Genesis LXP 200 Safety & Operator Manual Download Page 4

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Genesis LXP

TABLE OF CONTENTS

SAFETY

STATEMENTS

GENERAL

SAFETY

PROCESSOR

MARKINGS

INSTALLATION

Processor Installation

Lock Pin Electrical Installation

Hydraulic Start-up

OPERATION

Jaw Set Change-Over

MAINTENANCE

Maintenance Safety

Maintenance Schedule

Grease

Bolt Torque Specifications

SHEAR JAW SET MAINTENANCE

Piercing

Blades

Guide

Blades

Cutting

Edges

Razor

Blade

CONCRETE CRACKER JAW SET MAINTENANCE

Concrete

Cracking

Tips

Cutting Edges

CONCRETE PULVERIZER JAW SET MAINTENANCE

Pulverizing Teeth

WELDING

MAINTENANCE

HYDRAULIC/ROTATION MAINTENANCE

Hydraulic

Requirements

Rotation

Valve

GenFlow

Regeneration

Valve

Slewing

Ring

Planetary

Gearbox

Lubrication

Rotation Circuit

TROUBLE-SHOOTING

GUIDE

Processor

Trouble-Shooting

Rotator

Trouble-Shooting

Lock-Pin

Trouble-Shooting

WARRANTY CLAIM PROCEDURE

PARTS ORDER POLICY AND PROCEDURE

PARTS

ORDER

FORM

PARTS

LISTS

Third-Member Mount, Upper Head

Second-Member Mount, Upper Head

Multi

Processor

Body

Pivot Group Parts (Shear, Cracker, and Pulverizer)

Hydraulics

Jaw Set Parts (Shear, Cracker, and Pulverizer)

Rotation

Drive

Systems

Electrical

Tool

List

Summary of Contents for LXP 200

Page 1: ...Logix Processor LXP Safety Operator s Manual LXP 200 500 Models...

Page 2: ...addition due to Genesis policy of continually striving to improve its products occasional discrepancies may exist between individual processors and the descriptions and information con tained herein...

Page 3: ...2 3905 3405 E mail metalamericas metalamericas com Europe Africa Middle East Genesis GmbH Alpenstrasse 71 D 87700 Memmingen Germany Phone 49 83 31 9 25 98 0 Fax 49 83 31 9 25 98 80 genesis europe com...

Page 4: ...42 CONCRETE PULVERIZER JAW SET MAINTENANCE 44 Pulverizing Teeth 44 WELDING MAINTENANCE 45 HYDRAULIC ROTATION MAINTENANCE 51 Hydraulic Requirements 51 Rotation Valve 51 GenFlow Regeneration Valve 52 Sl...

Page 5: ...IF THE INSTRUCTIONS ARE NOT FOLLOWED PROPERLY THIS STATEMENT IS USED WHERE MINOR INJURY OR PROPERTY DAMAGE COULD RESULT IF THE INSTRUCTIONS ARE NOT FOLLOWED PROPERLY THIS SYMBOL BY ITSELF OR USED WIT...

Page 6: ...wer lines The lines should be moved insulated disconnected or de energized and grounded before operating in the area Equipment operation and maintenance practices directly affect your safety and the s...

Page 7: ...ND AVOID THEM ALL SAFETY GUARDS MUST BE IN PLACE 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 extin...

Page 8: ...around the machine Make sure all personnel and equipment are clear from the area of operation and equipment movement Check clearances in all directions including overhead Be properly seated in the op...

Page 9: ...ll bystanders at a safe distance Do not work under obstacles within the working range of the processor Check the location for overhead and buried power lines or other utilities before operation Check...

Page 10: ...s seat regardless of the reason or length of time away Do not operate without lights if conditions require them If lights are required and your excavator is not so equipped contact your excavator deal...

Page 11: ...ve hydraulic pressure IF MAINTENANCE OR SERVICE IS TO BE PERFORMED MAKE SURE THE ATTACHMENT IS PROPERLY BLOCKED TO PREVENT ACCIDENTAL ROTATION OF THE ATTACHMENT ONTO OPERATOR OR MECHANIC DO NOT RELY O...

