PREFACE To ensure years of safe, dependable service, only trained and authorized persons should operate and service your Genesis attachment. It is the responsibility of the product’s owner to ensure the operator is trained in the safe operation of the product and has available this manual for review. It is the responsibility of the operator and maintenance personnel to read, fully understand and follow all operational and safety-related instructions in this manual.
TABLE OF CONTENTS CONTACT INFORMATION PREFACE Important Manual Replacement Registration Form Possible Variations Public Notice Warranty SAFETY STATEMENTS OPERATIONAL SAFETY Read Manual Before Operating or Maintaining the Attachment Personal Protection Know Your Equipment Before Operating Check the Equipment Stability Know the Work Area Starting Procedure Place the Load Safely Safely Operate Equipment...
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TABLE OF CONTENTS HYDRAULIC START-UP Start-up Procedure GENERAL OPERATION INSTRUCTIONS Start-up Efficient and Productive Operation Cutting Larger Materials Chatter While Cutting Pulling / Back-Tracking Pushing / Tracking Forward Cutting in a Pile MAINTENANCE SAFETY MAINTENANCE SCHEDULE Scheduled Maintenance Four-Hour Checklist Eight-Hour Checklist LUBRICATION POINTS BOLT TORQUE SPECS...
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TABLE OF CONTENTS REGENERATION VALVE ADJUSTMENT GENFLOW REGENERATION VALVE - HOW IT WORKS REGEN BLOCK SUB-ASSEMBLY - 320 GPM GENFLOW REGENERATION VALVE - 240 GPM GENFLOW REGENERATION VALVE - 116 GPM SLEWING RING MAINTENANCE GEARBOX MAINTENANCE Planetary Gearbox Lubrication Gearbox Lube Change-out Procedure ROTATION WITH CROSSOVER RELIEF VALVE Setting the Crossover Reliefs ROTATION WITH MOTION CONTROL VALVE...
SAFETY STATEMENTS This symbol by itself or used with a safety signal word throughout this manual is used to call attention to instructions involving your personal safety or the safety of others. Failure to follow these instructions can result in injury or death.
OPERATIONAL SAFETY Read Manual Before Operating or Maintaining the Attachment Read this manual before attempting to operate the attachment. This operator’s manual should be regarded as part of the attachment. For proper installation, operation and maintenance of the attachment, operators and maintenance personnel must read this manual.
OPERATIONAL SAFETY Check the Equipment Before use, check the equipment to ensure it is in good operating condition. Check the following: 3 Grease fittings. Pump grease at all fitting locations, see page 38. 3 Hydraulic fluid level. Add hydraulic fluid as required. 3 Hydraulic hoses and hose connections for wear or leaks.
OPERATIONAL SAFETY Know the Work Area Check clearances in the work area. Keep all bystanders at a safe distance. Do not work under obstacles. Always check your location for overhead and buried power lines or other utilities before operation. Check ground conditions. Avoid unstable or slippery areas. Position the carrier on firm level ground.
OPERATIONAL SAFETY Safely Operate Equipment Do not operate equipment until you are trained by a qualified operator in its use and capabilities. See your carrier’s manual for these instructions. 3 Operate only from the operator’s seat. Check the seat belt daily and replace if frayed or damaged.
OPERATIONAL SAFETY Transporting the Attachment 3 Travel only with the attachment in a safe transport position to prevent uncontrolled movement. Drive slowly over rough ground and on slopes. 3 When driving on public roads use safety lights, reflectors, Slow Moving Vehicle signs, etc., to prevent accidents.
OPERATIONAL SAFETY Serious injury or death could result if warnings or WARNING instructions regarding hydraulic fluid pressure are not followed properly. 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.
OPERATIONAL SAFETY Prioritized Oil Flow Equipment operators must ensure there is prioritized oil flow to the main valves in overhead operations or high reach conditions. Emergency Situations Always be prepared for emergencies. Make sure a fire extinguisher is available. Be familiar with its operation. Make sure to inspect and service the fire extinguisher regularly.
