GXT Mobile Shear

Shear Jaw Armor™

FIELD INSTALLATION MANUAL
 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 genesis-europe.com

E-mail: E-mail:
[email protected] [email protected]

Asia Pacific Representative Office

24 Upper Serangoon View #12-28
Singapore 534205

Phone: +65 9673 9730

E-mail:
[email protected]

Central America & Colombia

Cra 13A #89-38 / Ofi 613
Bogota, Colombia

Phone: +57 1 610 8160 / 795 8747

E-mail:
[email protected]

View and download all manuals: genesisattachments.com/manuals

Patents: genesisattachments.com/products/patents

2 Genesis GXT Shear Jaw Armor™ © 2019 Genesis Attachments, LLC

 TABLE OF CONTENTS
CONTACT INFORMATION2
NOMENCLATURE4
PART NUMBERS6
GENERAL WELDING GUIDELINES8
Welding Ground Clamp8
Welding Rules8
Prepare the Surface8
WELDING PRE-HEAT AND POST-HEAT9
Welding Pre-Heat9
Welding Post-Heat9
DIMENSION AND WELDING SIZE KEY SHEET10
Side View10
Front View12
Detail Views14
TYPICAL EXTEND WELDS16
SET-UP AND TACK PROCEDURE17
Chin Front and Chin Top17
Lower Blade Side18
Lower Guide Side and Guide Blade Seat19
Upper20
NO WELD AREAS21
ROUTINE MAINTENANCE22
CONTACT INFORMATION24

© 2019 Genesis Attachments, LLC Genesis GXT Shear Jaw Armor™ 3

 NOMENCLATURE

2 5

1 4

4 Genesis GXT Shear Jaw Armor™ © 2019 Genesis Attachments, LLC

 NOMENCLATURE
ITEM QTY DESCRIPTION
1 1 Plt Frmd Shear Jaw Armor Lower Blade Side
2 1 Plt Frmd Shear Jaw Armor Lower Guide Side
3 1 Plt Shear Jaw Armor Chin Front
4 1 Plt Shear Jaw Armor Chin Top
5 1 Plt Shear Jaw Armor Guide Blade Seat
6 1 Plt Frmd Shear Jaw Armor Upper

© 2019 Genesis Attachments, LLC Genesis GXT Shear Jaw Armor™ 5

 PART NUMBERS

2 5

1 4

6 Genesis GXT Shear Jaw Armor™ © 2019 Genesis Attachments, LLC

 PART NUMBERS
PART NUMBER
ITEM GXT 115 GXT 225 GXT 335 GXT 445 GXT 555 GXT 665
1 1107458 1105490 1106912 1106595 1106470 1105891
2 1107459 1105491 1106913 1106596 1106471 1105892
3 1107462 1105494 1106916 1106599 1106472 1105893
4 1107461 1105493 1106915 1106598 1106473 1105894
5 1107460 1105492 1106914 1106597 1106474 1105895
SN6651002 & 6651003:
1105896
6 1107457 1105498 1106917 1106600 1106475
SN6651001 & 6651004+:
1106502

PART NUMBER
ITEM GXT 775 GXT 995 GXT 1555 GXT 2055 GXT 2555
1 1106699 1106791 1107046 1107221 1107750
SN15551001, 15551002 & 15551004+:
1107047*
2 1106700 1106792 1107222 1107751
SN15551003:
1107646**
3 1106701 1106793 1107048 1107223 1107752
4 1106702 1106794 1107049 1107224 1107753
5 1106703 1106795 1107050 1107225 1107754
6 1106704 1106796 1107051 1107226 1107755
* PN 1107047 is 3/8” thick.
**PN 1107646 is 1” thick.

© 2019 Genesis Attachments, LLC Genesis GXT Shear Jaw Armor™ 7

 GENERAL WELDING GUIDELINES
When welding around blade seats or the piercing tip tang area, maintain the factory machined
seat radius. If the rounded grooves are welded up, use a die grinder with a carbide tool to recut
these areas to their original profile. Leaving a squared edge will eventually cause structural crack-
ing. The radius provides a broader area to absorb structural stress.

Welding Ground Clamp

Disconnect 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 ground clamp as close as possible to the area being welded without allowing
current to pass through the pivot group, cylinder pin, cylinder, swivel, motor, gearbox or
slewing ring.

If you are welding on the lower jaw, connect weld clamp to the lower. If you are welding on
the upper jaw, connect to the upper but not to the cylinder clevis. If needed, weld a piece of
steel to the area for the grounding clamp and cut the piece off when welding is completed.

Welding Rules
Before you begin:
• Remove adjacent blades, as preheating and welding may cause blade damage.
• Wearing an approved respirator, grind the area to clean it, removing all existing
hard-surfacing.
• Preheat area to 350˚ F (177˚ C). Maintain this temperature throughout the procedure. Do
not exceed 450˚ F (232˚ C) interpass temperature.

During welding:
• Peen each weld pass to relieve stress and harden the welds.
• Do not undercut the ends of the welds.
• Do not start or stop welds directly above a bolt hole or in the apex of the jaw.