Page 12: ...n the jaws over people equipment or buildings Keep a safe dis tance between loaded processor and excavator cab Place the load gently Do not throw or drop the contents of the processor Operate the cont...

Page 13: ...15 Genesis Attachments LLC PROCESSOR MARKINGS Decals are necessary for safe operation and maintenance To reorder contact your Genesis dealer or call 715 395 5252 Logo Serial Number Welded Viewing Dist...

Page 14: ...g an auxiliary circuit spool to the stick circuit helps to reduce back pressure in the system and speed up jaw open and close In certain cases the bucket and auxiliary circuits can be summated to achi...

Page 15: ...rocessor Crowd and extend processor checking closely to make sure there is no interference between processor bracket and hard lines Also check for interference between cylin der and boom stick Install...

Page 16: ...r while rotating and cycling the jaws must never exceed 125 PSI Use the correct fittings Secure the line to the excavator stick Install the foot switch in the excavator and connect with electrical har...

Page 17: ...TION ROTATOR INSTALLATION Lock pin Valve Motor Case Drain Used on LXP 400 500 Models only WARNING Do not exceed 125 PSI while operating Crossover Relief Valve Rotate work lines Use 1 2 3000 PSI rated...

Page 18: ...head 24 Volt 10 11 6 Item Description 1 Mount three way locking toggle switch in excavator cab 2 Lock pin wiring harness sub assembly 3500209 inside upper head 3 Fuse holder 4 Two amp fuse 5 Insulated...

Page 19: ...pump cavitation Follow the OEM procedures for starting and warm up of the excavator hydraulic system Do not operate the processor circuit during the warm up period After the excavator has reached norm...

Page 20: ...Retract cylinders While continuing to hold on processor cylinders retract lever jaw open hit electric switch to retract lock pin Ensure both sides of lock pin have retracted One side may fully retract...

Page 21: ...fore other side begins to extend Shut off the machine Reinstall safety plates after the machine is shut off Slightly extend cylinders to ensure clearance at center formed plate in jaw set Articulate p...

Page 22: ...arts may compromise safety performance and durability of the processor and may void the warranty Follow the daily checklist and maintenance schedules in this manual Extreme conditions may dictate shor...

Page 23: ...LE THEY ARE PRESSURIZED ESCAPING HYDRAULIC FLUID CAN PENETRATE THE SKIN CAUSING SERIOUS INJURY OR DEATH RELIEVE PRESSURE BEFORE PERFORMING MAIN TENANCE KEEP HANDS AND BODY PARTS AWAY FROM PIN HOLES AN...

Page 24: ...d two locations ten pumps per fitting Main shaft end caps both sides five pumps with jaw open five pumps with jaw closed Main shaft lower two locations Rotation bearing four locations Rotation head tw...

Page 25: ...operation check every 250 hours change annually After the first 80 hours of operation check all bolts including slewing ring bolts Replace slewing ring bolts every 2000 hours Replace regeneration val...

Page 26: ...s every four hours of operation Grease until extrusion is visible After greasing the rotation bearing rotate the processor through two full rotations GREASE MAINTENANCE Rear pins one each side Rotatio...

Page 27: ...ed 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 air wrench on a torque multiplier Fastene...

Page 28: ...lts 376 Ft lbs 510 Nm 606 Ft lbs 822 Nm 606 Ft lbs 822 Nm C Guide blade bolts 376 Ft lbs 510 Nm 606 Ft lbs 822 Nm 900 Ft lbs 1220 Nm D Razor blade bolts 376 Ft lbs 510 Nm 606 Ft lbs 822 Nm 606 Ft lbs...

Page 29: ...B A B Item Description 200 300 400 500 A Tip blade bolts 450 Ft lbs 610 Nm 778 Ft lbs 1055 Nm B Cutting blade bolts 376 Ft lbs 510 Nm 376 Ft lbs 510 Nm MAINTENANCE BOLT TORQUE SPECIFICATIONS Visual Re...