OPERATIONAL SAFETY Using your Genesis attachment in unauthorized WARNING applications may create an unsafe situation and will void the warranty. Process Material Safely • Do not process hardened steel material such as tool steel, railroad rail, axles, springs, machined parts or high-strength material. Hardened/high-strength material breaks, rather than shears, which may cause flying debris.
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SHEAR NOMENCLATURE Connects the shear head to the shear stick or body. Not used on Slewing Ring straight shears. Houses and protects the hydraulic components used for 360° Shear Sub-Head rotation. Stick-Pin Connection Cylinder pin connection 4 Boom Pivot Connection Rear Cylinder Pin Main cylinder Shear Stick or Body Houses and protects the main hydraulic cylinder.
ROTATION LOCK Rotation (transport) locks are installed at the factory to allow the bracket to be shipped with the mounting pins facing upward. This is beneficial to the end user when removing the attachment from the truck and mounting it to the excavator. Rotation locks MUST be removed before operating the attachment to prevent rotation system damage.
SHEAR 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.
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SHEAR INSTALLATION Be sure hydraulic pressure is relieved before WARNING disconnecting hydraulic fittings. Remove necessary fittings SLOWLY. The attachment is usually shipped in an upright position. Extreme care must be used when inverting the attachment for installation. Follow the excavator OEM’s removal and safety instructions to remove the bucket or other stick attachments.
ROTATOR INSTALLATION The rotator requires a 1/2” minimum case-drain line with a minimum working pressure rating of 250 PSI. Run the -6 Flatface Case drain case-drain line from the rotation head of the shear to a dedicated filter on the excavator, plumbed directly into the main section of the hydraulic tank.
Rotation Circuit - Gear Pump / Rotation Valve / Piston Motor Inside Upper Head Inside Excavator Piston Motor Motor Case Drain Do not exceed 40 PSI while operating. 3 Motion Control Valve Flow Controls Rotate Work Lines Use 1/2” 3000 PSI rated hose. 3 position, tandem center, spring centered, with anti-cavitation Rotation Valve checks.
Rotation Circuit - Auxiliary / Rotation Valve / Piston Motor Inside Upper Head Inside Excavator Piston Motor Motor Case Drain Do not exceed 40 PSI while operating. 3 Motion Control Valve Flow Controls Rotate Work Lines Use 1/2” 3000 PSI rated hose. 3 position, tandem center, spring centered, with anti-cavitation Auxiliary Valve checks.
Rotation Circuit - Auxiliary / Rotation Valve / Gerotor Motor Inside Upper Head Inside Excavator Gerotor Motor 2 Motion Control Valve Flow Controls Rotate Work Lines Use 1/2” 3000 PSI rated hose. 3 position, tandem center, spring centered, with anti-cavitation Auxiliary Valve checks.
Rotation Circuit - Gear Pump / Rotation Valve / Gerotor Motor Inside Upper Head Inside Excavator Gerotor Motor 2 Motion Control Valve Flow Controls Rotate Work Lines Use 1/2” 3000 PSI rated hoses. 3 position, tandem center, spring centered, with anti-cavitation Rotation Valve checks.
Rotation Circuit - Gear Pump / Rotation Valve / Gear Motor Inside Upper Head Inside Excavator Gear Motor Motor Case Drain Do not exceed 40 PSI while operating. 3 Motion Control Valve Flow Controls Rotate Work Lines Use 1/2” 3000 PSI rated hose. 3 position, tandem center, spring centered, with anti-cavitation Rotation Valve checks.
Rotation Circuit - Gear Pump / Auxiliary / Gear Motor Inside Upper Head Inside Excavator Gear Motor Motor Case Drain Do not exceed 40 PSI while operating. 3 Motion Control Valve Flow Controls Rotate Work Lines Use 1/2” 3000 PSI rated hose. 3 position, tandem center, spring centered, with anti-cavitation Auxiliary Valve checks.
