Genesis Razer X Safety & Operator Manual Download Page 58

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Genesis GRX

Attachment

Symptom

Possible Cause

Possible Solution

Lacks power

Circuit not getting full pressure from

excavator

Check hydraulic pressure at port block

GenFlow cartridge needs adjustment

Make adjustments following procedure listed

in this manual

Attachment cylinder or swivel bypass

Check for bypass and replace seals if needed

Pilot check seals leaking

Replace seals

Poor cutting

Material size is beyond attachment appetite

range

Consult the factory

Worn blades (shear jaw set)

Refer to Jaw and Blade Maintenance in this

manual

Excess blade gap (shear jaw set)

Pilot check seals leaking

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 adjustments following procedure listed

in this manual

Material jamming

Excess blade gap

Refer to Jaw and Blade Maintenance in this

manual

Insufficient blade gap between piercing tips

and guides

Worn blades (shear jaw set)

Worn piercing blades (shear jaw set)

Slow jaw cycle in one

direction

Excess back pressure on return side of

cylinder

Check excavator main control valve and pilot

check seals

Jaws drift closed or can

be pushed closed

Excavator control valve

Check excavator main control valve

Attachment cylinder or swivel bypass

Check for bypass and replace seals if needed

Pilot check seals leaking

Replace seals

Bleed-down orifice plugged

Clean and replace orifice

TROUBLE-SHOOTING GUIDE

Summary of Contents for Razer X

Page 1: ...Razer X Multi Jaw Demolition Tool GRX SAFETY OPERATOR S MANUAL...

Page 2: ...tchoo genesisattachments com Europe Africa Middle East Genesis GmbH Teramostrasse 23 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 eur...

Page 3: ...nty Registration Form must be filled out by the dealer or customer and returned to Genesis indicating the date the attachment went into service Possible Variations Genesis cannot anticipate every poss...

Page 4: ...uipment 11 Transporting the Attachment 12 Equipment Condition 12 Working Overhead 12 Power Lines 12 Use Care with Hydraulic Fluid Pressure 13 Prioritized Oil Flow 14 Emergency Situations 14 Unsafe Con...

Page 5: ...Measuring Procedure 41 Shimming 41 RAZOR BLADE 42 CRACKER PULVERIZER JAW SET MAINTENANCE 43 Pulverizing Teeth 43 Concrete Cracking Tips 44 Cutting Blades 45 Blade Removal 45 GENERAL WELDING GUIDELINE...

Page 6: ...Attachment 58 Rotator 59 Lock Pin 60 WARRANTY 61 Claim Procedure 61 Blade Warranty 61 PARTS ORDER POLICY AND PROCEDURE 62 Parts Orders Should Include 62 Placing Orders 62 Part Numbers 62 Shipping 62 I...

Page 7: ...n injury or death This statement is used where serious injury or death could result if the instructions are not followed properly WARNING This statement is used where minor or moderate injury could re...

Page 8: ...replace any damaged or worn parts Before Operating 3 Warn all others in the area that you are about to start operation 3 Perform the Check the Equipment steps outlined in this manual 3 Check underneat...

Page 9: ...ng bolts 3 Check cylinders for dents barrel or dings rod GOOD CONDITION P WARNING Serious injury or death could result if warnings or instructions regarding carrier stability and the work area are not...

Page 10: ...5 feet away from the area of operation and equipment movement Let all other workers and bystanders know you are preparing to start DO NOT operate until everyone is clear Always be properly seated in t...

Page 11: ...ges banks and slopes Avoid operating across a slope which could cause the carrier to overturn 3 Reduce speed when driving over rough terrain on a slope or when turning to avoid overturning the carrier...

Page 12: ...ng Object Protection Structures or FOPS are necessary for any application where material is to be handled overhead Transporting the Attachment 3 Travel only with the attachment in a safe transport pos...

Page 13: ...fluid see a doctor immediately 3 Wear safety glasses and protective clothing and use a piece of cardboard or wood when searching for hydraulic leaks Do Not Use Your Hands See illustration below 3 Hyd...

Page 14: ...s 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 e...

Page 15: ...e of compressed springs is extremely dangerous Nothing made of spring material or containing springs should be processed Lift the Load Safely The hydraulic system has been preset and tested by your de...

