Gsgserviceweb PDF

Scrap Grapple
All Models
Safety &
Operators Manual
Locations
World Headquarters
Europe/Africa/Middle East
Genesis Attachments
1000 Genesis Drive Genesis GmbH
Superior, WI 54880 USA Alpenstrasse 71
D-87700 Memmingen, Germany
Toll Free: 888-SHEAR-IT
(888-743-2748)
Phone: +49 83 31 9 25 98 0
Phone: 715.395.5252 Fax: +49 83 31 9 25 98 80
Fax: 715.395.5255 genesis-europe.com
E-mail: E-mail:
info@genesis-europe.com
info@genesisattach
Asia Pacific Representative Office

24 Upper Serangoon View #12-28
Singapore 534205
Phone: +65 9673 9730
E-mail:
tchoo@genesisattachments.com
Central & South America, The Caribbean

Cra 13A #89-38 / Ofi 613
Bogota, Colombia
Phone: (57-1) 610-8160 / 795-8747
E-mail:
contact@themsagroup.com
Brazil
Rua Jos Alves dos Santos, 281 - Sala - 413
So Jos dos Campos / SP - Brazil
Phone: +55 (12) 3905-3405
E-mail:
metalamericas@metalamericas.com
View and download all manuals at genesisattachments.com/manuals.asp
2 2014 Genesis Attachments, LLC Genesis GSG Scrap Grapple

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 operator to read, fully under-
stand and follow all operational and safety-related instructions in this manual. Do not operate the
attachment until you have read and fully understand these instructions. Always use good safety
practices to protect yourself and those around you.
Registration Form
The Warranty Registration Form must be filled out by the dealer or customer and returned to Genesis
indicating the date the machine went into service.
Important
This operators manual must remain with the attachment at all times.
Manual Replacement
Should this manual become damaged or lost, immediately contact any authorized Genesis dealer or
the Genesis Service Department at 888-743-2748 or 715-395-5252 for a replacement.
Possible Variations
Genesis has made every effort to provide information as complete and accurate as possible for its
attachments. 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 attachments and the descriptions and information
contained herein.
Public Notice
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.
Warranty
All work or repairs to be considered for warranty reimbursement must be pre-authorized by the
Genesis Service Department. Any alterations, modifications or repairs performed before authoriza-
tion by the Genesis Service Department will render all warranty reimbursement consideration null
and void without exception. See page 48 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.
2014 Genesis Attachments, LLC Genesis GSG Scrap Grapple 3

table of contents
Safety statements 10
general safety 11
Read Manual Before Installation
Read and Understand All Safety Statements
Know Your Equipment
Lower or Support Raised Equipment
Do Not Modify Machine or Attachment
Protect Against Flying Debris
General Safety 12
Use Care with Hydraulic Fluid Pressure
General Safety 13
Safely Maintain and Repair Equipment
Transporting the Grapple
Maintaining the Grapple
General Safety 14
Safely Operate Equipment
General Safety 15
Safely Operate Equipment
Know Where Utilities Are
Operator Qualifications
Unsafe Conditions
Emergency Situations
General Safety 16
Personal Safety
Before Operating
Know the Work Area
General Safety 17
Machine Stability
Check the Equipment
Position the Attachment
General Safety 18
Operation Safety
Know the Rules
Lighting
Lockout / Tagout
Process Material Safely
Hydraulic Settings

table of contents
General Safety 19
Fire Hazards
Stability
Place the Load Safely
Fastener Identification
Secure the Load
Starting Procedure
To Start
To Shut Down
General safety 20
High Voltage Lines May Arc
Power Lines
Working Overhead
Prioritized Oil Flow
Maintenance Safety 21
Trained and Authorized
Repairs
Authorized Parts
Schedules
Torque Specs
Welding
Maintenance
Equipment Conditions
Removing Outer Cylinder Guard
Pressurized System
Medical Assistance
Burns
Ventilate the Area
Sanding / Grinding
Prevent Fires
Proper Bolts
Pinch Points & Crush Points
Performing Maintenance
Unsafe Condition
Equipment Condition
Maintenance Schedule
Eight Hour Checklist
Inspect
Grease
Tines
Long-Term Maintenance

table of contents
Maintenance 24
Bolt Torque Specifications
Hydraulic / Rotation Maintenance 25
Mounting Bolts
Bolt Torque
Grease Slewing Ring
Rotate After Greasing
Grease Points - Yoke & Pins
Grease Temperatures
Hydraulic Requirements - GSG075,100 26
Hydraulic Requirements - GSG125,150,200 27
General Arrangement 28
Features 29
Installation 30
Grapple Shipping Condition
Pin Removal
Before Grapple Installation
installation 31
Hydraulic Start-Up
Start-Up Procedure
Swivel seal removal & installation 32
Swivel seal removal & installation 33
Grapple Cylinders Valve Body / Manifold 34
Cylinder Port Arrangement & Sizes
troubleshooting guide 35
Hydraulic Assembly 36
Install Swivel Fittings
Install Swivel in Tower from Below
Hydraulic Component Relationships
Valve Body / Manifold Subassembly
hydraulic Assembly 39
Valve Body / Manifold Installation
Cylinder Subassembly
Cylinder No. 1 / Hose Installation
Install Retract Hose
Cylinders No. 2, 3 & 4 Installation

table of contents
Install Swivel Spool Fittings
Install Head Subassembly
Swivel Torque Arm Installation
Motor Fittings Installation
Install Motor Subassembly
Install Crossport Relief Cartridge
Cylinder Removal & replacement procedure 45
Before Starting Maintenance
Safety Reminder
Remove Outer Cylinder Guards
Remove Lower Cylinder Pin
Remove Cylinder Hoses
Support Cylinder / Remove Upper Pin & Cylinder
Installation
Tine Hardfacing 49
Tine Tip Removal 50
Tine Tip Replacement 51
Warranty Claim Procedure 53
Parts Order policy and procedure 54
Parts order form 55
Glossary 56
Index 57

safety statements
Death Will Result

This statement is used where serious injury or death will
result if the instructions are not followed properly.
Death Could Result

This statement is used where serious injury or death could
result if the instructions are not followed properly.
Damage Could Result

This statement is used where minor injury or property
damage could result if the instructions are not followed
properly.
Call Attention To
This symbol by itself or used with a safety signal word

throughout this manual is used to call attention to instruc-
tions involving your personal safety or the safety of others.
Failure to follow these instructions can result in injury or
death.

GENERAL SAFETY
Read Manual Before Installation
Read this manual before attempting to operate the attachment.
This operators manual should be regarded as part of the attach-
ment. For proper installation, operation or maintenance, opera-
tors and maintenance personnel should read this manual along
with the manuals of the material handler or serious injury or
death could result.
Read and Understand all Safety Statements
Read all safety statements in this manual prior to operating or working on this
attachment. Know and obey all OSHA regulations, local laws and other pro-
fessional guidelines for your operation. Know and follow good work practices
when assembling, maintaining, repairing, mounting, removing or operating this
attachment.
Know Your Equipment
Know your attachments capabilities, dimensions and opera-
tions before operating. Visually inspect your attachment before
you start and never operate an attachment that is not in proper
working order with all safety devices (ex: cylinder guards) in
place. Remove and replace any damaged or excessively worn
parts.
lower or support raised equipment
Do not work under raised booms without supporting them. Do not use support
material made of concrete blocks, logs, buckets, barrels, or any other material
that could suddenly collapse or shift positions. Make sure support material is
solid, not decayed, warped, twisted or tapered. Lower boom and grapple to the
ground before leaving the cab or operators station.
do not modify machine or attachment
Modifications may weaken an attachments integrity and impair its function, life
and performance. When making repairs, use only the manufacturers genuine
parts, following authorized instructions. Other parts may be substandard in fit
and quality. Never modify any ROPS (Roll Over Protection Structure) or FOPS
(Falling Object Protective Structure) equipment or device. Any modifications
must be authorized in writing by the manufacturer.
Protect against flying debris
Always wear proper safety glasses or a face shield
when driving pins in or out, or when an operation causes dust,
flying debris or any other hazardous material.

