Scrap Grapple. All Models SAFETY & OPERATOR S MANUAL

Transcription

1 Scrap Grapple All Models SAFETY & OPERATOR S MANUAL

2 LOCATIONS World Headquarters Genesis Attachments 1000 Genesis Drive Superior, WI USA Toll Free: 888-SHEAR-IT ( ) Phone: Fax: Europe/Africa/Middle East Genesis GmbH Alpenstrasse 71 D Memmingen, Germany Phone: Fax: genesis-europe.com info@genesis-europe.com Asia Pacific Representative Office 24 Upper Serangoon View #12-28 Singapore Phone: tchoo@genesisattachments.com Central & South America, The Caribbean Cra 13A #89-38 / Ofi 613 Bogota, Colombia Phone: (57-1) / contact@themsagroup.com Brazil Avenida Araça, 1677 Campinas - São Paulo Phone: gel@themsagroup.com View and download all manuals at genesisattachments.com/manuals.asp Genesis Attachments, LLC Genesis GSG Scrap Grapple

3 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 understand 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 operator s 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 or 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 authorization by the Genesis Service Department will render all warranty reimbursement consideration null and void without exception. See page 50 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple 3

4 TABLE OF CONTENTS SAFETY STATEMENTS GENERAL SAFETY 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 Use Care with Hydraulic Fluid Pressure GENERAL SAFETY Safely Maintain and Repair Equipment Transporting the Grapple Maintaining the Grapple GENERAL SAFETY Safely Operate Equipment GENERAL SAFETY Safely Operate Equipment Know Where Utilities Are Operator Qualifications Unsafe Conditions Emergency Situations GENERAL SAFETY Personal Safety Before Operating Know the Work Area GENERAL SAFETY Machine Stability Check the Equipment Position the Attachment GENERAL SAFETY Operation Safety Know the Rules Lighting Lockout / Tagout Process Material Safely Hydraulic Settings Genesis Attachments, LLC Genesis GSG Scrap Grapple 4

5 TABLE OF CONTENTS GENERAL SAFETY Fire Hazards Stability Place the Load Safely Fastener Identification Secure the Load Starting Procedure To Start To Shut Down GENERAL SAFETY High Voltage Lines May Arc Power Lines Working Overhead Prioritized Oil Flow MAINTENANCE SAFETY Trained and Authorized Repairs Authorized Parts Schedules Torque Specs Welding Maintenance Equipment Conditions Removing Outer Cylinder Guard MAINTENANCE SAFETY Pressurized System Medical Assistance Burns Ventilate the Area Sanding / Grinding Prevent Fires Proper Bolts MAINTENANCE SAFETY Pinch Points & Crush Points Performing Maintenance Unsafe Condition Equipment Condition Maintenance Schedule Eight Hour Checklist Inspect Grease Tines Long-Term Maintenance Genesis Attachments, LLC Genesis GSG Scrap Grapple

6 TABLE OF CONTENTS MAINTENANCE Bolt Torque Specifications HYDRAULIC / ROTATION MAINTENANCE Mounting Bolts Bolt Torque Grease Slewing Ring Rotate After Greasing Grease Points - Yoke & Pins Grease Temperatures HYDRAULIC REQUIREMENTS - GSG075,100 HYDRAULIC REQUIREMENTS - GSG125,150,200,250 GENERAL ARRANGEMENT FEATURES INSTALLATION Grapple Shipping Condition Pin Removal Before Grapple Installation INSTALLATION Hydraulic Start-Up Start-Up Procedure SWIVEL SEAL REMOVAL & INSTALLATION SWIVEL SEAL REMOVAL & INSTALLATION GRAPPLE CYLINDERS VALVE BODY / MANIFOLD Cylinder Port Arrangement & Sizes TROUBLESHOOTING GUIDE HYDRAULIC ASSEMBLY Install Swivel Fittings Install Swivel in Tower from Below HYDRAULIC ASSEMBLY Hydraulic Component Relationships HYDRAULIC ASSEMBLY Valve Body / Manifold Subassembly HYDRAULIC ASSEMBLY Valve Body / Manifold Installation Cylinder Subassembly HYDRAULIC ASSEMBLY Cylinder No. 1 / Hose Installation Install Retract Hose HYDRAULIC ASSEMBLY Cylinders No. 2, 3 & 4 Installation Genesis Attachments, LLC Genesis GSG Scrap Grapple 6