Page 30: ...XP 2015 Genesis Attachments LLC Description 200 300 400 500 Tooth bed bolts 778 Ft lbs 1055 Nm 1545 Ft lbs 2095 Nm MAINTENANCE BOLT TORQUE SPECIFICATIONS Visual Reference for Blade Bolt Torque Pulveri...

Page 31: ...QUE SPECIFICATIONS Visual Reference for Rotation and Pivot Bolt Torque Item Description 200 300 400 500 A End Cap Bolts 1138 Ft lbs 1543 Nm 778 Ft lbs 1055 Nm 1545 Ft lbs 2095 Nm B Rotation Bearing Bo...

Page 32: ...2 Guide Blades rotate shim to tolerance and replace when worn Note LXP 200 has only one guide blade 3 Upper and Lower Blades rotate replace when all edges are worn Shim lower blades to tolerance 4 Ra...

Page 33: ...the piercing blades with a straight edge or square Check the profile along the blades Badly worn blades must be replaced However slightly worn blades may be squared up with a grinder and a square This...

Page 34: ...vide clearance Build up tang area highlighted in yellow as needed following the procedures given in this manual After welding surfaces should be squared with a grinder and finished with a file and a m...

Page 35: ...where blades meet at piercing surface A very narrow gap may be confirmed by shining a flashlight from below the blades and seeing light pass through If gap exceeds 010 call the Genesis Service Departm...

Page 36: ...ce Therefore in most appli cations it is beneficial to maintain a wider gap at the guide blades The LXP 200 features a single guide blade as this model does not experience problematic blade expansion...

Page 37: ...LADES Guide Blade Adjustment Plates Do not remove the guide blade adjustment plates from the lower jaw during routine blade rotation or replacement These plates are custom machined for each jaw set an...

Page 38: ...to prevent upper jaw deflection excessive blade wear and undue stress to upper and lower jaws Rotate blades to use all four cutting edges Always use Genesis approved blades Blades that do not meet Gen...

Page 39: ...ment These plates are custom machined for each jaw set and need only be replaced when lost damaged or extremely worn Inspect the top of each adjustment plate for burs nicks or other imperfections that...

Page 40: ...ssed Thin materials may require shorter rotation intervals Blades must be replaced when all four edges are worn to 1 8 3 mm radius The following chart may be copied to track blade rotation Original Bl...

Page 41: ...ith a feeler gauge Cycle the jaws slowly and continue checking the gap at several points along the entire length of the blades Note The gap will be consistent along the entire length of the blades if...

Page 42: ...n After rotation check gap between razor blade and pierc ing blades If gap exceeds maximum tolerance after new piercing blades have been installed the razor blade must be replaced Do not shim the razo...

Page 43: ...ES Proper maintenance of the cutting edges is required for optimal performance of the attachment Blade rotation extends blade life and improves cutting performance Shimming to maintain blade tolerance...

Page 44: ...rotation shim lower blades to keep the gap within a range of 010 to 020 Do not shim the upper blades Use only Genesis shim kits Slowly close jaws until blades begin to bypass Stop the jaw and check t...

Page 45: ...ng gloves safety glasses safety boots and proper clothing Safe removal of pulverizing teeth requires two people one to steady the tooth bed while the other loosens the bolts Tooth beds are heavy and m...

Page 46: ...ore you begin Remove adjacent blades as preheating and welding may cause blade damage Wearinganapprovedrespirator grindtheareatocleanit removingallexistinghard surfacing Preheat area to 350 F 177 C Ma...

Page 47: ...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 Stagger the ends of the stringer welds so...

Page 48: ...or hard surfacing patterns indicate protection strips in blue These areas should be maintained between blade height and 010 lower than blade height These areas protect the bottom unused edges of the b...

Page 49: ...er Jaw Face Single passes approximately 1 apart Begin at the bottom of the upper face and continue approximately 2 3 up the front face Lower Jaw Single passes approximately 1 apart Work across the top...