GENERAL SAFETY
use care with hydraulic fluid pressure
Hydraulic fluid under pressure can penetrate the skin and cause serious injury
or death. Hydraulic leaks under pressure may not be visible. Before connect-
ing or disconnecting hydraulic hoses, read your material handlers operators
manual for detailed instructions on connecting and disconnecting hydraulic
hoses or fittings.
P Keep unprotected body parts, such as face, eyes and

arms as far away as possible from a suspected leak.
Flesh injected with hydraulic fluid may develop
gangrene or other permanent disabilities.
P If injured by injected fluid see a doctor at once. If your

doctor is not familiar with this type of injury, ask him to
research it immediately to determine the proper
treatment.
P 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.

GENERAL SAFETY
Safely maintain and repair equipment
P Do not wear loose clothing or any accessories that
can catch in moving parts. If you have long hair, cover
or secure it so it does not become entangled in the
equipment.
P Work on a level surface in a well lit area.

P Use properly grounded electrical outlets and tools.
P Use the correct tool for the job. Make sure
it is in good condition for the task required.
P Wear protective equipment specified by the tool

manufacturer.
TRANSPORTING THE GRAPPLE

P Travel only with the attachment in a safe transport
position to prevent uncontrolled movement. Drive
slowly over rough ground and on slopes.
P When driving on public roads use safety lights,

reflectors, Slow Moving Vehicle signs, etc., to prevent
accidents. Check local government regulations that
may affect you.
P Do not drive close to ditches, excavations, etc., cave in

could result. Do not smoke when refueling the prime
mover. Allow room in the fuel tank for expansion. Wipe
up any spilled fuel. Secure cap tightly when done.
MAINTAINING THE GRAPPLE

P Before performing maintenance, lower the attachment
to the ground, turn off the engine, remove the key and
apply the brakes. Perform appropriate Lockout / Tagout
procedures.
P Never perform any work on the attachment unless you

are authorized and qualified to do so. Always read the
operators service manuals before making any repair.
After completing maintenance or repair, check for
correct functioning of the attachment. If not functioning
properly, always tag DO NOT OPERATE until all
problems are corrected.
P Never make hydraulic repairs while the system is under

pressure. Serious personal injury or death could result.
GENERAL SAFETY
Safely operate equipment
Do not operate equipment until you are completely trained by a qualified opera-
tor in how to use the controls and know its capabilities, dimensions and all
safety requirements.
See your machines manual for these instructions.
P Operate only from the operators seat. Check the seat belt
daily and replace if frayed or damaged.
P An operator must not be under the influence of drugs or

alcohol, which can change their alertness or
coordination. An operator taking prescription or
over-the-counter drugs should seek medical advice on
whether or not they can safely operate equipment.
P Never leave equipment unattended with the engine running or with

the attachment in a raised position.
P Before exiting the prime mover, lower the attachment to the ground,
turn off the prime movers engine, remove the key and apply the
brakes.
P Do not exceed the lifting capacity of your prime mover.

P When operating on slopes, drive up and down, not
across. Avoid steep hillside operation, which could
cause the prime mover to overturn.
P Reduce speed when driving over rough terrain or on a

slope, or when turning, to avoid overturning the vehicle.
P Never heap-load heavy material where the combined weight of the
bucket and material could exceed the rated lifting capacity of the
loader.
P Never use the attachment for a work platform or personnel carrier.

P Keep all step plates, grab bars, pedals and controls free of dirt,
grease, debris and oil.
P Never allow anyone to be around the equipment when it is operating.

P Do not allow riders on the attachment or the prime
mover.

GENERAL SAFETY
safeLy operate equipment
P Do not alter or remove any safety feature from the
prime mover or this attachment.
P Know your work site safety rules as well as traffic rules

and flow. When in doubt on any safety issue, contact
your supervisor or safety coordinator for an explanation.
P A heavy load can cause instability of the prime mover.

Use extreme care during travel. Slow down on turns
and watch out for bumps. The prime mover may need
additional counter-weights to counter-balance the
weight of the attachment.
KNOW WHERE UTILITIES ARE

Observe overhead electrical and other utility lines. Be sure equipment will clear
them. When digging, call your local utilities for the location of buried utility lines,
gas, water and sewer lines, as well as any other hazards.
Operator Qualifications
Only trained and authorized persons should operate this machine
and attachment. To be qualified, you must understand the written
instructions in this manual and know all safety rules and
regulations of the job site.
Do not operate the machine until you fully understand the function
of all controls, indicators and instruments.
Unsafe Conditions
Do not operate if an unsafe condition exists. Stop operation immediately, shut
down the machine and report the unsafe condition to the proper authority.
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.
Emergency Situations
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 extinguisher.
Report all injuries to your supervisor or as directed.

GENERAL SAFETY
Personal Safety
Use all protective clothing and safety devices dictated by the working conditions.
These may include but are not limited to:
P Hard hat
P Safety glasses, goggles or face shield
P Hearing protection
P Safety shoes
P Heavy gloves
P Reflective clothing
P Respirator or filter mask
Before Operating
Warn all others in the area that you are about to start operation.
Perform the Check the Equipment (Page 17) steps outlined in this manual.
Check underneath and around the machine. Make sure all personnel and equip-
ment are clear from the area of operation and equipment movement. Check
clearances in all directions, including overhead.
Be properly seated in the operators seat.
Do not attempt to operate the controls until you have

read and fully understand the safety statements in
this manual and the OEM manual for your carrier
(skid steer or mini-excavator). Determine the control
for each function before operating the carrier.
Familiarize yourself with the carrier and attach-

ment before attempting to process material. Have
the carrier moved to a wide open area. The area
should be solid, level and free of obstacles such as people, equipment, buildings
and power lines. With the carrier 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.
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 your Genesis attachment.
Check the location for overhead and buried power lines or other utilities before
operation.
Check ground conditions. Be aware of and avoid unstable or slippery areas.

GENERAL SAFETY
Machine Stability
Your Genesis attachment is sized for carrier stability when properly operated.
However, improper operation, faulty maintenance or unauthorized modifications
may cause instability.
P Know the working ranges and capacities of the

carrier to avoid tipping.
P Use the recommended carrier counter weight.

The following conditions affect stability:
P Ground conditions
P Grade
P Weight of attachment
P Contents of attachment
P Operator judgement
Check the Equipment

Before beginning each shift, take the time to check the equipment and have all
systems in good operating condition.
Check the following:
P Warning decals, special instructions and owners manual. Make
sure they are legible and in the proper location.
P Grease fittings. Pump grease at all fitting locations. (See page 25)
P Hydraulic fluid level. Add hydraulic fluid as required.
P Hydraulic hoses and hose connections for wear or leaks. Repair or
replace any damaged hoses or connections.
P All control levers for proper operation.

