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Summary of Contents for Genesis Rail Breaker
- Page 1 Rail Breaker (GRB 30) SAFETY & OPERATOR’S MANUAL The GRB 30 processes 136 lb. and smaller low chrome rail.
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Page 2: Contact Information
Central America & Colombia Cra 13A #89-38 / Ofi 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 Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... -
Page 3: Preface
To ensure years of safe, dependable service, only trained and authorized persons should operate and service your Genesis attachment. It is the responsibility of the product’s owner to ensure the operator is trained in the safe operation of the product and has available this manual for review. -
Page 4: Table Of Contents
Rotation Circuit - Gear Pump Type HYDRAULIC START-UP Start-up Procedure GENERAL OPERATION INSTRUCTIONS The GRB 30 is designed to process 136 lb. and smaller low chrome rail. Start-up Efficient and Productive Operation Genesis Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... - Page 5 Adjusting the Rotation Motion Control Valve TROUBLE-SHOOTING GUIDE WARRANTY Claim Procedure Blade Warranty PARTS ORDER POLICY AND PROCEDURE Parts Orders Should Include Placing Orders Part Numbers Shipping Invoices Returns Return Goods Authorization © 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30...
- Page 6 TABLE OF CONTENTS PARTS ORDER FORM CONTACT INFORMATION NOTICE For bolt torque specs, see the Genesis Fastener Manual. genesisattachments.com/manuals Genesis Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC...
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Page 7: Safety Statements
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. © 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30... -
Page 8: Operational Safety
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 Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... -
Page 9: Check The Equipment
Stability Your Genesis attachment is sized for carrier stability. However, improper operation, faulty mainte- nance or unauthorized modifications may cause instability. 3 Know the working ranges and capacities of the carrier to avoid tipping. -
Page 10: Know The Work Area
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. -
Page 11: Safely Operate Equipment
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. © 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30 11... -
Page 12: Transporting The Attachment
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 Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... -
Page 13: Use Care With Hydraulic Fluid Pressure
Allow hydraulic com- ponents to cool before working on them. Use appropriate protective clothing and safety equipment. If burned, seek immediate medical attention. © 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30 13... -
Page 14: Prioritized Oil Flow
It is recommended to use dust suppression (such as water) or dust col- lection (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 Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... -
Page 15: Process Material Safely
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. -
Page 16: Attachment Nomenclature
ATTACHMENT NOMENCLATURE 3 4* Genesis Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... - Page 17 Rear Cylinder Pin Main cylinder connection to attachment stick Stick or Body Houses and protects the main hydraulic cylinder AutoGuide or Puck See the Genesis Fastener Manual for torque values. Pivot Group Includes the pivot shaft, bearings and end caps...
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Page 18: Attachment Installation
ATTACHMENT INSTALLATION Preparation of the excavator prior to attachment delivery will make installation safer and easier.Contact Genesis or your Genesis dealer for assistance. Dual-Pump Flow Typically, an excavator has two hydraulic pumps supplying oil to the main valves of the excavator. - Page 19 When these are reversed, extra pressure is needed to open the jaw, which pulls down the engine, destrokes the pumps, increases jaw cycle time, creates high oil temperatures and burns more fuel. © 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30 19...
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Page 20: Case Drain
The GRB 30 rotation system requires an additional case drain line to the tank. The case drain line (in red) can be relocated to either side of the head as required by the excavator pumbing. Genesis Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... -
Page 21: Rotation Circuit - Auxiliary Valve On Machine
Use 1/2” 3000 PSI rated hose Rotate Valve: Closed- center, three-position, spring-centered, with Flow anti-cavitation checks. Controls Relief valve setting: 1,950 PSI (mounted on excavator) Case Drain Inside Upper Head © 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30 21... -
Page 22: Foot Switch Installation
The rotator requires an additional hydraulic circuit. One of the several available options has been supplied with the attachment. These diagrams show the installation of the additional circuit. Refer to the Hydraulic/Rotation Maintenance section of this manual for valve descriptions, functions and settings. Genesis Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... -
Page 23: Rotation Circuit - Gear Pump Type
Rotation Valve Three-position, tandem center, spring-centered, with anti-cavi- tation checks. Flow Relief Setting: 1950 (mounted Controls on excavator) Case Drain Inside Upper Head Gear Pump Required Mount Valves in Excavator © 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30 23... -
Page 24: Hydraulic Start-Up
HYDRAULIC START-UP The Genesis Rail Breaker is designed to operate under full excavator pressure or up to 5500 PSI. Due to these high pressures, it is important that air is bled from the attachment cylinder after in- stallation. Failure to follow these procedures could result in cylinder seal damage and/or excavator hydraulic system damage. -
Page 25: General Operation Instructions
O-rings. More efficient processing will extend the life of the at- tachment. © 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30 25... -
Page 26: Common Operational Concerns
While most rail can be cut in any orientation, cutting just the head may ensure an easier break. Poor rail breaking can be attributed to worn blades. Regular maintenance and edge care can improve performance. Genesis Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... -
Page 27: Maintenance Safety
Do not exceed bolt torque specifications. See the Genesis Fastener Manual. Do not weld on structural components without consulting Genesis. Doing so may cause structural failure and void the warranty. Do not operate an attachment without the case-drain line properly installed if the attachment uses a rotation system that requires a case drain. - Page 28 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. Genesis Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC...