Page 50: ...material profile with E7018 Apply single passes in each line with the grain of the steel peening after each pass See drawings for grain as indicated by arrows Red lines indicate hard surfacing pattern...

Page 51: ...le with E7018 Apply single passes in each line with the grain of the steel peening after each pass See drawings for grain as indicated by arrows After build up is complete grind material to be flush w...

Page 52: ...Operating the processor below the recommended flow and or pressure range may cause damage to the rotate motor When checking the crossover relief valve settings put pressure gauges on both diagnostic...

Page 53: ...master regeneration valve only this will control the adjustment of the slave regeneration valve as well Regeneration valve adjustment is a two person job The ground crew must be in full view of the op...

Page 54: ...gh this speeds up the cylinder extend speed it also makes the cylinder fight itself If left in this mode cylinder power is greatly reduced Jaw Close in Power Mode To counteract this when the upper jaw...

Page 55: ...orque to 195 209 Ft lbs Zero leak plug 6300153 Torque to 250 in lbs Machine orifice Shuttle valve 6300621 External seal kit 6300622 Torque to 35 Ft lbs Pressure reducer valve 6300625 External seal kit...

Page 56: ...d allow the processor to break free This may result in serious personal injury and damage to equipment Improper torques will also cause uneven wear on the slewing ring Rotating components must be grea...

Page 57: ...Temp Grade Change 5 F 15 C SAE 80W 90W 500 hours or annually 50 F 45 C Synthetic ISO 150 1000 hours or two years Position processor so gearbox is level horizontal at a convenient working height Remove...

Page 58: ...n circuit see the chart below and information on the following pages Valves are factory set and should not need adjustment If you believe adjustment is necessary contact the Genesis Service Department...

Page 59: ...test ports 3 Plug hoses at motor or secure the processor from rotating 4 Pressurize the valve to rotate 5 Adjust the corresponding relief valve to the pressure specified in the table for rotation val...

Page 60: ...h to rotate left or right 6 Adjust the corresponding relief valve to the pressure specified in the table 7 Repeat for the other direction 8 Set the unloading valve before operating Setting the unloadi...

Page 61: ...ng Replace seals Poor piercing shear jaw set Piercing blades or razor blades are worn Refer to Jaw and Blade Maintenance in this manual Slow jaw cycle time Genflow cartridge needs adjustment Make adju...

Page 62: ...chatters Electrical short Test for continuity through circuit Low supply flow Back out flow controls Pressure settings too high Set pressures Supply flow too high Reduce flow from excavator control va...

Page 63: ...with Genesis replacement valve Tool misalignment Move tool to correct alignment Processor cylinder not dead headed open Dead head processor cylinder open and hold while depressing toggle switch Lock p...

Page 64: ...ory Replacement parts must be ordered using a purchase order number Shipping is standard ground Overnight shipping is available by request and Genesis will not cover the shipping charge When the repai...

Page 65: ...st way surface unless an alternate shipping method is requested Shipping charges are not included in the purchase price of parts All invoices are due upon receipt Any accounts with invoices open beyon...

Page 66: ...ne Shipping Address Purchase Order Model Date Contact Fax Billing Address Shipping Method Serial Number Quantity Part Number Description Price Fax to the Genesis Parts Department at 715 395 3411 For a...

Page 67: ...s included here are intended to aid in operation and maintenance If further infor mation is required contact the Genesis Parts Department for a breakdown and parts list specific to your processor mode...

Page 68: ...HIRD MEMBER MOUNT UPPER HEAD Item Description 1 Upper Head 2 Stick Pin 3 Spacer Sleeves where used 4 Pin Keeper 5 Strap 6 Bolt hex head capscrew 7 Lock Washer 8 Port Block Assembly 9 Bearings and or S...

Page 69: ...Strap 6 Bolt hex head capscrew 7 Lock Washer 8 Grease Fitting 9 Boom Bearings 10 Machine Bearings where used 11 Inspection Access Cover 12 Bolt hex head capscrew 13 Flat Washer 14 Port Block Assembly...