P Rotation bearing. Visually check for loose or
damaged bolts.
If repair is required, refer to qualified personnel.
P
Good
P Grease rotation bearing and pinion gear. Condition
P Check for loose or missing pin retaining bolts.
Position the Attachment

Position the carrier on firm level ground. Do not operate on slippery ground
conditions.
If level ground is not possible, position the carrier to use the attachment to the
front or back of the carrier. Avoid working over the side of the carrier.
To reduce the risk of tipping and slipping, never park on a grade exceeding 10%
(one-foot rise over the span of a ten-foot run).

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.
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.
Lighting
Do not operate without lights if conditions require them. If lights are required
and your machine is not so equipped, contact your carrier dealer for a lighting
package.
Lockout / Tagout
Rotation systems are designed to position the
attachment during operation, not as a locking or
supporting system during maintenance. Always
use proper blocking procedures during main-
tenance for operator safety. Always practice
lockout/tagout procedures before performing
maintenance.
Process Material Safely

Using your Genesis Scrap Grapple in unauthorized applications may create an
unsafe situation and will void the warranty.
Do not pull down structures with your Genesis Scrap Grapple. Doing so may
cause falling debris, or material may break free and exceed the capacities of the
carrier, causing a tipping hazard.
The rotator should only be used for positioning your Genesis attachment. Do not
use the rotator to pry or break loose material.
Hydraulic Settings
The hydraulic system has been preset and tested by your dealer.
Do not alter hydraulic settings without consulting an authorized
Genesis dealer or Genesis Service Department. Doing so will
void the warranty and may cause structural damage, accidents
or tipping.

GENERAL SAFETY
Fire Hazards
Avoid fire hazards. Keep the area clean. Remove all flammable
materials from the area during any welding or heating process.
Have a fire extinguisher nearby and know how to use it.
Stability
For greater stability, knuckle the grapple to bring the load closer to the center of
rotation (center of gravity) while lifting. Use extra caution during reaching to avoid
tipping.
Place the load safely
Do not move the grapple, or anything held in the tines, over people, equipment or
buildings. Do not throw or drop the contents. Operate the controls smoothly and
gradually. Jerky controls are hazardous and may damage the carrier.
Fastener Identification
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.
Secure the Load

Make sure the load is held securely in the grapple tines. Do not move a loaded
grapple if load is loose or dangling. Make sure the load is pinched between the
tines never cradle a load.
Starting Procedure
Before operating, walk completely around the equipment to make certain no one
is under, on or close to it. Keep all bystanders at least 75 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 the operators seat before operating any carrier
controls.
To start:
P Make sure all controls are in the center (neutral) position.
P Be properly seated.
P Slowly operate all functions to check for proper operation
and to bleed air from the hydraulic system.
To shut down:
P Return your Genesis attachment to a rest position on the ground.
P Shut off the carrier engine.
P Work controls in all directions to relieve hydraulic pressure.

GENERAL SAFETY
High voltage lines may arc
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.
Power Lines
Do not operate the machine near energized power lines. All
local, state/provincial and federal regulations must be met before
approaching power lines, overhead or underground cables, or
power sources with any part of the excavator. 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.
If loose bolts are found, do not operate the Attachment.

Contact the factory.
Stand clear when the Attachment is being rotated. Always

stay in clear view of the operator.
Working Overhead
Avoid handling material overhead whenever possible. Safety
glass and wire mesh cab guarding must be installed to protect the
operator from flying debris that may be created during handling.
Falling Object Protection Structures, or FOPS, are necessary for
any application where material is to be handled overhead.
Prioritized Oil Flow
Material handlers in overhead operations or high reach conditions must have
prioritized oil flow to their main valves.

Maintenance Safety
Trained and Authorized
Only trained and authorized persons should perform maintenance on the grapple.
To be qualified, you must understand the instructions in this manual, have train-
ing, and know the safety rules and regulations of the job site.
Repairs
Do not attempt repairs you do not understand. If any ques-
tions arise regarding a safety or maintenance procedure,
contact Genesis or your Genesis dealer.
Authorized Parts
Use factory authorized parts. The use of unauthorized parts may compromise
safety, performance and durability of the grapple and may void the warranty.
Schedules
Follow the daily checklist and maintenance schedules in this manual. Extreme
conditions may dictate shorter maintenance intervals.
Torque Specs
Do not exceed bolt torque specifications. (See page 24)
Welding
Do not weld on structural components without consulting Genesis. Doing so may
cause structural failure and void the warranty.
maintenance
Do not work on the grapple before ensuring it will not move. Completely lower the
boom to the ground or in a rest position and relieve hydraulic pressure.
Equipment Condition
Never operate poorly maintained equipment. When maintenance is required,
repair or replace parts immediately.
Removing outer Cylinder Guard

The Outer Cylinder Guards are of very heavy construction and
require extra caution and attention when removing and replacing
because of the unexpected weight that will be encountered during
maintenance. DO NOT remove guards by hand due to a possible
arm, shoulder or back hyperextension injury.

Maintenance Safety
Pressurized System
Do not work on any hydraulic lines or components while they are pressurized.
Escaping hydraulic fluid can penetrate the skin, causing serious injury or death.
Relieve pressure before performing maintenance. Keep hands and body parts
away from pin holes and nozzles, which eject fluids under high pressure. Use a
piece of cardboard to search for leaks.
Medical Assistance
If fluid is injected into the skin, seek medical assistance immediately from a doctor
familiar with this type of injury.
Burns
Hydraulic oil becomes hot during operation. Do not let hydraulic oil or compo-
nents contact skin, as it could cause severe burns. Allow hydraulic components
to cool before working on them. Use protective clothing and safety equipment.
If burned, seek immediate medical attention.
Ventilate the Area
Remove paint before welding or heating. Hazardous fumes/dust can be gener-
ated 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 solvent properly.
Sanding / Grinding
When sanding or grinding paint, avoid breathing the dust. Wear an approved res-
pirator. If you use solvent or paint stripper, remove stripper with soap and water
before welding. Remove solvent or paint stripper containers and other flammable
materials from area. Allow fumes to disperse at least 15 minutes before welding
or heating.
Prevent Fires
Avoid fire hazards. Keep the area clean. Remove all flammable materials from
the area during any welding or heating process. Have a fire extinguisher nearby
and know how to use it.
Proper Bolts
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.

Maintenance Safety
Pinch Points & Crush Points
During maintenance or servicing, lifting the attachment by the top pin may cause
the attachment to unexpectedly close, creating a crushing point. The grapple
and grapple tines must be properly blocked during maintenance. With the
grapple hydraulic system drained of oil, this condition may cause the unexpected
movement.
Performing Maintenance
If maintenance or service is to be performed on your Genesis attachment, make
sure it is properly blocked to prevent accidental rotation of the attachment onto
the operator or mechanic. Do not rely on the rotation motor or other rotation com-
ponents to inhibit movement of the attachment during maintenance or servicing.
Always perform appropriate Lockout / Tagout procedures.
Unsafe Condition
Do not operate under unsafe conditions. If an unsafe condition arises during
operation, immediately shut down the equipment and report the situation to the
proper authority.
Equipment Condition
Do not operate poorly maintained or otherwise faulty equipment. Inform the
proper authority and DO NOT resume operation until the problem has been fixed.
Maintenance Schedule
Performing scheduled maintenance will promote safe, reliable operation of your
grapple. 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.
Extreme operating conditions may require shortened maintenance intervals.
Eight-Hour Checklist
inspect
q Bolts - Check for loose bolts, replace if damaged
q Fittings and hoses for damage or leaks
q Cylinders for damage or leaks
q Hydraulic swivel for damage or leaks
Grease
q Slewing Ring, Drive Gear and Grapple Yoke (Page 25)
tines
q Check grapple tines for excessive wear
q Perform build-up and hardsurfacing as needed
Long-Term Maintenance
q Check all bolts for loose washers, including slewing ring bolts, after
the first 80 hours of operation
q Reseal cylinder every 2000 hours
MAINTENANCE
BOLT TORQUE SPECIFICATIONS
P Genesis typically uses dry torque measurements.
P Prior to using the chart below, clean all bolt holes, bolts and nuts to remove
dirt, grease and oil. See the Visual Reference below or Parts Manual to
identify bolt type.
P Never re-torque bolts that use Loctite. After initial use, when Loctite was
applied and the bolt was torqued, if the bolt becomes loose or damaged,
it must be replaced.
P Never break tightened bolts loose with a torque wrench. Doing so may break
the torque wrench or take it out of calibration.
P Torque wrenches should be calibrated on an annual basis.

