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Summary of Contents for Genesis Razer X
- Page 1 Razer X Multi-Jaw Demolition Tool (GRX) SAFETY & OPERATOR’S MANUAL...
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Page 2: Contact Information
Phone: +65 9673 9730 E-mail: tchoo@genesisattachments.com 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 GRX © 2021 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
Dual-Pump Flow ROTATOR INSTALLATION Case Drain Line Foot Switch Installation Rotation Circuit - Gear Pump Type Rotation Circuit - Auxiliary Valve on Machine ELECTRICAL INSTALLATION HYDRAULIC START-UP Start-up Procedure JAW SET CHANGE-OVER MAINTENANCE SAFETY Genesis GRX © 2021 Genesis Attachments, LLC... - Page 5 CRACKER JAW WELDING MAINTENANCE Hard-Surfacing Patterns HYDRAULIC/ROTATION MAINTENANCE Hydraulic Requirements Rotation Valve Input Rotation Valve Settings GenFlow Regeneration Valve Regeneration Valve Adjustment GENFLOW REGENERATION VALVE - HOW IT WORKS GENFLOW REGENERATION VALVE GRX 295 GRX 395 © 2021 Genesis Attachments, LLC Genesis GRX...
- Page 6 PARTS ORDER POLICY AND PROCEDURE Parts Orders Should Include Placing Orders Part Numbers Shipping Invoices Returns Return Goods Authorization PARTS ORDER FORM CONTACT INFORMATION NOTICE For bolt torque specs, see the Genesis Fastener Manual. genesisattachments.com/manuals Genesis GRX © 2021 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. © 2021 Genesis Attachments, LLC Genesis GRX... -
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 GRX © 2021 Genesis Attachments, LLC... -
Page 9: Check The Equipment
Stability Your Genesis attachment is sized for carrier stability. However, improper operation, faulty maintenance 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 hydraulic 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. © 2021 Genesis Attachments, LLC Genesis GRX 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 GRX © 2021 Genesis Attachments, LLC... -
Page 13: Use Care With Hydraulic Fluid Pressure
3 Hydraulic oil becomes hot during operation. Do not let hydraulic oil or components contact skin, as it could cause severe burns. Allow hydraulic components to cool before working on them. Use appropriate protective clothing and safety equipment. If burned, seek immediate medical attention. © 2021 Genesis Attachments, LLC Genesis GRX 13... -
Page 14: Prioritized Oil Flow
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 GRX © 2021 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: Maintenance/Transport Lock Bolts
The lock bolts are to be installed any time the tool is transported or maintenance is performed to prevent inadvertent lock pin movement during these operations. Remove the lock bolts prior to normal operation. Genesis GRX © 2021 Genesis Attachments, LLC... -
Page 17: Rotation Lock
There are TWO locks in every attachment, one on either side of the bracket. In some cases, one of the port blocks may need to be removed to access the rotation lock. The rotation locks and red flags should be saved for use during future transportation. © 2021 Genesis Attachments, LLC Genesis GRX 17... -
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 An excavator typically has two hydraulic pumps that supply oil to its main control valve, which is usually separated into two halves. - Page 19 Particles may fly when a pin is struck. Use a drift pin or mallet when striking pins. Keep all personnel at a safe distance. © 2021 Genesis Attachments, LLC Genesis GRX 19...
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Page 20: Rotator Installation
50 PSI at all times. Foot Switch Installation Install the foot switch in the excavator and connect with electrical harness. Consult excavator dealer when using an alternate to the Genesis supplied foot switch. White Normal Open Black Normal Open... -
Page 21: Rotation Circuit - Gear Pump Type
Motor spring-centered, with Flow anti-cavitation checks. Controls Relief Setting: 1950 (mounted on excavator) Inside Upper Head Rotate Work Lines: Use 1/2” 3000 PSI rated hose Gear Pump Required Mount Valves in Excavator © 2021 Genesis Attachments, LLC Genesis GRX 21... -
Page 22: Rotation Circuit - Auxiliary Valve On Machine
Use 1/2” 3000 PSI Rotate/Lock rated hose Pin Selector Valve Hydraulic Motor Rotate Valve: Closed- Flow center, three-position, Controls spring-centered, with anti- cavitation checks. Relief valve setting: 1,950 PSI (mounted on excavator) Inside Upper Head Genesis GRX © 2021 Genesis Attachments, LLC... -
Page 23: Electrical Installation
Fuse Holder Jump Boom/Stick 12V DC* 5A Fuse Harness Inside Upper Head Harness The GRX 295 requires 24V DC. GRX 395 SN395101-395110 requires 12V DC. GRX 395 SN395111 and up requires 24V DC. © 2021 Genesis Attachments, LLC Genesis GRX 23... -
Page 24: Hydraulic Start-Up
HYDRAULIC START-UP Genesis attachments are 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 cylinders after installation. Failure to follow these procedures could result in cylinder seal damage and/or excavator hydraulic system damage. -
Page 25: Jaw Set Change-Over
Press and hold BODY switch on the cab control box, actuate the appropriate joystick or foot switch to extend the body pins. Release BODY switch when pins are fully extended. © 2021 Genesis Attachments, LLC Genesis GRX 25... - Page 26 Rotate the GRX a full 360 degrees to visually ensure all pins are retracted completely as well as to confirm the valve has reset to the rotate mode. Genesis GRX © 2021 Genesis Attachments, LLC...
