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Related Manuals for Genesis GDR 150
Summary of Contents for Genesis GDR 150
- Page 1 Demolition Recycler (GDR) SAFETY, OPERATOR’S AND PARTS 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 GDR © 2025 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
ATTACHMENT INSTALLATION Installation Procedure ROTATOR INSTALLATION Foot Switch Installation Rotation Circuit - Gear Pump Type Rotation Circuit - Auxiliary Valve on Machine HYDRAULIC START-UP Start-up Procedure GENERAL OPERATION INSTRUCTIONS Start-up Efficient and Productive Operation Genesis GDR © 2025 Genesis Attachments, LLC... - Page 5 GENFLOW REGENERATION VALVE GDR 150/200/300 GDR 400 SLEWING RING MAINTENANCE ROTATION CIRCUIT Rotation with Motion Control Valve Flow Divider Rotation Gear Pump Rotation GDR 400 MOTOR REPLACEMENT TROUBLE-SHOOTING GUIDE WARRANTY Claim Procedure Blade Warranty © 2025 Genesis Attachments, LLC Genesis GDR...
- Page 6 Returns Warranty Returns PARTS ORDER FORM PARTS Third-member Mount Upper Head GDR 150/200 Cracker Jaw Configuration GDR 300/400 Cracker Jaw Configuration GDR 150/200 Pulverizer Jaw Configuration GDR 300/400 Pulverizer Jaw Configuration GDR 150/200 Shear Jaw Configuration GDR 300 Shear Jaw Configuration...
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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. © 2025 Genesis Attachments, LLC Genesis GDR... -
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 GDR © 2025 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. © 2025 Genesis Attachments, LLC Genesis GDR 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 GDR © 2025 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. © 2025 Genesis Attachments, LLC Genesis GDR 13... -
Page 14: Prioritized Oil Flow
Prop. 65 Warning for California Residents This product may contain chemicals known to the WARNING State of California to cause cancer, birth defects, or other reproductive harm. For more information visit: P65Warnings.ca.gov Genesis GDR © 2025 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 Markings
ATTACHMENT MARKINGS Decals are necessary for safe operation and maintenance. To reorder, contact your Genesis dealer or call 715-395-5252. Serial Number Logo Product Model Viewing Distance Genesis GDR © 2025 Genesis Attachments, LLC... -
Page 17: Transport 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. © 2025 Genesis Attachments, LLC Genesis GDR 17... -
Page 18: Attachment Installation
The attachment must be vertical before putting oil into it or an air lock in the regen valve may prevent the jaw from opening. Note: Genesis’ standard pin material is Induction Hardened Chrome (IHC), which is to be used for all direct pin 2 and 3 member mounting. -
Page 19: Rotator 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. © 2025 Genesis Attachments, LLC Genesis GDR 19... -
Page 20: Rotation Circuit - Gear Pump Type
1/2” 3000 PSI rated spring-centered, with anti-cavitation Valve Motor hose checks. Relief Setting: 1950 (mounted on excavator) Flow Control Inside Upper Head Foot Switch (or Joystick) Gear Pump Mount Valves in required Excavator Genesis GDR © 2025 Genesis Attachments, LLC... -
Page 21: Rotation Circuit - Auxiliary Valve On Machine
Rotate Work Lines: Motion Control with anti-cavitation checks. Use 1/2” 3000 PSI Hydraulic Flow Valve Relief valve setting: 1,950 PSI Controls rated hose Motor (mounted on excavator) Inside Upper Head © 2025 Genesis Attachments, LLC Genesis GDR 21... -
Page 22: 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 cylinder after installation. Failure to follow these procedures could result in cylinder seal damage and/or excavator hydraulic system damage. -
Page 23: General Operation Instructions
Bringing the jaws to full open, when only partial jaw open is needed, 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 life of the attachment. © 2025 Genesis Attachments, LLC Genesis GDR 23... -
Page 24: Common Operational Concerns
So if the attachment is jamming while closing, it won’t have enough retract force to open. Genesis GDR © 2025 Genesis Attachments, LLC... -
Page 25: 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 26 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 GDR © 2025 Genesis Attachments, LLC...
