Genesis LXP 200 User manual

Logix Processor (LXP®)
Safety & Operator’s Manual
LXP®200 - 500 Models

1
Genesis LXP®
© 2015 Genesis Attachments, LLC
PREFACE
To ensure years of safe, dependable service, only trained and authorized persons should operate
and service the processor. It is the responsibility of the operator to read, fully understand and
follow all operational and safety-related instructions in this manual. Do not operate the processor
until you have read and fully understand these instructions. Always use good safety practices to
protect yourself and those around you.
IMPORTANT
THIS OPERATORS MANUAL MUST REMAIN WITH THE PROCESSOR AT ALL TIMES!
Should it become damaged or lost, immediately contact any authorized Genesis dealer or contact
the Genesis Service Department at 888-743-2748 or 715-395-5252 for replacement.
Genesis has made every effort to provide information as complete and accurate as possible for
its processors. However, because of owner requirements, equipment and control, variations may
exist. In 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.
Genesis reserves the right to make changes and improvements to its products at any time without
public notice or obligation. Genesis also reserves the right to discontinue manufacturing any
product at its discretion at any time.
REGISTRATION
The Warranty Registration Form must be lled out by the dealer or customer and returned to
Genesis indicating the date the machine went into service.
WARRANTY
All work or repairs to be considered for warranty reimbursement must be pre-authorized by the
Genesis Service Department. Any alterations, modications or repairs performed before authoriza-
tion by the Genesis Service Department wil render all warranty reimbursement consideration null
and void without exception. See page 63 for Warranty Claim Procedures.
A lack of, or improperly performed, maintenance and procedures as set forth in this manual as well
as operator abuse may render warranty consideration null and void.

2Genesis LXP®© 2015 Genesis Attachments, LLC
CONTACT INFORMATION
View and download all manuals at genesisattachments.com/manuals.asp
Asia Pacic Representative Ofce
24 Upper Serangoon View #12-28
Singapore 534205
Phone: [phone]
E-mail:
[email protected]
Brazil
Rua José Alves dos Santos, 281 - Sala - 413
São José dos Campos / SP - Brazil
Phone: [phone]
E-mail:
[email protected]
Europe/Africa/Middle East
Genesis GmbH
Alpenstrasse 71
D-87700 Memmingen, Germany
Phone: [phone]
Fax: [phone]
genesis-europe.com
E-mail:
[email protected]
Central & South America, The Caribbean
Cra 13A #89-38 / O 613
Bogota, Colombia
Phone: [phone]
E-mail:
[email protected]
World Headquarters
Genesis Attachments
1000 Genesis Drive
Superior, WI 54880 USA
Toll Free: 888-SHEAR-IT
(888-743-2748)
Phone: [phone]
Fax: [phone]
E-mail:
[email protected]

3
Genesis LXP®
© 2015 Genesis Attachments, LLC
TABLE OF CONTENTS
SAFETY STATEMENTS 4
GENERAL SAFETY 5
PROCESSOR MARKINGS 12
INSTALLATION 13
Processor Installation 13
Lock Pin Electrical Installation 17
Hydraulic Start-up 18
OPERATION 19
Jaw Set Change-Over 19
MAINTENANCE 21
Maintenance Safety 21
Maintenance Schedule 23
Grease 25
Bolt Torque Specications 26
SHEAR JAW SET MAINTENANCE 31
Piercing Blades 32
Guide Blades 35
Cutting Edges 37
Razor Blade 41
CONCRETE CRACKER JAW SET MAINTENANCE 42
Concrete Cracking Tips 42
Cutting Edges 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
Slewing Ring 55
Planetary Gearbox Lubrication 56
Rotation Circuit 57
TROUBLE-SHOOTING GUIDE 60
Processor Trouble-Shooting 60
Rotator Trouble-Shooting 61
Lock-Pin Trouble-Shooting 62
WARRANTY CLAIM PROCEDURE 63
PARTS ORDER POLICY AND PROCEDURE 64
PARTS ORDER FORM 65
PARTS LISTS 66
Third-Member Mount, Upper Head 67
Second-Member Mount, Upper Head 68
Multi Processor Body 69
Pivot Group Parts (Shear, Cracker, and Pulverizer) 70
Hydraulics 73
Jaw Set Parts (Shear, Cracker, and Pulverizer) 74
Rotation Drive Systems 77
Electrical 79
Tool List 80