HYDRAULIC START-UP Genesis shears 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 shear cylinder after installation. Failure to follow these procedures could result in cylinder seal damage and/or excavator hydraulic system damage.
GENERAL OPERATION INSTRUCTIONS Follow all rules and procedures outlined in the Operation Safety section of this manual. Use the shear only as intended, in approved applications, as set forth in this manual. Do not allow shear, exposed cylinder rod or hoses to come into contact with any obstacles, buildings or the excavator.
GENERAL OPERATION INSTRUCTIONS Cutting Larger Materials When cutting larger materials 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 force, rapidly close the jaw on the material.
GENERAL OPERATION INSTRUCTIONS Pulling / Back-Tracking While pulling down structures is not recommended, it may, at times, be necessary to pull on objects to remove them from a pile or better position pieces to be cut. To minimize stress in the shear body and damage to the pivot components, it is best to keep the shear in line with the boom and stick. If the shear needs to be perpendicular to the boom and stick, the blade side of the shear should face TOWARD the operator.
GENERAL OPERATION INSTRUCTIONS Pushing / Tracking Forward When pushing material, it is best to keep the shear in line with the boom and stick. If the shear needs to be perpendicular to the boom and stick, the blade side of the shear should face AWAY from the operator. Best Best Blades Away...
GENERAL OPERATION INSTRUCTIONS Cutting in a Pile Material that is stacked in a pile has a resistance to movement that causes undo stress in the shear body when you try to cut it. This stress occurs in both straight and rotating units because the shear will work to align itself with the material. It is best to cut material that freely moves so work to free pieces or cut from the top of the pile down.
MAINTENANCE SAFETY Only trained and authorized persons should perform maintenance on the shear. To be qualified, you must understand the instructions in this manual, have training, and know the safety rules and regulations of the job site. Do not alter the physical, mechanical or hydraulic operation of the shear. Doing so may cause a dangerous situation for yourself and those around you and will void the warranty.
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MAINTENANCE SAFETY 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.
MAINTENANCE SCHEDULE Performing scheduled maintenance will promote safe, reliable operation of your shear. Inspect and grease components every eight hours of operation, as indicated on the following checklist. Use maintenance procedures described in this manual. If you are not able to safely and competently perform these procedures, have a Genesis dealer perform them.
MAINTENANCE SCHEDULE Four-Hour Checklist Mid-shift, perform a brief visual check for hydraulic leaks, blade damage, and loose or missing bolts. A more thorough inspection, to be performed at the end of each shift, is described below on the eight-hour checklist. Grease: •...
LUBRICATION POINTS DANGER Shut off excavator and disable hydraulics per OEM instructions before greasing. For normal conditions above 32˚F (0˚C), use a lithium-based, premium grade 2 extreme-pressure grease. For temperatures below 32˚F, use a grade 0 grease. Do not use grease containing Molybdenum (Moly). ®...
BLADE MAINTENANCE Blade and blade seat maintenance greatly affects performance. To maximize cutting performance and optimize the life of replaceable parts, follow this specific sequence of checks, adjustments and maintenance. 1. AutoGuide - shim to tolerance and replace when shims exceed 0.100”. 2.
AUTOGUIDE The AutoGuide (or puck) makes light contact with the wear surface of the upper jaw to maintain proper jaw alignment. Check the puck daily for wear or damage, replacing when grease grooves are no longer visible. Tolerances between the puck and the wear surface should be 0.005” to 0.010”. 3 Check tolerances every eight hours of operation and shim as needed.
PIERCING BLADES Piercing blade maintenance is crucial to productivity and safe shear operation. An improper blade gap may cause material jamming and/or blade breakage. Use the following procedure to check for wear. 1. Slowly close jaws until the piercing blades are flush with the top edge of the razor blade.