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Page 27: 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. NOTICE Extreme operating conditions may require shortened maintenance intervals. -
Page 28: Lubrication Points
The bracket and rotation should be greased at the end of an eight-hour shift. Grease locations: 1. Bracket pivot 2. Bracket cylinder 3. Attachment cylinder rod 4. Attachment cylinder butt 5. Main shaft/pivot (both sides) 6. Rotation bearing (four locations) 7. Rotation bearing gear teeth Genesis GDR © 2025 Genesis Attachments, LLC... -
Page 29: Tooth And Blade Maintenance
Line 2 1 inch wear - flip, rotate in jaw or build up Line 3 11/2 inch wear - replace, if all points are worn on flippable teeth Contact your local Genesis dealer or the Genesis Parts Department to order. Part... -
Page 30: Cutting 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 31: Blade Gap
Blade Gap After each blade rotation, shim lower blades to keep the gap within a range of 0.005” to 0.015”. Do not shim the upper blades. Use only Genesis shim kits. Blade Gap Measuring Procedure Slowly close jaws until blades begin to bypass. Stop the jaw and check the gap with a feeler gauge. -
Page 32: 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 GDR © 2025 Genesis Attachments, LLC... -
Page 33: Build-Up And Hard-Surfacing
Do not crosshatch the curved areas of the jaws near the pivot. Use only straight stringers on these areas. Grain Grain Follow hard-surfacing instructions on the following page. © 2025 Genesis Attachments, LLC Genesis GDR 33... -
Page 34: 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 previous page for hard-surfacing illustrations and instructions specific to each area of the jaws. Genesis GDR © 2025 Genesis Attachments, LLC... -
Page 35: Hydraulic/Rotation Maintenance
Increase supply pressure to achieve 7-11 GPM 1900 - 2100 PSI approved crossover relief value. Repeat (26-42 LPM) (131 - 145 Bar) procedure in counter-clockwise direction. Then lower supply pressure back to approved value. © 2025 Genesis Attachments, LLC Genesis GDR 35... -
Page 36: 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 GDR © 2025 Genesis Attachments, LLC... -
Page 37: 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 © 2025 Genesis Attachments, LLC Genesis GDR 37... -
Page 38: Genflow Regeneration Valve
Zero-leak plug 6300153 Torque to 250 in-lbs Machine orifice Check valve 6380039 External seal kit SK00026 Torque to 195-209 Ft-lbs Logic valve 6380038 External seal kit SK00026 Torque to 195-209 Ft-lbs O-ring 6300723 O-ring 6300638 Genesis GDR © 2025 Genesis Attachments, LLC... -
Page 39: Gdr 400
Logic valve 6300623 External seal kit 6300624 Zero-leak plug 6300075 Torque to 350-375 Ft-lbs Torque to 40 in-lbs O-ring 6300723 Shuttle valve 6300621 External seal kit 6300622 Torque to 30-35 Ft-lbs O-ring 6300638 © 2025 Genesis Attachments, LLC Genesis GDR 39... -
Page 40: 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. Genesis GDR © 2025 Genesis Attachments, LLC... -
Page 41: Rotation Circuit
ROTATION CIRCUIT To meet diverse customer needs, Genesis offers several rotation valve options. They vary in mounting, function, factory-supplied and customer-supplied parts, and operating advantages. For information on each type of rotation circuit, see the following pages. Valves are factory-set and should not need adjustment. If you believe adjustment is necessary, contact the Genesis Service Department. -
Page 42: Rotation With Motion Control Valve
2500 PSI is reached. • • Repeat steps 6 and 7 for setting the crossover reliefs. If you have questions regarding setting your rotation circuit, please contact the Genesis Service Department. Genesis GDR © 2025 Genesis Attachments, LLC... -
Page 43: Flow Divider Rotation
• Adjust the unloading valve to the pressure specified in the rotation valve settings table. • Plug the wires back into the directional valve. © 2025 Genesis Attachments, LLC Genesis GDR 43... -
Page 44: Gear Pump Rotation
7. Reduce supply pressure to the pressure-reducer valve setting specified on the table for rotation valve settings. Crossport Relief Assembly Control Valve Gear Pump Relief Valve Relief Valve Test Port Counterbalance Valve Flow Control Valve Reservoir Genesis GDR © 2025 Genesis Attachments, LLC... -
Page 45: Gdr 400 Motor Replacement
• Install the new motor ensuring that the timing mark on the spacer ring is aligned prior to torquing the motor bolts. Motor Spacer Timing Mark © 2025 Genesis Attachments, LLC Genesis GDR 45... -
Page 46: Trouble-Shooting Guide
Attachment may be partially stuck in regen mode; follow adjustment procedure 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 Genesis Service Department for procedures) Slow jaw open with... - Page 47 Attachment not kicking out of regeneration or kicking out at too high a pressure range - see Regeneration Valve section of manual Attachment swivel or cylinder is bypassing - contact Genesis Service Department for procedures to check for bypass Excessive blade gaps - shim to specs given in Cutting Blade section of manual...
- Page 48 Rotates too fast or Flow control out of adjustment; reset too slow Jam nut loosened on rotation valve Rotation speed Faulty cartridge (contamination) changed from original Faulty directional control valve setting Pressure set too low; reset Genesis GDR © 2025 Genesis Attachments, LLC...