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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 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. - 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 GRX © 2021 Genesis Attachments, LLC...
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Page 29: Maintenance Schedule
Performing scheduled maintenance will promote safe, reliable operation of your attachment. 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. -
Page 30: Eight-Hour Checklist
After the first 80 hours of operation, check all bolts, including slewing ring bolts. • Replace regeneration valve components every 4000 hours. • Reseal cylinders every 4000 hours initially and every 3000 hours following. • Reseal swivel every 4000 hours. Genesis GRX © 2021 Genesis Attachments, LLC... -
Page 31: Lubrication Points
For temperatures below 32˚F, use a grade 0 grease. Do not use grease containing Molybdenum (Moly). Genesis GLG-2™ anti-wear, extreme-pressure lithium grease, PN 6302601, is recommended for all temperature conditions. Grease all fittings every four hours of operation. Grease until extrusion is visible. -
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 GRX © 2021 Genesis Attachments, LLC... -
Page 33: Shear Jaw Set Maintenance
5. Welding Maintenance - perform jaw build-up and hard-surface as needed. Blade Bolts Torque blade bolts every eight hours to the specifications listed in the Genesis Fastener Manual torque chart. Check for broken bolts daily and replace them immediately. © 2021 Genesis Attachments, LLC... -
Page 34: Piercing Blades
Radius blades based on wear not hours of operation. 7. Width of blades, top to bottom, may taper 0.060” (2 mm) total. Bottom edges may be worn to a maximum radius of 3/16”. Genesis GRX © 2021 Genesis Attachments, LLC... - Page 35 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.
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Page 36: Replacement
If the gap exceeds the specified limit, call the Genesis Service Department. If no gap exists, remove blades, lightly grind facing surfaces and repeat GRX 295 & 395: 0.002” - 0.010”... -
Page 37: Guide Blades
Blade Gaps table. Shims To install shims, loosen blade bolts and slide shims between the guide blade and guide blade seat. Re-torque bolts and recheck the gap. Mach Guide Blade Adjust Plate © 2021 Genesis Attachments, LLC Genesis GRX 37... -
Page 38: Rotation
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 numbers of your attachment and jaw set. -
Page 39: Primary And Secondary Blades
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. -
Page 40: Adjustment Plates
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 shear. 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. -
Page 41: Blade Gap
PRIMARY AND SECONDARY BLADES Blade Gap After each blade rotation, shim the lower blades to keep the gap within the specifications listed in the table below. Do not shim the upper blades. Use only Genesis shim kits. Cutting Blade Gaps Model... -
Page 42: Razor Blade
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. Genesis GRX © 2021 Genesis Attachments, LLC... -
Page 43: Cracker & Pulverizer Jaw Set Maintenance
Pulverizing Teeth As teeth become worn, they need to be rotated, built-up or replaced. To help customers determine and monitor how far processor teeth have worn from their original shape, Genesis has tooth build- up templates available. Each template is sized and formed to that tooth’s original shape and features three lines that indicate wear level. -
Page 44: Concrete Cracking Tips
At the end of each shift, check the condition of the concrete cracking tips. Replace any broken bolts, and retorque loose bolts when cool. Replace tips when teeth become severely rounded or flat. A more pointed tooth will process concrete more efficiently. Genesis GRX © 2021 Genesis Attachments, LLC... -
Page 45: 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 jaws. 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. -
Page 46: 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 GRX © 2021 Genesis Attachments, LLC... -
Page 47: Hard-Surfacing
Grind the ends of all stringer welds, with the grain to taper grain 1” to 1-1/2” (25 - 38 mm) to the parent material. 1/4” from edge See the following pages for hard-surfacing illustrations and instructions specific to each area of the jaws. © 2021 Genesis Attachments, LLC Genesis GRX 47... -