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Page 29: Maintenance Schedule
Use maintenance procedures described in this manual. If you are not able to safely and com- petently perform these procedures, have a Genesis dealer perform them. After the first 80 hours of operation, check all bolts, including slewing ring bolts. -
Page 30: Four-Hour Checklist
A more thorough inspection, to be performed at the end of each shift, is described below on the eight-hour checklist. Grease: • Rail breaker cylinder - end of pin • Rail breaker cylinder rod • AutoGuide at fitting and smear grease on contact surface of upper jaw •... -
Page 31: Lubrication Points
Cylinder (4) Places (End of Pin) AutoGuide Bracket Cylinder (End of Pin) Bracket Pivot (Center of Tube) Main Shaft Bearing Slewing (4) Places Cylinder (End of Pin) Main Shaft © 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30 31... -
Page 32: Bolt Torque Specs
BOLT TORQUE SPECS Bolt torque specs and thread treatment procedures can be found in the Genesis Fastener Manual. genesisattachments.com/manuals Genesis Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... -
Page 33: Blade Maintenance
3. Guide Blades - non-rotating blades designed to prevent jaw wear. These are not the primary blades for cutting rail. 4. Jaw Hard-surfacing - build-up and hard-surface as needed. 5. Jaw Armor™ - Build-up or replace as wear out. © 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30 33... -
Page 34: Autoguide
3. Loosen the bolts on the outside of the stick. 4. Completely remove the upper bolt. 5. Insert shims, insert top bolt, tighten both bolts. 6. Check gap with feeler gauge. Genesis Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... -
Page 35: Guide Blades
Clean the adjustment plate as necessary. Inspect the blade seat for damage or imperfections and clean or repair as necessary. Replacement plates can be ordered from your Genesis dealer or the Genesis Parts Department with the serial number of your attachment. -
Page 36: Cutting Blades
Grind away dents or mushrooming of blade edges at the end of each day to prevent upper jaw deflection, excessive blade wear and undue stress to upper and lower jaws. Always use Genesis-approved blades. Blades that do not meet Genesis specifications can cause major problems, and using them may void the warranty. -
Page 37: Blade Gap
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 pivot group. © 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30 37... -
Page 38: General Welding Guidelines
Cover the area with a heat blanket and allow it to cool slowly, approximately eight hours. • Do not put the attachment into operation until the welds have been allowed to cool. Genesis Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... -
Page 39: Build-Up
© 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30 39... -
Page 40: Hard-Surfacing
1” to 1-1/2” (25 - 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 jaws. Genesis Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... -
Page 41: Hard-Surfacing Patterns
Single passes approximately 1” apart. Work across the top of the chin plate and along the lower jaw toward the throat. Use two to three stringers, depending on the at- Grain tachment model. © 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30 41... -
Page 42: Hydraulic/Rotation Maintenance
The maximum case drain pressure measured at the attachment while rotating and cycling the jaws must never exceed 80 PSI. Pressure increases during cold-weather operation. Flow Pressure 5-7 GPM 1800-2000 PSI 19-26 LPM 125-138 Bar Genesis Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... -
Page 43: Slewing Ring Maintenance
For temperatures below 32˚ F, a grade 0 grease is recommended. DANGER Stand clear when the attachment is being rotated. Always stay in clear view of the operator. © 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30 43... -
Page 44: Rotation Motion Control Valve Adjustment
Again, stall the shear in each direction to verify the screws have returned to their original 2200 PSI setting. If they have not, adjust to 2200 PSI. 6. Reduce the rotation valve input pressure as indicated on page 42 Genesis Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC... -
Page 45: Trouble-Shooting Guide
Wear in main bearings is causing jaw deflection and inconsistent blade gaps Poor Cutting Pressures from excavator too low - check at attachment port blocks Swivel or cylinder is bypassing - contact the Genesis Service Department for procedures to check for bypass © 2020 Genesis Attachments, LLC... - Page 46 Flow control out of adjustment; reset slow Jam nut loosened on rotation valve Faulty cartridge (contamination) Rotation speed changed from original setting Faulty directional control valve Pressure set too low; reset Genesis Rail Breaker GRB 30 © 2020 Genesis Attachments, LLC...
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Page 47: Warranty
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. -
Page 48: Parts Order Policy And Procedure
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. - Page 49 Contact: Shipping Address: E-mail: Billing Address: Purchase Order: Shipping Method: Model: Serial Number: Quantity Part Number Description Price E-mail to the Genesis Parts Department: genesisparts@genesisattachments.com For assistance, call 715-395-5252 © 2020 Genesis Attachments, LLC Genesis Rail Breaker GRB 30 49...
- Page 50 CONTACT INFORMATION Genesis Attachments Europe/Africa/Middle East Genesis GmbH 1000 Genesis Drive Superior, WI 54880 USA Teramostrasse 23 87700 Memmingen, Germany Toll Free: 888-Attachment-IT (888-743-2748) Phone: +49 83 31 9 25 98 0 Fax: +49 83 31 9 25 98 80 Phone: 715.395.5252...
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