Page 70: ...eeper 2 3500831 3500309 3500634 3500022 4 Rear Cylinder Pin 2 3500837 3500342 3500636 3500607 5 Keeper Bolt 2 F0616150 F0620150 F0620180 F0620180 6 Keeper Nut 2 F1016200 F1020250 F1020250 F1020250 7 L...

Page 71: ...4 3500270 3500027 3500027 7 LH Bushing 1 3500817 3500268 3500028 3500028 8 End Cap Bolt F0627050 12 F0624060 16 F0630060 16 F0630060 16 9 Grease Fitting 4 6200002 6200002 6200002 6200002 10 Wiper Seal...

Page 72: ...032 6 Main Shaft Bushings 2 3500817 3500399 3500118 3500118 7 End Cap Bolt F0627050 12 F0624060 16 F0630060 16 F0630060 16 8 Grease Fitting 4 6200002 6200002 6200002 6200002 9 Wiper Seal 2 S0800002 63...

Page 73: ...100326 6 Main Shaft Bushings 2 3500817 3500399 3500118 3500118 7 End Cap Bolt F0627050 12 F0624060 16 F0630060 16 F0630060 16 8 Grease Fitting 4 6200002 6200002 6200002 6200002 9 Wiper Seal 2 S0800002...

Page 74: ...0773 6300773 5 Regen Bolts 12 F0620100 F0620100 F0620100 F0620100 6 Adapter 4 6310004 6310004 6310004 6310004 7 Hose 2 5300263 5300025 5300173 5300019 8 Hose 2 5300262 5300026 5300174 5300021 9 Wiper...

Page 75: ...500395 1103539 1103539 1103539 3 Cutting blades 4 4500397 upper 4500396 lower 1103534 1103536 1103536 4 Guide blades 2 4500398 qty 1 1103540 1103540 1103540 5 Razor blade 1 4500399 1101955 1101955 110...

Page 76: ...00559 3 Cutting blade 2 4500397 4500397 4500396 4500396 4 Tip bolt 24 F0120045 F0124065 F0124060 F0124065 5 Blade bolt 4 F0575250 F0575250 F0575275 F0575250 6 Hex nut 4 F0907510 F0907510 F0907510 F090...

Page 77: ...chments LLC Item Description Qty 200 300 400 500 1 Upper tooth bed 1 3500815 3500780 2 Lower tooth bed 1 3500816 3500781 3 Bolt 24 F0124050 F0130070 4 Flat washer 24 F1202444 F1203056 CONCRETE PULVERI...

Page 78: ...ttachments LLC PARTS LISTS ROTATION DRIVE SYSTEM LXP 200 300 Item Description Part Number 1 Motor 6300159 2 Swivel Assembly 5410015 3 Pinion 3100324 4 Spacer 3100450 5 Rotation Bearing 6100092 6 Bolts...

Page 79: ...LXP 400 500 Item Description Part Number 1 Motor 6300420 2 Gearbox 6300445 3 Swivel Assembly 5410012 4 Rotation Bearing 6300429 5 Bolts qty F0127130 60 6 Washers F1202750 4 1 2 3 5 6 Torque Arm Sub c...

Page 80: ...in 3500211 7 Cable ties not shown included in 3500211 8 Insulated ring terminal green to ground included in 3500211 9 Cable use cable ties to secure along stick boom included in 3500211 10 Plug connec...

Page 81: ...t hex bit socket 3 4 drive 6900006 3 4 drive female to 1 drive male adapter 6900007 1 1 4 combo wrench 6900008 Jet needle scaler 6900009 17mm socket 3 4 drive metric impact 6900010 Torque multiplier 2...

Page 82: ...81 Genesis LXP 2015 Genesis Attachments LLC NOTES...

Page 83: ...etalamericas metalamericas com Europe Africa Middle East Genesis GmbH Alpenstrasse 71 D 87700 Memmingen Germany Phone 49 83 31 9 25 98 0 Fax 49 83 31 9 25 98 80 genesis europe com E mail info genesis...

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