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Page 49: 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 50: Parts Order Policy And Procedure
Items shipped without an RGA may be returned to sender. Warranty Returns All parts returned to Genesis for warranty consideration must be returned with a completed RGA (Return Goods Authorization) provided by the Genesis Service Department. The form needs to be completed in its entirety, including any additional information requested by the Service Department. -
Page 51: 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 715-395-3488 © 2025 Genesis Attachments, LLC Genesis GDR 51... -
Page 52: Parts
The parts lists included here are intended to aid in operation and maintenance. If further information is required, contact the Genesis Parts Department for a breakdown and parts list specific to your model and serial number. Part numbers listed are those currently used. These may differ from the part numbers of the components originally installed in your attachment. -
Page 53: Third-Member Mount Upper Head
Bearings and/or spacer sleeves, where used Stick pin Inspection/Access cover Bolt (hex head capscrew) Flat washer Custom parts - call the Genesis Parts Department for part numbers specific to your serial number. © 2025 Genesis Attachments, LLC Genesis GDR 53... -
Page 54: Gdr 150/200 Cracker Jaw Configuration
PARTS GDR 150/200 Cracker Jaw Configuration 4, 5, 6 4, 5, 6 7, 8 Part Number Item GDR 150 GDR 200 Description 3501009 3501009 Pulverizing tooth 4500398 1101762 Cutting blade 4500470 1102013 Shim set F0575250 F0588350 Bolt (blade) ¾ - 10 x 2½, ⅞ - 9 x 3½... -
Page 55: Gdr 300/400 Cracker Jaw Configuration
Tooth holder, upper right-hand 3501466 3501825 Blade seat, upper 3501454 3501454 Tooth holder, lower left-hand 3501455 3501455 Tooth holder, lower right-hand 3501458 3501831 Tooth holder, lower center 3501460 3501828 Blade seat, lower © 2025 Genesis Attachments, LLC Genesis GDR 55... -
Page 56: Gdr 150/200 Pulverizer Jaw Configuration
PARTS GDR 150/200 Pulverizer Jaw Configuration 4, 5, 6 4, 5, 6 7, 8 Part Number Item GDR 150 GDR 200 GDR 150 GDR 200 Description 3501009 3501009 Pulverizing tooth 4500398 1101762 Cutting blade 4500470 1102013 Shim set F0575250 F0588350 Bolt (blade) ¾... -
Page 57: Gdr 300/400 Pulverizer Jaw Configuration
Tooth holder, upper, right 3501382 3501855 Blade seat, upper 3501389 3501853 Blade seat, lower 3501385 3501385 Tooth holder, lower, left 3501386 3501386 Tooth holder, lower, right 3501446 3501851 Tooth holder, lower center © 2025 Genesis Attachments, LLC Genesis GDR 57... -
Page 58: Gdr 150/200 Shear Jaw Configuration
PARTS GDR 150/200 Shear Jaw Configuration 4, 5, 6 4, 5, 6 7, 8 Part Number Item GDR 150 GDR 200 Description 3501009 3501009 Pulverizing tooth 4500398 1101762 Cutting blade 4500470 1102013 Shim set F0575250 F0588350 Bolt (blade) ¾ - 10 x 2½, ⅞ - 9 x 3½... -
Page 59: Gdr 300 Shear Jaw Configuration
Tooth holder, upper left-hand 3501479 Tooth holder, upper right-hand 3501488 Blade holder, upper 3501486 Blade holder, lower 3501478 Tooth holder, lower, left 3501479 Tooth holder, lower, right 3501484 Tooth holder, lower, center © 2025 Genesis Attachments, LLC Genesis GDR 59... -
Page 60: Gdr 150 Pivot And Pins
PARTS GDR 150 Pivot and Pins Item Part Number Description 3501322 Shaft 3501318 End cap 3501320 Bearing S0190264 O-ring (bearing) S0190367 O-ring (end cap) 3501268 Shim set F0624060 End cap bolt 6200066 Dowel pin 3501321 Cylinder upper pin 3501323 Cylinder stick pin... -
Page 61: Gdr 200 - 400 Pivot And Pins
Pin Keeper (Upper Pin) 3501742 3501695 3501808 End Cap (Upper Pin) F0616040 F0616040 F0616040 Upper End Cap Bolt * M16 x 2 x 150 ** M20 x 2.5 x 160 ***M20 x 2.5 x 180 © 2025 Genesis Attachments, LLC Genesis GDR 61... -
Page 62: Gdr 150 Cylinder Assembly
Hex Head Capscrew M10 x 1.50 x 90 H0262100 Split Flange 6310161 Adapter Spacer * Part number is Serial Number specific. For replacement parts call the Genesis Parts Department. Europe 715-395-3488 +49 83 31 9 25 98 0 Genesis GDR... -