7 TABLE OF CONTENTS HYDRAULIC ASSEMBLY Install Swivel Spool Fittings Install Head Subassembly HYDRAULIC ASSEMBLY Swivel Torque Arm Installation Motor Fittings Installation HYDRAULIC ASSEMBLY Install Motor Subassembly Install Crossport Relief Cartridge CYLINDER REMOVAL & REPLACEMENT PROCEDURE Before Starting Maintenance Safety Reminder CYLINDER REMOVAL & REPLACEMENT PROCEDURE Remove Outer Cylinder Guards Remove Lower Cylinder Pin CYLINDER REMOVAL & REPLACEMENT PROCEDURE Remove Cylinder Hoses Support Cylinder / Remove Upper Pin & Cylinder CYLINDER REMOVAL & REPLACEMENT PROCEDURE Installation TINE HARD-SURFACING TINE TIP REMOVAL TINE TIP REPLACEMENT WARRANTY CLAIM PROCEDURE PARTS ORDER POLICY AND PROCEDURE PARTS ORDER FORM GLOSSARY INDEX Genesis Attachments, LLC Genesis GSG Scrap Grapple

8 SAFETY STATEMENTS Death Will Result! DANGER This statement is used where serious injury or death will result if the instructions are not followed properly. Death Could Result! Damage Could Result! CAUTION 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. Call Attention To This symbol by itself or used with a safety signal word throughout this manual is used to call attention to instructions involving your personal safety or the safety of others. Failure to follow these instructions can result in injury or death Genesis Attachments, LLC Genesis GSG Scrap Grapple

9 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 professional guidelines for your operation. Know and follow good work practices when assembling, maintaining, repairing, mounting, removing or operating this attachment. KNOW YOUR EQUIPMENT GENERAL SAFETY READ MANUAL BEFORE INSTALLATION Read this manual before attempting to operate the attachment. This operator s manual should be regarded as part of the attachment. For proper installation, operation or maintenance, operators and maintenance personnel should read this manual along with the manuals of the material handler or serious injury or death could result. Know your attachment s capabilities, dimensions and operations 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 operator s station. DO NOT MODIFY MACHINE OR ATTACHMENT Modifications may weaken an attachment s integrity and impair its function, life and performance. When making repairs, use only the manufacturer s 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple 9

10 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 connecting or disconnecting hydraulic hoses, read your material handler s operator s 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple

11 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 operator s 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple 11

12 GENERAL SAFETY SAFELY OPERATE EQUIPMENT Do not operate equipment until you are completely trained by a qualified operator in how to use the controls and know its capabilities, dimensions and all safety requirements. See your machine s manual for these instructions. P Operate only from the operator s 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 mover s 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple

13 SAFELY OPERATE EQUIPMENT KNOW WHERE UTILITIES ARE GENERAL SAFETY 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. 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple 13

14 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 GENERAL SAFETY Warn all others in the area that you are about to start operation. Perform the Check the Equipment (Page 15) 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 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 attachment 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple

15 MACHINE STABILITY GENERAL SAFETY 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 owner s manual. Make sure they are legible and in the proper location. P Grease fittings. Pump grease at all fitting locations. (See page 23) 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 Grease rotation bearing and pinion gear. P Check for loose or missing pin retaining bolts. POSITION THE ATTACHMENT P GOOD CONDITION 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) Genesis Attachments, LLC Genesis GSG Scrap Grapple 15

16 OPERATION SAFETY KNOW THE RULES GENERAL 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. 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 maintenance 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple

17 FIRE HAZARDS STABILITY SECURE THE LOAD GENERAL SAFETY 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. 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. 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 operator s 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple 17

18 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.! DANGER 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple

19 TRAINED AND AUTHORIZED MAINTENANCE SAFETY Only trained and authorized persons should perform maintenance on the grapple. To be qualified, you must understand the instructions in this manual, have training, and know the safety rules and regulations of the job site. REPAIRS Do not attempt repairs you do not understand. If any questions 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 22) 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple 19

20 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 components 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 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 solvent properly. SANDING / GRINDING When sanding or grinding paint, avoid breathing the dust. Wear an approved respirator. 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple

21 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 components 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 q q q GREASE q q Bolts - Check for loose bolts, replace if damaged Fittings and hoses for damage or leaks Cylinders for damage or leaks Hydraulic swivel for damage or leaks q Slewing Ring, Drive Gear and Grapple Yoke (Page 23) TINES q q Check grapple tines for excessive wear Perform build-up and hard-surfacing as needed Long-Term Maintenance Check all bolts for loose washers, including slewing ring bolts, after the first 80 hours of operation Reseal cylinder every 2000 hours 2017 Genesis Attachments, LLC Genesis GSG Scrap Grapple 21!

