stick handles available for purchase Versi Pro standard eight pin electrical connector Genesis wiring Versi Pro Standard Eight Pin Connection CONNECTOR PIN OUT YEL BLK Keyed power HYDRAULIC INSTALLATION For Fully Hydraulic Option OEM auxiliary lines The Versi Pro 07 is equipped with bulkhead connector fittings to enable the installation of hydr
47. t edge or square Check the profile along the blades If the piercing tip is only slightly worn it can be built up following the build up and hard surfacing procedure in this manual When the tip is severely worn it must be replaced PIERCING TIP REPLACEMENT Important Remove the upper secondary blade and upper wear plate during this procedure to prevent damage Preheat the tip area to 350 F 177 C six to eight inches around the tip Maintain this temperature throughout the procedure Do not exceed 400 F interpass temperature Air arc to remove the piercing tip Clean the pocket and Check chamfer the perimeter at gt x 45 angles gap Position and tack the new piercing tip in place square with the blades and new wear plate 34 2015 Genesis Attachments LLC Genesis Versi Pro 07 Weld with AWS E7018 electrode Begin with the sides filling in the chamfered area with single passes alternating sides and peening each pass Weld the back and front following the same method When welding is complete grind the welds flush on each side Cycle the jaw slowly to check for interference 0 0 Cover with heat blanket and allow to cool slowly DO NOT put unit into operation until cool WEAR PLATE REPLACEMENT Important Remove the upper secondary blade during this procedure to prevent interpass temperature Position and tack the new wear plate in place Weld with AWS E7018 el
48. te the GVP attachment until the jaw set is A CAU T O N properly installed and the Front Cylinder Pin is inserted and secured 40 2015 Genesis Attachments LLC Genesis Versi Pro 07 WIRE CUTTER JAW REMOVAL To properly cut the material for which it s designed the wire cutter is very narrow so a special Wire Cutter Jaw Stand has been developed to facilitate the jaw changing process Fully extend the cylinder Remove Front Cylinder Pin PN 3500352 Set the GVP shear down in a secure position Fig 2 Retract the cylinder Fig 3 Remove Lower pin PN 3500352 2015 Genesis Attachments LLC Genesis Versi Pro 07 41 Make sure the M16 x 2 00 bolts are tightened only to the extent the stands have a secure fit but can still swing freely Mount the Wire Cutter Jaw Stand PN 3501533 on both sides of the jaw set Raise the stick as illustrated and then move it out of the Wire Cutter Jaw Stand 42 2015 Genesis Attachments LLC Genesis Versi Pro 07 WIRE CUTTER JAW INSTALLATION Position the stick as illustrated and hook the jaw set Rotate the stick until the stick and lower jaw bores align and install Lower Pin Lower Pin PN 3501023 2015 Genesis Attachments LLC Genesis Versi Pro 07 43 Extend the cylinder After the Lower Pin has been installed the Wire Cutter Jaw Stand can be safely removed Lower Pin PN 3501023 Extend the cylinder un
49. tements in this manual and the OEM manual for your carrier skid steer or mini excavator Determine the control for each function before operat ing the carrier Familiarize yourself with the carrier and attachment before attempting to process material Have the carrier moved to a wide open area The area should be solid level and free of obstacles such as people equipment buildings and power lines With the carrier engine running at a reduced speed operate one control at a time Continue this practice until you have learned and become comfortable with the function of each control KNOW THE WORK AREA Check clearances in the work area Keep all bystanders at a safe distance Do not work under obstacles within the working range of your Genesis attachment Check the location for overhead and buried power lines or other utilities before operation Check ground conditions Be aware of and avoid unstable or slippery areas 16 2015 Genesis Attachments LLC Genesis Versi Pro 07 MACHINE STABILITY Your Genesis attachment is sized for carrier stability when properly operated However improper operation faulty maintenance or unauthorized modifications may cause instability Y Know the working ranges and capacities of the carrier to avoid tipping v Use the recommended carrier counter weight The following conditions affect stability v Ground conditions v Grade THINK _ v Weight of attachment SAFETY vV Contents of attachment FIR
50. til the bores of the cylinder rod end and the upper jaw align and install the Cylinder Rod End Pin Install Cylinder Rod End Pin PN 3500352 Fig 9 44 2015 Genesis Attachments LLC Genesis Versi Pro 07 The blade gap as well as the pre load of the Blades are set through the Castle Nut with Spring Washer The Spring Washer pre serves the tension of the Blades until they are worn in significantly As the Blades wear in adjust the Castle Nut to restore tension Blades PN 20000704 Castle Nut PN GN F4052003 Spring Pin PN 7 Spring Washer PN 20000715 To add tension to the Blades remove Spring Pin tighten the Castle Nut then Fig 10 replace the Spring Pin The cutting edges can be very sharp even after use Always wear suitable protective gear and gloves To change the Blades remove the Bolts F0620040 then remove the Blades and replace with new or resharpened Blades Re install the bolts and tighten to 450 Ft Lbs or 610 Nm Check blade gap and pre tension m Fig 11 Cross section view To resharpen the blades they must be removed from the shear and reground Dee ata 45 degree angle While grinding the temperature of the cutting edges must not exceed 200 C or 392 F to preserve the material properties The blades must be replaced when they do not overlap in the fully closed position NOTE Before using of the wire cutter the ball valve located on the side of the shear must be