P When using a torque multiplier with a torque wrench, incorrect settings will be
multiplied by the ratio of the torque wrench.
P Never use an air wrench on a torque multiplier.
Dry Torque Values Wet Torque Values

Fastener Grade Size x Pitch Nm Ft-lb Fastener Grade Size x Pitch Nm Ft-lb
M8 x 1.25 36.5 27 M20 x 2.50 458 338
M10 x 1.50 72 53 CL 10.9 M27 x 3.00 1157 850
M12 x 1.75 125 92 M30 x 3.50 1572 1160
M14 x 1.50 210 154 3/4-10 383 282
M14 x 2.00 200 148 7/8-9 617 455
8
CL 10.9 M16 x 2.00 313 230 1.00-8 916 675
M20 x 1.50 640 472 1.25-7 1847 1362
M20 x 2.50 610 450 9 1.50-12 4067 3000
M24 x 3.00 1055 778
Apply grease or anti-seize on threads and under bolt heads
M27 x 3.00 1543 1138
M30 x 3.50 2095 1545
1/2-13 145 107
Visual Reference
1/2-20 163 120
5/8-11 286 211
3/4-10 510 376
8
7/8-9 822 606
1.00-8 1220 900
1.00-14 1345 992
1.50-6 4280 3160
L9 1.00-8 1152 850
9 1.25-7 2464 1817

HYDRAULIC / ROTATION MAINTENANCE
Mounting Bolts
Visually check slewing ring (rotation bearing) bolts every eight hours of operation
and replace every 2000 hours. Do not reuse or re-torque these bolts. Immediately
replace a loose or broken bolt, and replace the bolts on either side of it. Apply
Loctite to the bolt threads and under the bolt head per Loctite instructions.
Bolt torque
The bolts that secure the slewing ring are critical to safe operation of the attach-
ment. Improper bolt torques may cause the bolts to fail and allow the attachment
to break free. This may result in serious personal injury and damage to equip-
ment. Improper torques will also cause uneven wear on the slewing ring. See
Page 24 for proper bolt torque specifications.
Grease Points
Grease Slewing Ring
Rotating components must be greased daily.
Grease fittings are located on the outside of the
slewing ring and on the inside of the rotating head
assembly. Grease locations are marked with
decals.
Rotate after greasing

Grease each slewing ring grease fitting with several strokes and rotate the
attachment two full rotations after greasing each fitting.
grease Points - Yoke & Bearings

Grapple yoke & pins must be greased daily.
Grease Points
Bearing
Grease Points
Grease Points
Grease Temperatures
For normal conditions above 32F (0C), use a lithium-based, premium
grade 2 extreme pressure grease. For temperatures below 32F, a grade 0
grease is recommended.
HYDRAULIC REQUIREMENTS
Important
Do not operate the Genesis GSG Series Scrap Grapple without first reading and understanding
this Owners Manual.
Genesis GSG075 / GSG100 Scrap Grapple
Tine Circuit
Pressure: Full system pressure or 5000 PSI maximum
Flow: 50 - 75 GPM - (190 - 284 LPM)
Fittings: 3/4 (.75) SAE Flat Face O-Ring Adaptor Fitting
Notes: The tine circuit is equipped with cross-over relief valves.

The valves are factory set to provide optimum performance.
All hydraulic plumbing for the tine circuit must be rated for full machine
pressure.
Rotation
Pressure: 1200 PSI
Flow: 3 6 GPM - (11 - 23 LPM)
Notes: The rotation motor is equipped with a cross-over relief valve. The valves
are factory set to provide optimum performance.
Modifications
Please review this information with an authorized excavator dealer or OEM prior to making any
modifications to the machine. Please call the Genesis Technical Service Department if you have
any questions.

HYDRAULIC REQUIREMENTS
Important
Do not operate the Genesis GSG Series Scrap Grapple without first reading and understanding
this Owners Manual.
Genesis GSG125 / GSG150 / GSG200 / GSG250 Scrap Grapple
Tine Circuit
Pressure: Full system pressure or 5000 PSI maximum
Flow: 60 - 100 GPM - (227 - 378 LPM)
Notes: The tine circuit is equipped with cross-over relief valves.

The valves are factory set to provide optimum performance.
All hydraulic plumbing for the tine circuit must be rated for full machine
pressure.
Rotation
Pressure: 1200 PSI
Flow: 3 6 GPM - (11 - 23 LPM)
Notes: The rotation motor is equipped with a cross-over relief valve. The valves
are factory set to provide optimum performance.
Modifications
Please review this information with an authorized excavator dealer or OEM prior to making any
modifications to the machine. Please call the Genesis Technical Service Department if you have
any questions.

General Arrangement
Grapple Rotate Motor
Upper Head
Slewing Ring
Serial Number
Outer Cylinder (Weld On)
Guard
Product Model Grapple Frame
Under Cylinder
Guard
Grapple Cylinder
Tines

Features
1 Heavy-duty guarding system completely

protects cylinders and internal components:
removes easily for internal maintenance access
5 1
2 Reverse-mounted cylinders protect rods
3 from damage
3 Large bore hydraulic cylinders maximize

2 7 clamping force
4 Internally located manifold provides safe and easy

access to hydraulic hoses
5 High-torque continuous 360 rotation for

handling large and uneven loads
6 Large diameter hardened steel pins with

integrated shear-proof pin retainers
7 Identical hardened steel bearings with dust seals at

all pivot points
6
8 Long-life, abrasion resistant steel tips are
4 easily replaced with simple perimeter weld
9 All tine styles feature fully boxed construction

9 for strength and durability
10 Overall footprint easily fits inside trailers
8
10
Pointed Flat
Tine Tine
B D
B D
C
C
A A
Diagram Dimensions A B C D E
Capacity Weight Min. Machine Jaw Open Jaw Open Jaw Closed Jaw Closed Footprint
Model (yd3) (lbs.) Size (mt) Width (ins.) Height (ins.) Width (ins.) Height (ins.) (ins.)
Tine Shape Flat Point Flat Point Flat Point Flat Point Flat Point
GSG75 0.75 3,800 20 70 71 76 85 63 60 88 95 64 65
GSG100 1 4,000 22 78 79 77 86 66 63 91 98 71 72
GSG125 1.25 4,100 25 85 86 79 88 71 67 95 102 77 78
GSG150 1.5 4,300 30 91 89 81 94 75 72 100 108 80 81
GSG200 2 4,500 40 96 95 82 96 78 76 103 112 84 86
GSG250 2.5 5,200 45 108 105 84 100 86 85 109 118 94 95
Installation
Installation Procedure
Grapple Shipping Condition
The attachment is usually shipped in an upright position. Extreme care must be used when posi-
tioning the attachment for installation. Typically the grapple is shipped without hydraulic oil in the
system. If the grapple is raised but the system is charged, the tines will move / close unexpectedly.
Stand clear when raising the grapple for the first time.
Pin Removal
Removing any connecting pin may be hazardous. To remove
a connecting pin, position the attachment on the ground and
properly support.
Particles may fly when a pin is struck. Use a drift pin or mallet
when striking pins. Keep all personnel at a safe distance.
Before Grapple Installation