Page 16: ...p from the factory with lock bolts installed in the body and cylinder lock pins as show below The lock bolts are to be installed any time the tool is transported or maintenance is performed to prevent...

Page 17: ...ore operating the attachment to prevent rotation system damage The rotation locks are located inside the small bolt covers for the slewing ring and marked with a red flag labeled REMOVE ROTATION LOCK...

Page 18: ...on whether the bucket and auxiliary are on separate sides of the main valve and whether the auxiliary circuit can be proportionally controlled by teeing into the bucket pilot control circuit The auxi...

Page 19: ...ely to make sure there is no interference between the bracket and hard lines Also check for interference between the cylinder and boom stick Install excavator hydraulic hoses supply and return from th...

Page 20: ...his line must be below 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...

Page 21: ...SI rated hose Hydraulic Motor Inside Upper Head Mount Valves in Excavator ROTATOR INSTALLATION Motion Control Valve Rotate Lock Pin Selector Valve Flow Controls Rotation Valve Three position tandem ce...

Page 22: ...e on Machine Hydraulic Motor Motion Control Valve Rotate Lock Pin Selector Valve Inside Upper Head Flow Controls Rotate Work Lines Use 1 2 3000 PSI rated hose Rotate Valve Closed center three position...

Page 23: ...er head Inside Upper Head 12V DC ELECTRICAL INSTALLATION Cylinder Pin Body Pin Sub head Harness Jump Harness Boom Stick Harness Cab Harness Fuse Holder 5A Fuse Cab Control Body Cylinder The GRX 295 re...

Page 24: ...may cause pump cavitation 3 Follow the OEM procedures for starting and warming the excavator hydraulic system Do not operate the attachment circuit during the warm up period 3 After the excavator has...

Page 25: ...l ground personnel are clear while making the jaw change JAW SET CHANGE OVER Change over procedure Close jaw set completely prior to setting it in the stand Press and hold CYL switch on the cab contro...

Page 26: ...ody pins Release BODY switch when pins are fully retracted Body pins must be retracted completely prior to lifting the jaw set out of the jaw stand Lift jaw set out of the jaw stand Articulate the GRX...

Page 27: ...Use factory authorized parts The use of unauthorized parts may compromise safety performance and durability of the attachment and may void the warranty Follow the daily checklist and maintenance sched...

Page 28: ...before welding or heating Hazardous fumes dust can be generated when paint is heated by welding soldering or using a torch Do all work outside or in a well ventilated area and dispose of paint and so...

Page 29: ...equire shortened maintenance intervals Four Hour Checklist Inspect Bolts check for loose bolts replace if damaged Fittings and hoses for damage or leaks Bracket pivot for wear and pin retainers Cylind...

Page 30: ...and hard surface as required Concrete cracker jaw set Check blade edge radius Check for loose or damaged bolts retorquing loose bolts when cool Build up and hard surface as required For all jaw sets E...

Page 31: ...recommended for all temperature conditions Grease all fittings every four hours of operation Grease until extrusion is visible After greasing the rotation bearing rotate the attachment through two fu...

Page 32: ...2021 Genesis Attachments LLC Genesis GRX 32 BOLT TORQUE SPECS Bolt torque specs and thread treatment procedures can be found in the Genesis Fastener Manual genesisattachments com manuals...

Page 33: ...es rotate shim to tolerance and replace when worn 3 Primary and Secondary Blades rotate replace when all edges are worn Shim lower blades to tolerance 4 Razor Blade rotate and replace when all edges a...

Page 34: ...raight edge or square 4 Check the profile along the blades 5 Badly worn blades must be replaced However slightly worn blades may be squared up with a grinder and a square This may be repeated until a...

Page 35: ...rcing blade pocket and tang surfaces are straight and true without dings deformations high or low spots or areas that are worn away Piercing blade bolts must not make hard contact with the bolt holes...

Page 36: ...blade seats 8 With a feeler gauge confirm there is a gap where the blades meet Gap width by model is shown below the graphic to the right A very narrow gap may be confirmed by shining a flashlight fr...

Page 37: ...ing clearance possibly to the point of blade interference Therefore in most applications it is beneficial to maintain a wider gap at the guide blades Guide Blade to Piercing Blades Gap Model Minimum M...