51. to check for interference Cover with heat blanket or insulation and allow to cool slowly DO NOT put unit into operation until cool approximately eight hours 2015 Genesis Attachments LLC Genesis Versi Pro 07 39 The wire cutting jaw set is solely designed to process CAU T O N single or multi strand wires made of non ferrous metals such as aluminum or copper High strength alloys of these metals may not be processed with this jaw set Single strand wires processed with this jaw set may not be larger than 200mm 7 7 8 inches in diameter including the insulation Furthermore the wires may not be coated with materials having higher tensile strength or hardness than copper or aluminum e g steel Processing of such materi als will damage the blades and the entire jaw set When cutting multiple wires at once the circumference of all the wires must be inside the jaw during the entire cutting cycle Please contact Genesis or your local Genesis Dealer before usingthe wire cutting jaw set in an application not described above Always fully extend the cylinder before removing the Front Cylinder Pin PN 3500352 otherwise the upper jaw may suddenly and unexpectedly close CAU T O When changing jaw sets be sure the jaws are securely positioned even when uncoupled from the stick C AU T O N Never activate the rotation function of the shear without having the jaw set in properly engaged Do not opera
52. tor from flying debris that may be created during handling Falling Object Protection Structures or FOPS are necessary for application where material is to be handled overhead PRIORITIZED OIL FLOW Material handlers in overhead operations or high reach conditions must have prioritized oil flow to their main valves 20 2015 Genesis Attachments LLC Genesis Versi Pro 07 TRAINED AND AUTHORIZED Only trained and authorized persons should perform maintenance on the Versi Pro To be qualified you must understand the instructions in this manual have training and know the safety rules and regulations of the job site REPAIRS Do not attempt repairs you do not understand If any ques NOTICE tions arise regarding a safety or maintenance procedure contact Genesis or your Genesis dealer AUTHORIZED PERSONNEL ONLY AUTHORIZED PARTS Use factory authorized parts The use of unauthorized parts may compromise safety performance and durability of the attachment and may void the warranty SCHEDULES Follow the daily checklist and maintenance schedules in this manual Extreme conditions may dictate shorter maintenance intervals TORQUE SPECS Do not exceed bolt torque specifications See Page 24 WELDING Do not weld on structural components without consulting Genesis Doing so may cause structural failure and void the warranty MAINTENANCE Do not work on the attachment before ensuring it
53. torques will also cause uneven wear on the slewing ring See Page 24 for proper bolt torque specifications GREASE DAILY Rotating components must be greased daily The rotation bearing features a remote grease fitting at the top of the quick attach plate The gear teeth should also be greased and can be accessed by removing the bearing shroud STAND CLEAR Stand clear when the Versi Pro is being rotated Always stay in clear view of the operator ROTATE AFTER GREASING Grease each slewing ring grease fitting with several strokes and rotate the attachment two full rotations after greasing each fitting GREASE TEMPERATURES For normal conditions above 32 F 0 C use a lithium based premium grade 2 extreme pressure grease For temperatures below 32 F a grade 0 grease is recommended 2015 Genesis Attachments LLC Genesis Versi Pro 07 25 GREASE AA DANGER SHUT OFF EXCAVATOR OR SKID STEER AND DISABLE HYDRAULICS PER OEM INSTRUCTIONS BEFORE GREASING Use a lithium based premium EP 2 in normal conditions above 32 F 0 C Use Grade 0 in temperatures below freezing Grease all fittings every eight hours of operation Grease until extrusion is visible Grease at the end of the shift when the attachment is warm After greasing the rotation bearing rotate the Versi Pro through two full rotations Grease locations 1 Front cylinder pin 2 Rear cylinder pin 3 Pivot group 4 Remote grease fitting for rotation bea
54. will not move Completely lower the boom to the ground or in a rest position and relieve hydraulic pressure EQUIPMENT CONDITION Never operate poorly maintained equipment When maintenance is required repair or replace parts immediately 2015 Genesis Attachments LLC Genesis Versi Pro 07 21 PRESSURIZED SYSTEM Do not work on any hydraulic lines or components while they are pressurized Escaping hydraulic fluid can penetrate the skin causing serious injury or death Relieve pressure before performing maintenance Keep hands and body parts away from pin holes and nozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks MEDICAL ASSISTANCE If fluid is injected into the skin seek medical assistance immediately from a doctor familiar with this type of injury BURNS Hydraulic oil becomes hot during operation Do not let hydraulic oil or compo nents contact skin as it could cause severe burns Allow hydraulic components to cool before working on them Use protective clothing and safety equipment If burned seek immediate medical attention VENTILATE THE AREA Remove paint before welding or heating Hazardous fumes dust can be gener ated 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 SANDING GRINDING When sanding or grinding paint avoid breathing the dust Wear an a
55. zed Genesis dealer or Genesis Service Department Doing so will void the warranty and may cause structural damage accidents or tipping 18 2015 Genesis Attachments LLC Genesis Versi Pro 07 FIRE HAZARDS Avoid fire hazards Keep the area clean Remove all flammable materials from the area during any welding or heating process Have a fire extinguisher nearby and know how to use it STABILITY 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 Do not throw or drop the contents Operate the controls smoothly and gradually Jerky controls are hazardous and may damage the carrier FASTENER IDENTIFICATION 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 STARTING PROCEDURE Before operating walk completely around the equipment to make certain no one is under on 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
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