Remove bucket or other stick attachments, following the exca-
vator OEMs removal and safety instructions.

installation
Hydraulic Start-up
Genesis grapples are designed to operate under full excavator pressure or up to 5000 PSI. Due to
these high pressures, it is important that air is bled from the shear cylinder after installation. Failure
to follow these procedures could result in cylinder seal damage and/or excavator hydraulic system
damage.
Start-up Procedure:
P Check the excavator hydraulic tank for proper fluid level.
P Follow the OEM procedures for starting and warm-up of the excavator hydraulic system.
Do not operate the shear circuit during the warm-up period.
P After the excavator has reached normal operating temperature, set the engine to idle
speed.
P Slowly fill the bore end of the shear cylinder to partially close the jaws.
P Slowly fill the rod end of the shear cylinder to open the jaws. Note: Do not fully extend
or retract shear cylinder with the first cycles. Use partial strokes extending and retracting,
slowly working to full strokes.
P Stop and check the excavator hydraulic fluid level again to be sure there is still sufficient
fluid. Service as required.
P Cycle the shear jaws five or six times before increasing the full operating pressure.

Swivel seal removal & installation
Apply Loctite #262 to threads

torque to 81 Ft-Lbs
Assemble with U-Cup
(3 Places)
lips facing inward
as shown
13
14 4
Lightly grease area outside

of end seals on each end before
assembly. (Grease either on
spool or each end of housing bore)
Lightly grease
after assembled
in housing groove 6 Assemble with U-Cup
8 lips facing inward
Lightly grease 12
10 11
9
10 11
2
10 11
9
Assemble with U-Cup

8 Assemble with U-Cup
lips facing inward
lips facing inward
as shown
12 Lightly grease
1
Lightly grease 7 5 3
after assembled
in housing groove
Tool List
q Loctite #262 or equal q Clean oil for lubricating parts
q Snap Ring Wrench q Clean solvent for cleaning parts
q Grease to lube parts q Means of getting unit apart / together
q Small, dull, flat-blade screwdriver q Means of dry heating seals or oil bath
q Torch or means of heating screwdriver q Rags
Swivel seal removal & installation
Prior to seal removal, note locations of all seals on spool or if possible take a digital
picture. When servicing this swivel, perform the following:
1. Remove snap ring (Item #3), flat washer (Item #5) and thrust washer (Item #12),
then carefully remove spool (Item #13) from housing (Item #1).
2. Inspect housing bore for any galling or excessive wear.
3. Inspect spool for any galling or excessive wear.
4. Carefully remove seals (Items #8, #10 & #11), thrust washer (Item #12) and wear rings (Items #2 & #9)
from spool. During seal removal, take caution not to scratch or nick seal grooves or spool OD. One method
of seal removal is to heat a small, dull, flat-blade screwdriver with a torch, then carefully press the heated
screwdriver through the seal and twist the screwdriver to break the seal.
5. Carefully remove wiper seals (Items #6 & #7) from housing.
6. AIl parts must be thoroughly cleaned and free of contaminants before assembling new seal kit (use a white
lint-free wiper to clean)
7. Assemble new seal kit as outlined below: Do not assemble energizers or seals out of sequence; this may
cause assembly difficulty or damage seals. When using tape strip, care must be taken when removing it from
the seal after assembled in the necessary groove. Motion of removing tape strip should be slow and away
from backside of seal at an angle. If not careful, scoring of underside edge of seal may occur causing
premature seal failure and/or leakage.
A. Seals (Item #10) need to be heated with dry heat or in oil (not water) to 120-150 F for
5-7 minutes (Do not overheat).
B. While seals are heating, assemble thrust washer (Item #12) onto spool (Item #13).
C. Using tape strip supplied (Item #15), (Do not heat) slightly stretch U-Cup (Item #8) to
seal groove closest to spool head by walking from flow groove to flow groove. Final
assemble with lips facing inward.
D. Slightly stretch energizer (Item #11) to next seal groove closest to spool head by
walking from flow groove to flow groove. One method of assembling energizer without
twisting is to firmly grip energizer 180 degrees apart then walk to necessary groove.
E. Once seals are heated, using tape strip supplied quickly walk seal from flow
groove to flow groove (Do not go into other seal grooves) to seal groove closest to spool
head (approx. 10-15 seconds before seal cools). If seals start to cool before getting to
necessary groove, it may be necessary to reheat seal by carefully removing from
spool. If seal is overstretched during either the assembly or removal step, discard
the seal (dont use, seal may not perform correctly and cause unit to leak).
F. Repeat steps D and E for middle and end energizer and seal. (Install energizer just
before seal).
G. Using tape strip supplied (Item #15), (Do not heat) slightly stretch U-Cup (Item #8) to
seal groove closest to snap ring. Final assemble with lips facing inward.
H. Assemble wear rings (Items #2 & #9) onto spool (Item #13).
J. Assemble wiper seals (Items #6 & #7) into groove on each end of housing
(Item #11).
8. Oil seals and housing bore (areas not greased) prior to assembly.
9. For greased components/areas synthetic grease is recommended.
10. Lightly grease thrust washer, wiper seals and other areas noted on drawing prior to assembly.
11. Carefully reassemble sealed spool (Item #13) into housing (Item #11).
12. Assemble snap ring end thrust washer (Item #12), flat washer (Item #5) and snap ring (Item #3).
13. After unit is assembled into machine, reassemble torque arm (Item #14). Apply loctite #262 to bolt threads
of (Item #4) and torque to 81 Ft-Lbs.

Grapple Cylinders Valve Body / Manifold
Cylinder Port arrangement & Sizes
Cavity Plug
Relief Cartridge
Port: VB Test Port: GB
Port: CB1 Port: CR4
Port: CR1 Port: CB4

Ports 1
Ports 4
Cavity Plug
Relief Cartridge
Test Port: GR
Port: VA
Port: CR2
Port: CB3
Port: CB2
Port: CR3 Ports 3 Ports 2
Supply Ports VA & VB - 12 SAE O-ring Boss

Working Ports - 08 SAE O-ring Boss
Troubleshooting guide
General Grapple Troubleshooting Guide
Possible Possible
symptom
Cause solution
1. Tine lack clamping power A. Excavator is not putting 1. Check excavator circuit
out full pressure to the tine relief valve.
circuit.
2. Adjust the cross-over
B. Cross-over relief valve relief valves.
setting is too low.
3. Replace cylinder seals.
C. Tine cylinder(s) is bypass-
4. Replace swivel seals.
ing internally.
5. Reseal or replace the
D. Shear swivel is bypassing
cross-over relief valves.
internally.
E. Cross-over relief valves are
bypassing.
2. Tines drift open. A. Shear swivel is bypassing 1. Replace swivel seals.