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PIERCING BLADES Piercing blades must fit tightly in some areas while having clearance in others. Piercing blades are made from the same material as the cutting blades to withstand the friction caused by piercing hard materials. Areas Highlighted in Blue require contact fit to the upper jaw and tang to prevent shattering.
PIERCING BLADES Replacement 1. Remove blades using an air-impact wrench or breaker bar and multiplier. 2. Remove dust and debris from blade seats; wipe down with a rag and solvent. 3. Lightly file deformities from blade seat edges. Do not sand or grind face of blade seats. 4.
GUIDE BLADES After adjusting the AutoGuide, check guide blade tolerances. When necessary, shim the guide blade to keep the gap within the specifications listed in the Blade Gap table below. Rotate the guide blades when worn to a 1/8” (3 mm) radius. Replace a guide blade when more than 0.075”...
GUIDE BLADES Rotation Remove the blade bolts, guide blade and shims. Rotate the blade end-for-end or side-to-side; reinstall and torque bolts. Check gap; shim if required. If the guide blade faces are excessively worn, the blades cannot be rotated. Excessively worn blades will have uneven surfaces that, when placed upon guide blade seat surfaces, will not be supported and will break, resulting in blade seat damage.
PRIMARY AND SECONDARY BLADES Proper maintenance of the primary and secondary blades, or cutting blades, is required for optimal performance. Blade rotation extends blade life and improves cutting performance. Shimming to maintain blade tolerances helps prevent jamming. Dull blades make the excavator hydraulic system work harder and may cause structural damage to the shear.
PRIMARY AND SECONDARY BLADES Adjustment Plates Do not remove the adjustment plates from the lower jaw during routine blade rotation or replacement. These plates are custom-machined for each shear and need only be replaced when lost, damaged or extremely worn. Inspect the top of each adjustment plate and seat for burrs, nicks or other imperfections that may prevent proper seating of the blades and cause errant blade gap readings.
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 Minimum Maximum...
RAZOR BLADE Check the razor blade for wear every eight hours of operation. Rotate when worn, using the edges in the sequence indicated by the illustration. After rotation, check the gap between the razor blade and piercing blades. If the gap exceeds the maximum tolerance after new piercing blades have been installed, the razor blade must be replaced.
GENERAL WELDING GUIDELINES Build-up and hard-surfacing are welding procedures 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 shear.
BUILD-UP Procedure: Follow the General Welding Guidelines and Rules. 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.
HARD-SURFACING Do not apply hard-surfacing directly to the parent material as this could cause toe cracking, and the hard-surfacing will break away. Procedure: Follow the General Welding Guidelines and Rules. Apply a single pass stringer bead pattern, with the grain, using E7018 electrode.
HARD-SURFACING PATTERNS Upper Jaw Single passes approximately 1” apart. Begin just behind the piercing blade seats and continue toward the throat. Use three to five stringers, depending on the shear model. Grain Staggered stringers Lower Jaw Single passes approximately 1” apart. Work across the top of the chin plate and along the lower jaw toward the throat.
HYDRAULIC/ROTATION MAINTENANCE Hydraulic Requirements Operating the shear below the recommended flow and/or pressure range will adversely affect performance and may damage the rotate motor. Operating the shear above the recommended flow and/or pressure range may damage the shear and its hydraulic components. Model Flow Pressure...
HYDRAULIC/ROTATION MAINTENANCE GenFlow Regeneration Valve Your regeneration valve features a GenFlow adjustment cartridge to control the timing of the shift between speed and power modes. When the cartridge is properly set, the shear closes rapidly until it begins to cut. The valve shifts, slowing jaw close and increasing power. You may hear a squeal or hiss as this happens.
REGENERATION VALVE ADJUSTMENT Requires a hydraulic gauge with a range up to 6000 PSI or higher, with the capability to record the maximum pressure achieved. With the excavator at idle speed, open the shear jaw to full open then slowly close to about 12 inches from full open.