22 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. Fastener Grade CL Size x Pitch Dry Torque Values Hex Head Flat Head Nm Ft-lb Nm Ft-lb M8 x M10 x M12 x M14 x M14 x M16 x M20 x M20 x M24 x M27 x M30 x / / / / / L Fastener Grade CL Size x Pitch Wet Torque Values Hex Head Flat Head Nm Ft-lb Nm Ft-lb M20 x M24 x M27 x M30 x / / Apply grease or anti-seize on threads and under bolt heads Visual Reference Genesis Attachments, LLC Genesis GSG Scrap Grapple

23 MOUNTING BOLTS HYDRAULIC / ROTATION MAINTENANCE 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 attachment. 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 equipment. Improper torques will also cause uneven wear on the slewing ring. See Page 22 for proper bolt torque specifications. 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 Grease Points Grease Points GREASE TEMPERATURES Bearing Grease Points For normal conditions above 32 F (0 C), use a lithium-based, premium grade 2 extreme pressure grease. For temperatures below 32 F, a grade 0 grease is recommended Genesis Attachments, LLC Genesis GSG Scrap Grapple 23

24 IMPORTANT HYDRAULIC REQUIREMENTS 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: Flow: Fittings: Notes: Full system pressure or 5000 PSI maximum GPM - ( LPM) 3/4 (.75 ) SAE Flat Face O-Ring Adaptor Fitting 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: Flow: Fittings: Notes: 1200 PSI 3 6 GPM - (11-23 LPM) 1/2 (.50 ) SAE Flat Face O-Ring Adaptor Fitting 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple

25 IMPORTANT HYDRAULIC REQUIREMENTS 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: Flow: Fittings: Notes: Full system pressure or 5000 PSI maximum GPM - ( LPM) 3/4 (.75 ) SAE Flat Face O-Ring Adaptor Fitting 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: Flow: Fittings: Notes: 1200 PSI 3 6 GPM - (11-23 LPM) 1/2 (.50 ) SAE Flat Face O-Ring Adaptor Fitting 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple 25

26 GENERAL ARRANGEMENT Grapple Rotate Motor Slewing Ring Outer Cylinder Guard Upper Head Serial Number (Weld On) Product Model Grapple Frame Under Cylinder Guard Grapple Cylinder Tines Genesis Attachments, LLC Genesis GSG Scrap Grapple

27 FEATURES Heavy-duty guarding system completely protects cylinders and internal components: removes easily for internal maintenance access Reverse-mounted cylinders protect rods from damage Large bore hydraulic cylinders maximize clamping force 4 High-torque continuous 360º rotation for handling large and uneven loads 5 Large diameter hardened steel pins with integrated shear-proof pin retainers 6 Identical hardened steel bearings with dust seals at all pivot points Long-life, abrasion resistant steel tips are easily replaced with simple perimeter weld All tine styles feature fully boxed construction for strength and durability 8 9 Overall footprint easily fits inside trailers 7 9 Pointed Tine Flat Tine B D B D C A C A Diagram Dimensions Model Capacity (yd 3 ) Weight (lbs.) Min. Machine Size (mt) A B C D E Jaw Open Width (ins.) Jaw Open Height (ins.) Jaw Closed Width (ins.) Jaw Closed Height (ins.) Footprint (ins.) Tine Shape Flat Point Flat Point Flat Point Flat Point Flat Point GSG , GSG , GSG , GSG , GSG , GSG , Genesis Attachments, LLC Genesis GSG Scrap Grapple 27

28 GRAPPLE SHIPPING CONDITION PIN REMOVAL INSTALLATION INSTALLATION PROCEDURE The attachment is usually shipped in an upright position. Extreme care must be used when positioning 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. 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 excavator OEM s removal and safety instructions Genesis Attachments, LLC Genesis GSG Scrap Grapple

29 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: INSTALLATION 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple 29

30 SWIVEL SEAL REMOVAL & INSTALLATION Apply Loctite #262 to threads torque to 81 Ft-Lbs (3 Places) Assemble with U-Cup lips facing inward as shown Assemble with U-Cup lips facing inward as shown Lightly grease after assembled in housing groove Lightly grease Lightly grease area outside of end seals on each end before assembly. (Grease either on spool or each end of housing bore) Assemble with U-Cup lips facing inward Assemble with U-Cup lips facing inward 1 12 Lightly grease Lightly grease 7 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 2017 Genesis Attachments, LLC Genesis GSG Scrap Grapple

31 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 º 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 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 (don t 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple 31