After welding maintenance is complete:

• Cover the area with a heat blanket and allow it to cool slowly, approximately eight hours.
• Do not put the shear into operation until the welds have been allowed to cool.

Prepare the Surface

Remove all existing hard-surfacing from the upper and lower jaw areas to which the Jaw Armor is
to be applied.

If required, build-up all areas of the upper and lower jaw parent material so they are flush with the
top of the new blades.

The outer edge of these areas must be squared up The mating surfaces of the upper and lower
jaws must also be built up to conform to the Jaw Armor profile.

8 Genesis GXT Shear Jaw Armor™ © 2019 Genesis Attachments, LLC

 WELDING PRE-HEAT AND POST-HEAT
Welding Pre-Heat
It is critical that the parent material be pre-heated to 350º F (177º C) before welding the Jaw
Armor. For good results, it is essential for the heating to be uniform around the joint area. The pre-
heated area should extend a minimum of 6 inches in any direction away for the weld joint.

To ensure the proper temperature has been reached, using

Temperature Indicating Crayons or an Infrared Thermometer is
recommended.

Welding Post-Heat
Post-heating is critical to relieve internal stress. It is important to slow
the cooling process down as slowly as possible. A weld blanket works well. If not available, fiber-
glass insulation wrapped generously around the weldment is a good substitute.

© 2019 Genesis Attachments, LLC Genesis GXT Shear Jaw Armor™ 9

 DIMENSION AND WELDING SIZE KEY SHEET
Side View

6 Typ.
A

A
B B

( (
D
D

F E
5
E

10 Genesis GXT Shear Jaw Armor™ © 2019 Genesis Attachments, LLC

 DIMENSION AND WELDING SIZE KEY SHEET
ITEM GXT 115 GXT 225 GXT 335 GXT 445 GXT 555 GXT 665
A 1/4” 1/4” 1/4” 1/4” 3/8 3/8
B 1/4” 1/4” 1/4” 3/8” 3/8 3/8
C 9/16” 9/16” 9/16” 5/8” 3/4 3/4
D 3/8” 3/8” 3/8” 3/8” 1/2 1/2
E 3/8” 3/8” 3/8” 3/8” 3/8 3/8
F 3/8” 3/8” 3/8” 3/8” 3/8 3/8

ITEM GXT 775 GXT 995 GXT 1555 GXT 2055 GXT 2555
A 3/8” 3/8” 3/8” 3/8” 3/8”
B 3/8” 3/8” 1/2” 1/2” 1/2”
C 3/4” 11/16” 13/16” 13/16” 15/16”
D 1/2” 1/2” 1/2” 1/2” 1/2”
E 3/8” 1/2” 1/2” 1/2” 1/2”
F 3/8” 1/2” 1/2” 1/2” 1/2”

© 2019 Genesis Attachments, LLC Genesis GXT Shear Jaw Armor™ 11

 DIMENSION AND WELDING SIZE KEY SHEET
Front View

(B)
D
No Weld Here

A See Note
(A)
(B)
2
See Note
No Weld Here See Note

1
A
5
4

3 A

Note: Extend welds 1.50” past the Jaw Armor. Then grind weld ends smooth and taper to parent
metal. See “Typical Extend Welds” on page 16.

12 Genesis GXT Shear Jaw Armor™ © 2019 Genesis Attachments, LLC

 DIMENSION AND WELDING SIZE KEY SHEET
ITEM GXT 115 GXT 225 GXT 335 GXT 445 GXT 555 GXT 665
A 1/4” 1/4” 1/4” 1/4” 3/8 3/8
B 1/4” 1/4” 1/4” 3/8” 3/8 3/8
C 9/16” 9/16” 9/16” 5/8” 3/4 3/4
D 3/8” 3/8” 3/8” 3/8” 1/2 1/2
E 3/8” 3/8” 3/8” 3/8” 3/8 3/8
F 3/8” 3/8” 3/8” 3/8” 3/8 3/8

ITEM GXT 775 GXT 995 GXT 1555 GXT 2055 GXT 2555
A 3/8” 3/8” 3/8” 3/8” 3/8”
B 3/8” 3/8” 1/2” 1/2” 1/2”
C 3/4” 11/16” 13/16” 13/16” 15/16”
D 1/2” 1/2” 1/2” 1/2” 1/2”
E 3/8” 1/2” 1/2” 1/2” 1/2”
F 3/8” 1/2” 1/2” 1/2” 1/2”

© 2019 Genesis Attachments, LLC Genesis GXT Shear Jaw Armor™ 13

 DIMENSION AND WELDING SIZE KEY SHEET
Detail Views

Typ.
A
B

(
D

(
2

5 Typ.
A

4
Detail A No Weld
1

A
(

A 5
F Typ.