GENFLOW REGENERATION VALVE - HOW IT WORKS Jaw Close in Regeneration: Oil that would normally leave the rod end of the cylinder and return to the tank is diverted to the bore end of the cylinder, increasing flow by approximately 50 percent and speeding up jaw close.
REGEN BLOCK SUB-ASSEMBLY - 320 GPM Pressure Reducing Torque to Valve 6300625 30-35 ft-lbs Logic Valve Torque to Seal Kit 6300622 41-47 Nm 6300623 454-486 ft-lbs Seal Kit 6300624 616-659 Nm Shifts between speed and power Directs oil from rod to tank in power modes.
GENFLOW REGENERATION VALVE - 240 GPM Pressure Reducing Torque to Valve 6300625 30-35 ft-lbs Logic Torque to Seal Kit 6300622 41-47 Nm Valve 6300623 454-486 ft-lbs Shifts between speed and power modes. Seal Kit 6300624 616-659 Nm Directs oil from rod to tank in power mode;...
GENFLOW REGENERATION VALVE - 116 GPM Pressure Reducing Torque to Valve 6300625 30-35 ft-lbs Seal Kit 6300622 41-47 Nm Shuttle Valve Torque to Shifts between speed and power modes. Valve 6301200 30-35 ft-lbs Seal Kit SK00125 41-47 Nm Blocks off path between A & B ports and directs oil to pilot port of Logic Valve.
SLEWING RING MAINTENANCE Visually check slewing ring (rotation bearing) bolts every eight hours of operation. Do not reuse or re-torque these bolts. Loose or broken bolts, along with the bolts on either side, must be immediately replaced. The bolts that secure the slewing ring are critical for safe attachment operation. Improper torque may cause the bolts to fail and the attachment to break free, which may result in serious personal injury and equipment damage.
GEARBOX MAINTENANCE Planetary Gearbox Lubrication Grade Change Proper lubrication is critical to ensure performance Temp. and long life of the gearbox. Change gearbox lubricant 5˚ F 500 hours or after the initial 50 hours of operation. Check gearbox SAE 80W-90W (-15˚...
ROTATION WITH MOTION CONTROL VALVE Counterbalance Valve Relief Valve 1 turn = 400 PSI Relief Valve 1 turn = 400 PSI Counterbalance Valve Flow Control Valve Follow steps 1 - 7 on the previous page to set the crossover reliefs. If you cannot reach the pressure specified in the rotation valve setting table, adjust the counterbalance valves using the following procedure: Turn the crossover relief valve adjustment screws clockwise to their maximum setting, recording...
TROUBLE-SHOOTING GUIDE Symptom Possible Causes/Solutions Check operating pressures and back pressure at port blocks on shear Isolate shear from excavator and check excavator pressures at boom tip Shear may be partially stuck in regen mode; follow adjustment procedure in this manual Low power If speed is good with low power, internal seals on logix cartridge may need to be replaced Possible cylinder, swivel or regen bypass (contact the Genesis Service Department for...
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TROUBLE-SHOOTING GUIDE Symptom Possible Causes/Solutions Material is beyond shear appetite range Material is harder than mild steel Blades are worn beyond 1/8” radius - rotate or replace Blade gaps are too wide for thin material Blade protection strips are too high, causing jaw deflection and excessive blade gaps Piercing tips are worn and need to be squared up or replaced Poor Cutting Too much end play in pivot group - shim to 0.002”...
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TROUBLE-SHOOTING GUIDE Symptom Possible Causes/Solutions Blown fuse Does not rotate Test for 24V at plugs on directional valve while depressing foot switch Incorrect pressure settings; reset No electrical power to one side; test for 24V at plugs on directional valve while depressing foot switch Does not rotate in one direction...
WARRANTY Claim Procedure 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.
PARTS ORDER POLICY AND PROCEDURE Parts Orders Should Include • Purchase order number • Model and serial number of attachment • Part number and quantity needed • Shipping and billing address • Method of shipment or required delivery date Placing Orders Orders may be placed by phone or e-mail.
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