4Genesis LXP®© 2015 Genesis Attachments, LLC
SAFETY STATEMENTS
THIS STATEMENT IS USED WHERE SERIOUS INJURY
OR DEATH WILL RESULT IF THE INSTRUCTIONS ARE
NOT FOLLOWED PROPERLY.
THIS STATEMENT IS USED WHERE SERIOUS INJURY
OR DEATH COULD RESULT 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 WITH A SAFETY
SIGNAL WORD THROUGHOUT THIS MANUAL IS
USED TO CALL YOUR ATTENTION TO INSTRUCTIONS
INVOLVING YOUR PERSONAL SAFETY OR THE
SAFETY OF OTHERS. FAILURE TO FOLLOW THESE
INSTRUCTIONS CAN RESULT IN INJURY OR DEATH.
!WARNING
!
CAUTION
!DANGER
!

5
Genesis LXP®
© 2015 Genesis Attachments, LLC
GENERAL SAFETY
NEVER OPERATE AN EXCAVATOR WITHOUT SAFETY
GUARDS INSTALLED.
Safety glass and wire mesh cab guarding must be
installed to protect the operator from ying debris that may
be created during processing. Falling Object Protection
Structures, or FOPS, are required for any application
where material is to be handled overheard. AVOID THIS
SITUATION WHENEVER POSSIBLE.
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.
All local, state/provincial and federal regulations must be
met before approaching power lines, overhead or under-
ground cables, or power sources with any part of the exca-
vator. Do not operate the machine near energized power
lines. Always contact the electrical power company when
operating near power 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 safety of those around you.
Always use common sense while operating and be alert
to unsafe conditions.
Do not operate if an unsafe condition exists. Stop opera-
tion immediately, shut down the machine and report the
unsafe condition to the proper authority.
EXCAVATORS IN OVERHEAD DEMOLITION OR HIGH
REACH APPLICATIONS MUST HAVE PRIORITIZED
OIL FLOW TO THEIR MAIN VALVES.
Processors require high volumes of oil at lower pressures
to open and close the jaw in the non-cutting mode. In the
event of a building or structure collapse, if the excavator
does not have prioritized ow, opening the jaw will render
other functions, such as stick, boom and tracking, slow or
inoperable because oil will go to the path of least resis-
tance, which is the jaw function. Although this is not a
common situation, it must be addressed with your excava-
tor dealer prior to installation.
!DANGER
!WARNING

6Genesis LXP®© 2015 Genesis Attachments, LLC
GENERAL SAFETY
Use all protective clothing and safety devices dictated by the working condi-
tions. These may include but are not limited to:
• Hard hat
• Safety glasses, goggles, or face shield
• Hearing protection
• Safety shoes
• Heavy gloves
• Reective clothing
• Respirator or lter mask
AVOID ENTANGLEMENT HAZARDS. DO NOT WEAR CLOTHING OR
JEWELRY THAT COULD GET CAUGHT IN MACHINERY AND CAUSE
INJURY.
KEEP HANDS, FEET, HAIR AND CLOTHING AWAY FROM MOVING PARTS.
KEEP HANDS AND FEET WITHIN THE OPERATOR PLATFORM.
KNOW THE PINCH POINTS, CRUSHING POINTS AND ROTATING PART
OF THE EQUIPMENT AND 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 rst aid kit and re
extinguisher.
Report all injuries to your supervisor or as directed.
OPERATOR QUALIFICATIONS
Only trained and authorized persons should operate the machine. To be quali-
ed, you must understand the written instructions in this manual, receive train-
ing including actual operation of this machine, and know all safety rules and
regulations of the job site.
Do not operate the machine until you fully understand the function of all con-
trols, indicators and instruments.
PERSONAL SAFETY
DO NOT OPERATE POORLY MAINTAINED, FAULTY EQUIPMENT. INFORM
THE PROPER AUTHORITY AND DO NOT RESUME OPERATION UNTIL
THE PROBLEM HAS BEEN FIXED.
!
!