Page 63: Gdr 200 Cylinder Assembly
Plug 04MB 6310148 Adapter Spacer 6300582 Plug 04MP * Part number is Serial Number specific. For replacement parts call the Genesis Parts Department. Europe 715-395-3488 +49 83 31 9 25 98 0 © 2025 Genesis Attachments, LLC Genesis GDR 63... -
Page 64: Gdr 300 Cylinder Assembly
Lock Washer M12 H0262125 Split Flange S0190222 O-Ring 6310164 Adapter Spacer * Part number is Serial Number specific. For replacement parts call the Genesis Parts Department. Europe 715-395-3488 +49 83 31 9 25 98 0 Genesis GDR © 2025 Genesis Attachments, LLC... -
Page 65: Gdr 400 Cylinder Assembly
Hex Head Capscrew M10 x 1.5 x 90 6310178 Adapter Spacer 3501822 Hose * Part number is Serial Number specific. For replacement parts call the Genesis Parts Department. Europe 715-395-3488 +49 83 31 9 25 98 0 © 2025 Genesis Attachments, LLC... -
Page 66: Rotation Drive System
PARTS Rotation Drive System GDR 150 Item Description Part Number Motor 6380100 Swivel Assy 63500029 Pinion 3502192 Spacer 1107014 Rotation Brg 6100397 Bolts M20 x 2.5 x 90 F0120090 (qty 56) Genesis GDR © 2025 Genesis Attachments, LLC... - Page 67 Pinion 1107014 Mach Spacer 1108183 Mach Bolt Socket Head Capscrew F1900050 Washer Nord Lock 3101226 Mach Washer Motor Pinion F0238100 Hex Head Capscrew ⅜ - 16 x 1 6350066 Assy Swivel Manifold © 2025 Genesis Attachments, LLC Genesis GDR 67...
- Page 68 Bolt - Custom M12 x 1.75 F1900050 Nord Lock Washer F0116240 Bolt M16 x 2 x 240 F1900063 Nord Lock Washer 6300429 Rotation Brg F2802700 Hytorc Washer F0127130 Bolt M27 x 3 x 130 Genesis GDR © 2025 Genesis Attachments, LLC...
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Page 69: Tool List
TOOL LIST The following is a list of tools available for purchase from Genesis. This list may not include every tool used for this attachment, such as those that would also commonly be used for maintaining an excavator. Part Number... -
Page 70: Bolt Torque Specifications
Torque wrenches should be calibrated on an annual basis. When using a torque multiplier with a torque wrench, incorrect settings will be multiplied by the ratio of the torque wrench. Never use an impact driver on a torque multiplier. Genesis GDR © 2025 Genesis Attachments, LLC... -
Page 71: Thread Treatment Diagram
THREAD TREATMENT DIAGRAM Processors Use this diagram to determine what thread treatment, if any, is required for each fastener. For thread treatment application procedures, see page 72. For prescribed torque values, see page 74. © 2025 Genesis Attachments, LLC Genesis GDR 71... -
Page 72: Procedures
• Apply threadlocker to 360 degrees of the threads on the male fitting, ensuring adequate coverage. • Assemble fitting per directions in operator’s manual. • For O-ring boss and flat face O-ring connections, torque fittings to values specified on page 75. Genesis GDR © 2025 Genesis Attachments, LLC... -
Page 73: Anti-Seize
• Torque bolt to specified Wet Torque Value, see page 74. No Thread Treatment • Clean and degrease all threads. • Torque bolt to specified Dry Torque Value, see page 74. © 2025 Genesis Attachments, LLC Genesis GDR 73... -
Page 74: Bolt Torque Specifications
1.00-8 1232 1007 1.00-8 1046 1.00-14 1383 1020 1130 1.00-14 1175 1.25-7 2463 1817 2013 1453 1.25-7 2095 1545 1712 1236 8/L9 1.50-6 4287 3162 3504 2529 8/L9 1.50-6 3644 2688 2979 2150 Genesis GDR © 2025 Genesis Attachments, LLC... -
Page 75: O-Ring Boss & Flat Face O-Ring Torque Specifications
O-RING BOSS & FLAT FACE O-RING TORQUE SPECIFICATIONS O-Ring Boss Torque Values Flat Face O-Ring Torque Values Size Dash Ft-lb Size Dash Ft-lb © 2025 Genesis Attachments, LLC Genesis GDR 75... -
Page 76: Bolt Drive Specifications
5/16" 1/2-20 3/4" 3/8" 5/16" 5/8-11 15/16" 1/2" 3/8" 3/4-10 1-1/8" 5/8" 1/2" 7/8-9 1-5/16" 3/4" 9/16" 1.00-8 1-1/2" 3/4" 5/8" 1.00-14 1-1/2" 3/4" 5/8" 1.25-7 1-7/8" 7/8" 7/8" 1.50-6 2-1/4" 1" 1" Genesis GDR © 2025 Genesis Attachments, LLC... -
Page 77: 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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