Typ. A
F

F 2
3
Detail B

14 Genesis GXT Shear Jaw Armor™ © 2019 Genesis Attachments, LLC

 DIMENSION AND WELDING SIZE KEY SHEET
ITEM GXT 115 GXT 225 GXT 335 GXT 445 GXT 555 GXT 665
A 1/4” 1/4” 1/4” 1/4” 3/8 3/8
B 1/4” 1/4” 1/4” 3/8” 3/8 3/8
C 9/16” 9/16” 9/16” 5/8” 3/4 3/4
D 3/8” 3/8” 3/8” 3/8” 1/2 1/2
E 3/8” 3/8” 3/8” 3/8” 3/8 3/8
F 3/8” 3/8” 3/8” 3/8” 3/8 3/8

ITEM GXT 775 GXT 995 GXT 1555 GXT 2055 GXT 2555
A 3/8” 3/8” 3/8” 3/8” 3/8”
B 3/8” 3/8” 1/2” 1/2” 1/2”
C 3/4” 11/16” 13/16” 13/16” 15/16”
D 1/2” 1/2” 1/2” 1/2” 1/2”
E 3/8” 1/2” 1/2” 1/2” 1/2”
F 3/8” 1/2” 1/2” 1/2” 1/2”

© 2019 Genesis Attachments, LLC Genesis GXT Shear Jaw Armor™ 15

 TYPICAL EXTEND WELDS
Extend welds 1.50” past the Jaw Armor. Then grind weld ends smooth and taper to parent metal.

No Weld

Typical

Typical

16 Genesis GXT Shear Jaw Armor™ © 2019 Genesis Attachments, LLC

 SET-UP AND TACK PROCEDURE
Chin Front and Chin Top
Place Item 3 against the front of the chin while maintaining dimensions “F” and clamp in place.
Center Item 4 from side to side and maintain dimension “D”. Use spacers if necessary to hold
the dimension required between the plates to achieve the correct size welds.

A F

F
3
Figure 17a
Typ.
F

Typ.
A
D

D
(

3
Figure 17b

© 2019 Genesis Attachments, LLC Genesis GXT Shear Jaw Armor™ 17

 SET-UP AND TACK PROCEDURE
Lower Blade Side
Set Item 1 onto the lower blade side, hold the offset dimension (See Figure 18b). Clamp down flush
with the profile and tack weld into position.

A
B B
(

Figure 18a

Figure 18b

18 Genesis GXT Shear Jaw Armor™ © 2019 Genesis Attachments, LLC

 SET-UP AND TACK PROCEDURE
Lower Guide Side and Guide Blade Seat
Set Item 2 onto the lower guide side and hold the offset dimension (See Figure 19b). Clamp down
flush with the profile and tack weld into position. Set Item 5 onto the guide blade seat and hold
the offset dimension (See Figures 19a and b). Clamp down and tack weld into position.

2 B
(

Extend welds 1.50” past the Jaw Armor.

D Then grind weld ends smooth and taper to
parent metal. See “Typical Extend Welds”
A
on page 16.

Figure 19a

A A

Figure 19b

© 2019 Genesis Attachments, LLC Genesis GXT Shear Jaw Armor™ 19

 SET-UP AND TACK PROCEDURE
Upper
Place Item 6 at the bottom of the upper jaw (See Figure 20a). Make sure the plate has the required
width on all sides for the correct size weld. Clamp flush to the jaw profile and tack weld in place.

6
A

A
B Extend welds 1.50” past the Jaw
Armor. Then grind weld ends smooth
D and taper to parent metal. See “Typical
Extend Welds” on page 16.

Figure 20a

Figure 20b

20 Genesis GXT Shear Jaw Armor™ © 2019 Genesis Attachments, LLC

 NO WELD AREAS

No Weld

No Weld

No Weld

© 2019 Genesis Attachments, LLC Genesis GXT Shear Jaw Armor™ 21

 ROUTINE MAINTENANCE
At the 4- and 8-hour maintenance intervals it is important to check the Jaw Armor welds for crack-
ing and wear. Any cracked or worn thin welds need to be addressed as soon as possible to keep
the plates from being torn loose, bent or lost. Cracked or worn welds should be ground or arc
gouged and re-welded using E7018 stick or equivalent wire. Follow all weld procedures and pre-
cautions found in your Genesis GXT Mobile Shear Safety & Operator’s Manual.

Pay special attention to higher wear areas such as the top of the chin plate in front of the razor
blade (Figure 22a), the area behind the piercing tips on the bottom of the upper jaw (Figure 23a) and
the inside corner where Items 3 and 4 meet (Figure 23b), as these are areas where the welds are
most subject to wear.

Contact the Genesis Service Department at 715-395-5252 with any questions.

Figure 22a

22 Genesis GXT Shear Jaw Armor™ © 2019 Genesis Attachments, LLC

 ROUTINE MAINTENANCE

Figure 23a

Figure 23b

© 2019 Genesis Attachments, LLC Genesis GXT Shear Jaw Armor™ 23

 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 genesis-europe.com

E-mail: E-mail:
[email protected] [email protected]

Asia Pacific Representative Office

24 Upper Serangoon View #12-28
Singapore 534205

Phone: +65 9673 9730

E-mail:
[email protected]

Central America & Colombia

Cra 13A #89-38 / Ofi 613
Bogota, Colombia

Phone: +57 1 610 8160 / 795 8747

E-mail:
[email protected]

View and download all manuals: genesisattachments.com/manuals

Patents: genesisattachments.com/products/patents

Rev. I - 8-26-19