Page 38: ...e lower jaw during routine blade rotation or replacement These plates are custom machined for each jaw set and need only be replaced when lost damaged or extremely worn Inspect the top of the adjustme...

Page 39: ...g edges Always use Genesis approved blades Blades that do not meet Genesis specifications can cause major problems and using them may void the warranty Before performing any blade maintenance read ful...

Page 40: ...d in each adjustment plate When replacing adjustment plates make sure these holes are aligned with the corresponding holes in the blade seat Do not grind blade seat areas Rotation Rotate blades when t...

Page 41: ...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 they have been rotated and shimmed correctly If the blade gap excee...

Page 42: ...ustration 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 replac...

Page 43: ...r strike a blade with a hardened steel tool The blade may fragment creating sharp flying debris Pulverizing Teeth As teeth become worn they need to be rotated built up or replaced To help customers de...

Page 44: ...ncrete more efficiently Pulverizing teeth may be welded to tooth holder if desired Concrete Cracking Tips At the end of each shift check the condition of the concrete cracking tips Replace any broken...

Page 45: ...bolts and replace broken bolts 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...

Page 46: ...sconnect all battery ground cables or shut off master battery switch if equipped Failure to do so may cause excavator electrical problems including permanent damage to onboard computer systems Connect...

Page 47: ...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 they do not end in a straig...

Page 48: ...surfacing patterns indicate protection strips in blue These areas should be maintained between blade height and 0 010 lower than blade height These areas protect the bottom unused edges of the blades...

Page 49: ...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 Staggered stringers Grain Lower Jaw Single pas...

Page 50: ...is complete grind material to be flush with the flat surfaces of the tool or if building up a blade seat grind material to be flush with a new blade Hard Surfacing Patterns Where parallel lines are sh...

Page 51: ...ports Stall attachment rotation in clockwise direction Increase supply pressure until pressure at gauge on crossover stops rising This is the crossover relief setting Increase supply pressure to achi...

Page 52: ...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 operator at all times and must stand clear of the attachment jaws...

Page 53: ...ed it results in pressurized fluid on the rod side If left in this mode cylinder power is greatly reduced Jaw Close in Power Mode To provide full power when the upper jaw hits the material the pressur...

Page 54: ...t 6300622 Torque to 30 35 Ft lbs Shuttle valve 6300621 External seal kit 6300622 Torque to 30 35 Ft lbs Machine orifice Zero leak plug 6300153 Torque to 250 in lbs GRX 295 Check valve 6380039 External...

Page 55: ...tachment to break free which may result in serious personal injury and equipment damage Improper torque will also cause uneven slewing ring wear Rotating components must be greased daily Grease fittin...

Page 56: ...valve to the pressure specified in the table for rotation valve settings 6 Repeat for the other direction 7 Reduce supply pressure to the pressure reducer valve setting specified on the table for rot...

Page 57: ...nts LLC Genesis GRX 57 ROTATION CIRCUIT Flow control Flow control Relief Valve Counterbalance Valve Relief Valve Rotate Lock Pin Selector Valve In standard position Rotate function is active Cylinder...

Page 58: ...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 adjustments following procedure li...

Page 59: ...ce valve Rotator 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 exc...

Page 60: ...ggle switch Lock pin selector valve not shifting Replace with Genesis replacement valve Tool misalignment Move tool to correct alignment Hoses between lock pin cylinder and valve connected incorrectly...

Page 61: ...invoice to the Genesis Service Department within 30 days Include itemized internal labor reporting parts lists and invoices for outside contractors Reference the authorization number on all invoices...

Page 62: ...ces open beyond 60 days are subject to review and may be placed on C O D status without further notice Returns Unused Genesis parts may be returned with proper documentation Return shipping is the res...

Page 63: ...tomer Phone Shipping Address Purchase Order Model Date Contact E mail Billing Address Shipping Method Serial Number Quantity Part Number Description Price E mail to the Genesis Parts Department genesi...

Page 64: ...enesis europe com E mail info genesis europe com Central America Colombia Cra 13A 89 38 Ofi 613 Bogota Colombia Phone 57 1 610 8160 795 8747 E mail contact themsagroup com Genesis Attachments 1000 Gen...

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Genesis Razer X, Safety & Operator Manual

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