internally.
2. Replace cylinder seals.
B. Tine cylinder(s) is
bypassing internally.
3. Tines closing and A. Flow from excavator is too 1. Check excavator

opening speed is slow. slow. hydraulic system flow.
B. Swivel is bypassing. 2. Replace swivel seals.
C. Tine cylinder(s) is 3. Replace the hydraulic
bypassing internally. motor.
4. Grapple rotation is weak. A. Cross-over relief valve set 1. Check rotation pressure,
too low. adjust or replace the relief
valve.
B. Hydraulic motor is worn.
2. Replace hydraulic motor.
5. Grapple rotation is slow. A. Flow from excavator is too 1. Check excavator

slow. hydraulic system flow.
B. Worn hydraulic motor. 2. Replace the hydraulic
motor.

hydraulic assembly
Hydraulic swivel Subassembly
1. Assemble the swivel (P/N 6350039)

with the barrel port hydraulic fittings as
shown.
P/N 6310036 P/N 6310036

Torque Specs Torque Specs
125 - 135 Ft-Lb. 125 - 135 Ft-Lb.
170 - 183 Nm 170 - 183 Nm
Barrel - Port 2
Barrel - Port 1 Barrel fittings
face straight
down.
Figure 36a - Install Swivel Fittings
(4) F0116035 - Hex Head Capscrew M16 x 2.0

(4) F1201630 - Flat Washer M16 Barrel - Port 1
Swivel Mounting Bolt Torque Specs
230 Ft-Lb.
313 Nm
Figure 36b - Install Swivel in Tower from Below

hydraulic assembly
Hydraulic component relationships
Cylinder No. 3
Cylinder No. 2
Cylinder No. 4
Cylinder No. 1
Swivel Barrel
Port Number 1
Valve Manifold
Port VB

hydraulic assembly
Valve Body / Manifold SubAssembly
P/N 6390017 - Cavity Plug P/N 6300916 - Relief Valve
Torque Specs Torque Specs
350 - 375 Ft-Lb 24 - 26 Ft-Lb
475 - 500 Nm 32.6 - 35.4 Nm
Manifold Block
P/N 6310915
Port VB
P/N 6310036 - Adaptor 3/4 - 90
Torque Specs
125 - 135 Ft-Lb
170 - 183 Nm
Port CB12
Port CB1 P/N 6300017 Adaptor
P/N 6300017 Adaptor 1/2 Straight 1/2 Straight
50 - 60 Ft-Lb 50 - 60 Ft-Lb
68 - 78 Nm
Ports 1 Ports 4 68 - 78 Nm
Figure 38a - Install Fittings on Cylinder 1 Side
Port VA
P/N 6310036 - Adaptor 3/4 - 90
Torque Specs
125 - 135 Ft-Lb
170 - 183 Nm Port CB3
P/N 6300017 Adaptor
1/2 Straight
Port CB3 Torque Specs
P/N 6300017 Adaptor 1/2 Straight 50 - 60 Ft-Lb
Torque Specs 68 - 78 Nm
50 - 60 Ft-Lb
68 - 78 Nm
Ports 3 Ports 2
Figure 38b - Install Fittings on Cylinder 3 Side

hydraulic assembly
Valve Body / Manifold installation - Cylinder Subassembly
Reference
Port 1
(4) F0112180 - Hex Head Capscrew M12 x 1.75

(4) F1201224 - Flat Washer M12
Torque Specs
92 Ft-Lb
125 Nm
Manifold Block Subassembly

P/N 6310915
Reference
Port VB
Figure 39a - Install Valve Body / Manifold
P/N 6300302 - Adaptor 1/2 45

Torque Specs
50 - 60 Ft-Lb
68 - 78 Nm
Retract
Models GSG075, GSG100 - Cylinder P/N 6350037

Models GSG125, GSG150, GSG200 - Cylinder P/N 6350036 Extend
Figure 39b - Cylinder Subassembly

hydraulic assembly
Cylinder No. 1 / Hose installation
P/N F0124050 - Hex Head Capscrew M24 x 3 x 50

P/N 2200232 - Mach Washer
Torque Specs
778 Ft-Lb
1055 Nm Wldt Pin P/N 2200255
P/N 5300411 - Assembly Hose Cylinder No. 1

Torque Specs
32 - 40 Ft-Lb
43 - 54 Nm
(EXT on Cylinder to CB1 on
Valve Body / Manifold)
Figure 40a - Install Cylinder No. 1 and Extend Hose
P/N 5300412 - Assembly Hose

Torque Specs
32 - 40 Ft-Lb
43 - 54 Nm
(RET on Cylinder to CR1 on
Valve Body / Manifold)
Figure 40b - Install Retract Hose

hydraulic assembly
Cylinders No. 2, 3 & 4 installation
Port CB2 Port CR2 Port CB4 Port CR4

P/N 6300017 Adaptor P/N 6300017 Adaptor P/N 6300017 Adaptor P/N 6300017 Adaptor
1/2 Straight 1/2 Straight 1/2 Straight 1/2 Straight
50 - 60 Ft-Lb 50 - 60 Ft-Lb 50 - 60 Ft-Lb 50 - 60 Ft-Lb
68 - 78 Nm 68 - 78 Nm 68 - 78 Nm 68 - 78 Nm
Figure 41a - Valve / Manifold Fittings Figure 41b - Valve / Manifold Fittings
Cylinder No. 2 Location Cylinder No. 4 Location
1. Install Cylinder No. 3 (back side

of tower) and hoses in the same
manner as Cylinder Number 1
2. Install Cylinder No. 2 3. Install Cylinder No. 4
Figure 41c - Cylinders No. 2, 3 & 4 Installation

hydraulic assembly
Swivel fittings and head installation
P/N 6310034 - Adaptor 3/4 45

Torque Specs
65 - 80 Ft-Lb.
90 - 110 Nm
Figure 42a - Install Swivel Spool Fittings
Head Subassembly
(1) P/N 2200291 - Head Wtmg
(1) P/N 6300900 - Slewing Bearing
(20) P/N F0116080 - Hex Head Capscrew M16 x 2 x 80

(20) P/N F1201630 - Flat Washer M16
Torque Specs
230 Ft-Lb.
313 Nm
Figure 42b - Install Head Subassembly

hydraulic assembly
Swivel Torque arm / motor fittings installation
(3) P/N 6300952 - Hex Head Capscrew

M12 x 1.75x 45
Torque Specs
P/N 6300962 - Torque Arm 92 Ft-Lb.
125 Nm
Figure 43a - Swivel Torque Arm Installation
Relief Valve Port

DO NOT install until
Face fittings
after the motor has been
straight up
installed in grapple head
P/N 6300303 - Adaptor 1/2 90 P/N 6300901 - Pinion

Torque Specs P/N F0375201 - Hex Head
125 - 135 Ft-Lb. Capscrew 5/8-11 x 1
170 - 183 Nm Torque Specs
376 Ft-Lb.
510 Nm
Figure 43b - Motor Subassembly

hydraulic assembly
Motor subassembly installation
Motor Subassembly
(4) F1201630 - Socket Head

Capscrew M12 x 1.75
Torque Specs
92 Ft-Lb
125 Nm
Figure 44a - Install Motor Subassembly
P/N 6300902 - Cartridge, Crossport Relief

Torque Specs
24 - 26 Ft-Lb
33 - 35 Nm
Figure 44b - Install Crossport Relief Cartridge

Cylinder Removal & replacement procedure
1. Before starting any maintenance

work on the grapple, support the
weight of the grapple at the bottom
of the frame.
Safety Refresher
Read and Understand all Safety Statements Page 11

lower or support raised equipment Page 11
Maintenance Page 21
Removing outer cylinder guard Page 21
Pressurized System Page 22
Pinch points and crush points Page 23

2. Remove outer
cylinder guards
3. Remove lower
cylinder pin

4. Remove cylinder hoses

from the valve body / manifold
subassembly.
5. Support the cylinder with suitable lifting device (ex. jib crane)
and strap, rigged choke style. Remove the upper pin and
remove the cylinder.