7
Genesis LXP®
© 2015 Genesis Attachments, LLC
GENERAL SAFETY
MACHINE STABILITY
Your Genesis processor is sized for excavator stability when properly oper-
ated. However, improper operation, faulty maintenance or unauthorized modi-
cations may cause instability.
KNOW THE WORKING RANGES AND CAPACITIES OF THE EXCAVATOR
TO AVOID TIPPING.
USE THE RECOMMENDED EXCAVATOR COUNTERWEIGHT.
The following conditions affect stability:
• Ground conditions
• Grade
• Weight of attachment
• Contents of attachment
• Operator judgment
BEFORE OPERATING
WARN ALL OTHERS IN THE AREA THAT YOU ARE ABOUT TO START
OPERATION.
Perform the Check the Equipment steps outlined in this manual.
Check underneath and 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 operator’s seat.
Do not attempt to operate the controls until you have read and fully under-
stand the safety statements in this manual and the manual for your excavator.
Determine the control for each function before operating the excavator.
Familiarize yourself with the excavator and processor before attempting to
process material. Have the excavator moved to a wide open area. The area
should be solid, level, and free of obstacles such as people, equipment, build-
ings and power lines. With the excavator engine running at a reduced speed,
operate one control at a time. Continue this practice until you have learned
and become comfortable with the function of each control.
!
!

8Genesis LXP®© 2015 Genesis Attachments, LLC
GENERAL SAFETY
Check the Equipment
Before beginning each shift, take the time to check the equipment and have all systems in good
operational condition.
Check the following:
• Warning decals, special instructions and operator’s manuals. Make sure they are legible
and in the proper location.
• Grease ttings. Pump grease at all tting locations.
• Blades and wear surfaces for wear or damage.
• Hydraulic uid level. Add hydraulic uid as required.
• Hydraulic hoses and hose connections for wear or leaks. Repair or replace any damaged
hoses or connections.
• All control levers for proper operation.
• Rotation bearing. Visually check for loose or damaged bolts. If repair is required, refer to
qualied personnel.
• Grease rotation bearing and pinion gear.
Know the Work Area
Check clearances in the work area. Keep all 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 ground conditions. Be aware of unstable or slippery areas and avoid them.
Know the Rules
Most employers have rules governing proper operation and maintenance of equipment. Before
starting work at a new location, ask your supervisor or safety coordinator about rules you are
expected to obey.
Understand trafc rules at your job site. You must recognize and understand all signs, ags and
markings; hand, ag, whistle, siren and bell signals.
Position the Processor
Position the excavator on rm, level ground. Do not operate on slippery ground conditions.
If level ground is not possible, position the excavator to use the processor to the front or back of
the excavator. Avoid working over the side of the excavator.
To avoid tipping and slipping, do not park on a grade exceeding 10% (one-foot rise over the span
of a ten-foot run).
BEFORE OPERATING

9
Genesis LXP®
© 2015 Genesis Attachments, LLC
GENERAL SAFETY
OPERATION SAFETY
Safe operation is the responsibility of the operator. Improper use of the
machine can lead to dangerous situations for yourself, those around you, the
machine and the work area. Practice safe working habits and be aware of
hazardous conditions.
Thoroughly read and understand this entire manual. Follow all safety rules
and practices explained in this manual.
Be seated in the operator’s seat at all times while operating the processor.
Always return the processor to a rest position on the ground before leaving the
operator’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 dealer for a
lighting package.
Do not operate under the inuence of drugs or alcohol, which can affect your
alertness and coordination. If you use prescription or over-the-counter medi-
cation, get medical approval to operate the equipment.
Do not allow riders on the processor. Do not use the processor as a personnel
lift or work platform.
Report all accidents to your supervisor or as directed.
Rotation systems are designed to position the processor during operation, not
as a locking or supporting system during maintenance. Always use proper
blocking procedures during maintenance for operator safety.
!