Page 48: Shear Jaw Build-Up
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. Genesis GRX © 2021 Genesis Attachments, LLC... -
Page 49: Shear Jaw Hard-Surfacing Patterns
Use two to three stringers, depending on the Grain shear model. Grain Staggered stringers Lower Jaw Chin Crosshatch the chin plate with stringer beads at 45˚ angles to form 1” squares. © 2021 Genesis Attachments, LLC Genesis GRX 49... -
Page 50: Cracker Jaw Welding Maintenance
Do not crosshatch the curved areas of the jaws near Grain the pivot. Use only straight stringers on these areas. Grain Follow hard-surfacing instructions on the following page. Genesis GRX © 2021 Genesis Attachments, LLC... -
Page 51: Hydraulic/Rotation Maintenance
Note: with supply set at 2000 PSI, you should not hear oil bypassing in the crossover when stalling the rotation motor. If bypass is heard, either the crossover is set lower than 2200 PSI or the supply is set higher than 2200 PSI. © 2021 Genesis Attachments, LLC Genesis GRX 51... -
Page 52: Genflow Regeneration Valve
Repeat until the preferred balance of speed and power is met. Final adjustment may require less than a half-turn. DANGER Shut off the excavator and disable the hydraulics per OEM instructions before adjusting the cartridge. Genesis GRX © 2021 Genesis Attachments, LLC... -
Page 53: Genflow Regeneration Valve - How It Works
Jaw Open: Oil goes to the rod end of the cylinder, and bore oil goes back to the tank. Return line Pressure line Regeneration on close Power mode on close Opening jaw © 2021 Genesis Attachments, LLC Genesis GRX 53... -
Page 54: Genflow Regeneration Valve
Logic valve 6300623 Zero-leak plug 6300075 External seal kit 6300624 Torque to 40 in-lbs Torque to 350-375 Ft-lbs O-Ring 2.25” 6300723 Shuttle valve 6300621 External seal kit 6300622 O-Ring 2.0” 6300638 Torque to 30-35 Ft-lbs Genesis GRX © 2021 Genesis Attachments, LLC... -
Page 55: Slewing Ring Maintenance
Molybdenum (Moly). Genesis GLG-2™ anti-wear, extreme-pressure lithium grease, PN 6302601, is recommended for all temperature conditions. DANGER Stand clear when the attachment is being rotated. Always stay in clear view of the operator. © 2021 Genesis Attachments, LLC Genesis GRX 55... -
Page 56: Rotation Circuit
ROTATION CIRCUIT To meet diverse customer needs, Genesis offers two rotation valve options. They vary in mounting, function, factory-supplied and customer-supplied parts, and operating advantages. Valves are factory-set and should not need adjustment. If you believe adjustment is necessary, contact the Genesis Service Department. - Page 57 ROTATION CIRCUIT Cylinder Lock Pin Rotate/Lock Pin Body Lock Pin Selector Valve In standard position Rotate function is active Flow control Relief Valve Flow control Counterbalance Relief Valve Valve © 2021 Genesis Attachments, LLC Genesis GRX 57...
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Page 58: Trouble-Shooting Guide
Attachment cylinder or swivel bypass Check for bypass and replace seals if needed Jaws drift closed or can be pushed closed Pilot check seals leaking Replace seals Bleed-down orifice plugged Clean and replace orifice Genesis GRX © 2021 Genesis Attachments, LLC... -
Page 59: Rotator
Does not rotate Incorrect pressure settings Set pressures Faulty components Contact Genesis to replace valve Test for 24V at plugs on directional valve No electrical power to one side while depressing foot switch Check if directional control valve shifts both... -
Page 60: Lock-Pin
Test for 12V at plugs on selector valve while No electrical power depressing toggle switch Lock-pin selector valve not shifting Replace with Genesis replacement valve Tool misalignment Move tool to correct alignment Lock-pin not operating Verify that hoses are routed to factory-... -
Page 61: 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 62: Parts Order Policy And Procedure
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. -
Page 63: Parts Order Form
Customer: Date: Phone: 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 © 2021 Genesis Attachments, LLC Genesis GRX 63... -
Page 64: Contact Information
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-SHEAR-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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