6. Remove cylinder hoses and

note the position of the adaptors
before removing them.
Extend
Retract
Note: Primarily from this point on, follow the same instructions, only in reverse.
7. Install adaptors on new cylinder with the same orientation.
8. Lift cylinder with a strap, choke style, and line up the upper cylinder bore with the
main frame bores. Install the pin and retaining bolt.
9. Connect the extend hose (90 end) to the valve body / manifold subassembly,
finger tight only. Connect the other end (straight end) to the cylinder. Tighten both
ends 32-40 Ft-Lbs (43-54 Nm).
10. Connect the retract hose (90 end) to the valve body / manifold subassembly,
finger tight only. Connect the other end (straight end) to the cylinder. Tighten both
ends 32-40 Ft-Lbs (43-54 Nm).
11. Lower Cylinder and line up lower cylinder bore with the tine bore and install pin.
12. Loctite and install the pin retainer bolts and torque to specs.

Tine HardSurfacing
Suggested Tine hardSurfacing procedure
Do not apply hardsurfacing directly to the parent material
as this could cause toe cracking, and the hardsurfacing will
break away.
Procedure:
Follow these general welding guidelines and rules.
Apply a single pass 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. Taper ends
Hardsurface Grain
bead
Stagger the ends of the stringer welds so they do not end in
Stringer
a straight line.
bead
Cap each stringer bead with one pass of GenWire or GenRod
to hardsurface. Do not apply more than two layers of hardsur-
facing. Peen each pass.
Grind
Grind the ends of all stringer welds, with the grain to taper 1 with
Stagger ends
grain
to 1-1/2 (31-38 mm) to the parent material.
See the following page for hardsurfacing illustrations and 1/4 from edge
instructions specific to each area of the tines.
Staggered stringers
Crosshatch the inside roll plate with

stringer beads at 45 angles to form 1
squares.

Tine Tip Removal
Tip Removal:
The joint between the tip and tine is a
straight line. When arcing the remaining
tip, care must be taken not to carve into the
parent metal. (Arc off weld only).
Re-bevel inside
roll plate
Joint line between tine and tip

Arc out along this line
Angle can
be used as a
straight edge
during installation
of new tip.
Figure 46a
Edges should be
straight and square.
Weld on:
Inside roll plate should be re-beveled before
welding on new tip. All excess weld on tine
plates should be removed. (Tine should look
Bevel inside roll plate like Fig. 46b)
Figure 46b

Tine Tip Replacement
Factory Welding Process
Tine Plate
Inside Roll Plate
Note: It is important to
duplicate this process when
replacing the tip.
1/2
3 Sides
1/2
Tip
Figure 47a
Angles to help
center new tip.
The new tip can be located using

(3) pieces of straight angle (or bar).
Depending on the tine shape (point or
flat), the tip may be flush with the angle
at widest or narrower, in either case
the tip should be centered between the
two angles as it sits squarely on the
end tine.
Center tip
between bars
Figure 47b
Warranty Claim Procedure
Notify the Genesis Service Department of the potential warranty claim prior to making the repair.
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.
The Genesis Service Department will issue an authorization number to track the repair costs, out-
going parts, and/or defective parts returning to the factory.
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 repair is complete, submit an 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.
When returning parts for warranty consideration, include a copy of any related Genesis paperwork
along with any other necessary documentation to ensure proper processing and credit. The
Genesis Service Department will provide the necessary forms.
Your account will be credited when the warranty claim is accepted.
Please direct any questions to the Genesis Service Department: 715-395-5252

parts order policy and procedure
Order Placement
Parts orders should include the following:
q Purchase order number

q Model and serial number of attachment
q Part number and quantity needed
q Shipping and billing address
q Method of shipment or required delivery date
Placing Orders
Orders may be placed by phone, e-mail or fax. To fax an order, use the form on the following page.
Contact information is located at the front of this manual.
Part Numbers
Part numbers are listed in the Parts Manual. Contact the Genesis Parts Department with questions
regarding part numbers, availability and pricing.
Parts Policy
Shipping
All orders will be shipped best way surface unless an alternate shipping method is requested.
Shipping charges are not included in the purchase price of parts.
Invoices
All invoices are due upon receipt. Any accounts with invoices open beyond 60 days are subject to
review and may be place on C.O.D. status without further notice.
Returns
Unused Genesis parts may be returned with proper documentation. Return shipping is the respon-
sibility of the purchasing party. Credit will be issued upon return, less a 20% restocking fee.
Documentation is required for credit of returned parts. Contact the Genesis Parts Department at
715-395-5252 for a RGA (Return Goods Authorization) number and form.
Return Good authorization

All parts returned to Genesis for warranty consideration must be returned with a completed RGA
(Return Goods Authorization) provided by the Genesis Parts Department. The form needs to be
completed in its entirety; including any additional information requested by the Parts or Service
Department. Return freight is the responsibility of the shipper and will be credited upon claim
approval. A determination to accept or deny the claim will be made based on the information avail-
able to Genesis. Warranty on purchased parts other than wear components is 6 months. There is
no warranty period on wear parts or components.

Parts Order Form
Date:
Customer: Contact:
Phone: Fax:
Shipping Address: Billing Address:
Purchase Order: Shipping Method:
Model: Serial Number:
Quantity Part Number Description Price
Fax to the Genesis Parts Department at 715-395-3411

For assistance, call 715-395-5252 or e-mail genesisparts@paladinbrands.com
Glossary
Terms used in this manual
Anti-seize - A material used to prevent cohesion of parts moving relative to each other.
Attachment - Scrap Grapple
Authorized Employee - An employee who can lockout or tagout machines or equipment in

order to perform servicing or maintenance on that machine or equipment. An affected employee
becomes an authorized employee when that employees duties include performing servicing or
maintenance.
Dry Torque - Any bolt that is not lubricated or coated with an antiseize compound.
Energized - Connected to any source of stored or live energy of electrical, mechanical,

hydraulic, pneumatic, chemical or thermal natures.
FOPS - Falling Object Protective Structure
Good Work Practices (Examples)

P Practicing good housekeeping;
P Wearing personal protective equipment;
P Applying first-aid procedures (if trained);
P Using good ergonomic principles;
P Wearing respiratory protection;
P Using and following lockout/tagout procedures;
P Using and following confined-space entry;
P Using hazard communication;
P Avoiding blood-borne pathogens, if applicable.
Lithium-based Grease - Heat-stable, water-resistant lubricating grease with lithium salts

of higher fatty acids (or lithium soaps of fatty glycerides) as a base; used for low-temperature
service.
Loctite - A brand of, among others, bonding adhesives, thread lockers and thread sealants.
Lockout - Lock the only means to re-energize equipment prior to servicing or maintenance.
Material Handler - Vehicle on which the grapple is mounted.
OEM - Original Equipment Manufacturer

OSHA - Occupational Safety and Health Administration (OSHA) An agency of the United States
Department of Labor. Its mission is to prevent work-related injuries, illnesses and occupational
fatalities by issuing and enforcing standards for workplace safety and health.
Prime Mover - Vehicle on which the grapple is mounted.
RGA - Return Goods Authorization
ROPS - Roll Over Protection Structure
SAE Flat Face O-Ring Adaptor Fitting - For optimal leakage control in medium and high
pressure hydraulic systems. The male fitting has a straight thread and O-ring. The female port has
a straight thread, a machined surface (minimum spot face) and a chamfer to accept the O-ring.
The seal takes place by compressing the O-ring in the chamfer. The threads hold the connection
mechanically.
Slewing Ring - or Slewing Bearing or Rotation Bearing. A rotational rolling element bearing that
typically supports a heavy but slow turning load.
Tagout - Remove the lock so the equipment can be re-energized.
Torque Multiplier - Enables small amounts of input torque (pulling) to produce large amounts
of output torque (turning), efficiently and safely.
Wet Torque - Any bolt that is lubricated or coated with an anti-seize compound.

Index
Authorized Parts 21
Before Grapple Installation 30

Before Operating 16
Bolt Torque Specifications 24
Bolt Visual Reference 24
Check the Equipment 17

Crush Points, Pinch Points 23
Cylinder Guard, Outer - Removal 21
Cylinder Removal & Installation Procedure 45 - 48
Before Starting Maintenance 45
Installation 48
Remove Cylinder 47
Remove Cylinder Hoses 48
Remove Lower Cylinder Pin 46
Remove Outer Cylinder Guards 46
Remove Upper Pin 47
Safety Refresher 45
Support Cylinder 47
Dry Torque Values 24
Emergency Situations 15
Fastener Identification 19
Features 29
General Arrangement 28
Glossary 51
Grapple Shipping Condition 30
Grease Temperatures 25
Greasing Slewing Ring, Yoke & Bearings 25
Hardsurfacing - Tines 45
High Voltage Lines 20
Hydraulic Assembly 36 - 44
Crossport Relief Installation 41
Cylinders 2, 3 & 4 Installation 44
Cylinder & Hose Installation 40
Cylinder Subassembly 39
Head Installation 42
Hydraulic Assembly (continued)

Index
Hydraulic Assembly 36 - 44
Hydraulic Component Relationships 37
Motor Installation 44
Motor Subassembly 43
Swivel Fittings Installation 42
Swivel Installation 36
Swivel Subassembly 36
Torque Arm Installation 43
Valve Body / Manifold Installation 39
Valve Body / Manifold Subassembly 38
Hydraulic / Rotation Maintenance 25

Hydraulic Requirements - GSG075, 100 26
Hydraulic Requirements - GSG125, 150, 200 27
Hydraulic Settings 18
Hydraulic Start-Up 31
Installation Procedure 30
Installation - Hydraulic Start-Up 31
Invoices 49
Know Where the Utilities Are 15
Lighting 18
Lockout / Tagout 18
Machine Stability 17
Maintaining the Grapple 13
Maintenance Schedule 23
Manifold, Valve Body 34
Manual Replacement 3
Mounting Bolts 25
Operator Qualifications 15
Order Placement 49
Part Numbers 49
Parts Order Form 50
Parts Order Policy 49
Parts Order Procedure 49
Performing Maintenance 23
Personal Safety 16

Index
Pin Removal 30
Pinch Points and Crush Points 23
Placing Orders 49
Position the Attachment 17
Possible (Product) Variations 3
Power Lines 20
Prioritized Oil Flow 20
Proper Bolts 22
Public Notice 3
Registration Form 3
Removing Outer Cylinder Guard 21
Repairs 21
Return Goods Authorization 49
Returns 49
RGA 49
Safety Statements 10
Sanding and Grinding 22
Shipping 49
Slewing Ring - Greasing 25
Starting Procedure 19
Swivel Seal Removal and Installation 32
Tine Hardsurfacing 45
Tine Tip - Removal 46
Tine Tip - Replacement 47
Torque Specs - Bolt 24
Trained and Authorized Persons 21
Transporting the Grapple 13
Troubleshooting 35
Unsafe Conditions 15
Valve Body / Manifold 34
Warranty 3
Warranty Claim Procedure 48
Warranty Work or Repairs 3
Welding 21
Wet Torque Values 24
Working Overhead 20

Locations
World Headquarters
Europe/Africa/Middle East
Genesis Attachments
1000 Genesis Drive Genesis GmbH
Superior, WI 54880 USA Alpenstrasse 71
D-87700 Memmingen, Germany
Toll Free: 888-SHEAR-IT
(888-743-2748)
Phone: +49 83 31 9 25 98 0
Phone: 715.395.5252 Fax: +49 83 31 9 25 98 80
Fax: 715.395.5255 genesis-europe.com
E-mail: E-mail:
info@genesis-europe.com
info@genesisattach
Asia Pacific Representative Office

24 Upper Serangoon View #12-28
Singapore 534205
Phone: +65 9673 9730
E-mail:
tchoo@genesisattachments.com
Central & South America, The Caribbean

Cra 13A #89-38 / Ofi 613
Bogota, Colombia
Phone: (57-1) 610-8160 / 795-8747
E-mail:
contact@themsagroup.com
Brazil
Rua Jos Alves dos Santos, 281 - Sala - 413
So Jos dos Campos / SP - Brazil
Phone: +55 (12) 3905-3405
E-mail:
metalamericas@metalamericas.com
View and download all manuals at genesisattachments.com/manuals.asp
Rev. B - 10-29-14

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Scrap Grapple

Asia Pacific Representative Office

Phone: +65 9673 9730

Central & South America, The Caribbean

Phone: (57-1) 610-8160 / 795-8747

Phone: +55 (12) 3905-3405

View and download all manuals at genesisattachments.com/manuals.asp

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2014 Genesis Attachments, LLC Genesis GSG Scrap Grapple 3

2014 Genesis Attachments, LLC Genesis GSG Scrap Grapple 5

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Death Will Result

Death Could Result

Damage Could Result

This symbol by itself or used with a safety signal word

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P Keep unprotected body parts, such as face, eyes and

P If injured by injected fluid see a doctor at once. If your

P Wear safety glasses and protective clothing and use a

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P Work on a level surface in a well lit area.

P Wear protective equipment specified by the tool

TRANSPORTING THE GRAPPLE

P When driving on public roads use safety lights,

P Do not drive close to ditches, excavations, etc., cave in

MAINTAINING THE GRAPPLE

P Never perform any work on the attachment unless you

P Never make hydraulic repairs while the system is under

See your machines manual for these instructions.

P An operator must not be under the influence of drugs or

P Never leave equipment unattended with the engine running or with

P Do not exceed the lifting capacity of your prime mover.

P Reduce speed when driving over rough terrain or on a

P Never use the attachment for a work platform or personnel carrier.

P Never allow anyone to be around the equipment when it is operating.

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P Know your work site safety rules as well as traffic rules

P A heavy load can cause instability of the prime mover.

KNOW WHERE UTILITIES ARE

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Be properly seated in the operators seat.

Do not attempt to operate the controls until you have

Familiarize yourself with the carrier and attach-

Know the Work Area

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P Know the working ranges and capacities of the

P Use the recommended carrier counter weight.

Check the Equipment

Position the Attachment

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Process Material Safely

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Secure the Load

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If loose bolts are found, do not operate the Attachment.

Stand clear when the Attachment is being rotated. Always

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Removing outer Cylinder Guard

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