32 GRAPPLE CYLINDERS VALVE BODY / MANIFOLD CYLINDER PORT ARRANGEMENT & SIZES Cavity Plug Relief Cartridge Port: VB Test Port: GB Port: CB1 Port: CR4 Port: CR1 Ports 1 Ports 4 Port: CB4 Relief Cartridge Cavity Plug Test Port: GR Port: VA Port: CR2 Port: CB3 Port: CR3 Ports 3 Ports 2 Port: CB2 Supply Ports VA & VB - 12 SAE O-ring Boss Working Ports - 08 SAE O-ring Boss Genesis Attachments, LLC Genesis GSG Scrap Grapple

33 SYMPTOM TROUBLESHOOTING GUIDE GENERAL GRAPPLE TROUBLESHOOTING GUIDE 1. Tine lack clamping power A. Excavator is not putting out full pressure to the tine circuit. B. Cross-over relief valve setting is too low. C. Tine cylinder(s) is bypassing internally. 1. Check excavator circuit relief valve. 2. Adjust the cross-over relief valves. 3. Replace cylinder seals. 4. Replace swivel seals. D. E. POSSIBLE CAUSE Shear swivel is bypassing internally. Cross-over relief valves are bypassing. 5. POSSIBLE SOLUTION Reseal or replace the cross-over relief valves. 2. Tines drift open. A. B. Shear swivel is bypassing internally. Tine cylinder(s) is bypassing internally Replace swivel seals. Replace cylinder seals. 3. Tines closing and opening speed is slow. A. B. C. Flow from excavator is too slow. Swivel is bypassing. Tine cylinder(s) is bypassing internally Check excavator hydraulic system flow. Replace swivel seals. Replace the hydraulic motor. 4. Grapple rotation is weak. A. B. 5. Grapple rotation is slow. A. B. Cross-over relief valve set too low. Hydraulic motor is worn. Flow from excavator is too slow. Worn hydraulic motor Check rotation pressure, adjust or replace the relief valve. Replace hydraulic motor. Check excavator hydraulic system flow. Replace the hydraulic motor Genesis Attachments, LLC Genesis GSG Scrap Grapple 33

34 1. Assemble the swivel (P/N ) with the barrel port hydraulic fittings as shown. HYDRAULIC ASSEMBLY HYDRAULIC SWIVEL SUBASSEMBLY P/N Torque Specs Ft-Lb Nm P/N Torque Specs Ft-Lb Nm Barrel - Port 1 Barrel fittings face straight down. Barrel - Port 2 Figure 36a - Install Swivel Fittings (4) F Hex Head Capscrew M16 x 2.0 (4) F Flat Washer M16 Swivel Mounting Bolt Torque Specs 230 Ft-Lb. 313 Nm Barrel - Port 1 Figure 36b - Install Swivel in Tower from Below Genesis Attachments, LLC Genesis GSG Scrap Grapple

35 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 2017 Genesis Attachments, LLC Genesis GSG Scrap Grapple 35

36 HYDRAULIC ASSEMBLY VALVE BODY / MANIFOLD SUBASSEMBLY P/N Cavity Plug Torque Specs Ft-Lb Nm P/N Relief Valve Torque Specs Ft-Lb Nm Manifold Block P/N Port VB P/N Adaptor 3/4-90 Torque Specs Ft-Lb Nm Port CB1 P/N Adaptor 1/2 Straight Ft-Lb Nm Ports 1 Ports 4 Port CB12 P/N Adaptor 1/2 Straight Ft-Lb Nm Figure 38a - Install Fittings on Cylinder 1 Side Port VA P/N Adaptor 3/4-90 Torque Specs Ft-Lb Nm Port CB3 P/N Adaptor 1/2 Straight Torque Specs Ft-Lb Nm Port CB3 P/N Adaptor 1/2 Straight Torque Specs Ft-Lb Nm Ports 3 Ports 2 Figure 38b - Install Fittings on Cylinder 3 Side Genesis Attachments, LLC Genesis GSG Scrap Grapple

37 HYDRAULIC ASSEMBLY VALVE BODY / MANIFOLD INSTALLATION - CYLINDER SUBASSEMBLY Reference Port 1 (4) F Hex Head Capscrew M12 x 1.75 (4) F Flat Washer M12 Torque Specs 92 Ft-Lb 125 Nm Manifold Block Subassembly P/N Reference Port VB Figure 39a - Install Valve Body / Manifold P/N Adaptor 1/2 45 Torque Specs Ft-Lb Nm Retract Models GSG075, GSG100 - Cylinder P/N Models GSG125, GSG150, GSG200 - Cylinder P/N Extend Figure 39b - Cylinder Subassembly 2017 Genesis Attachments, LLC Genesis GSG Scrap Grapple 37

38 HYDRAULIC ASSEMBLY CYLINDER NO. 1 / HOSE INSTALLATION P/N F Hex Head Capscrew M24 x 3 x 50 P/N Mach Washer Torque Specs 778 Ft-Lb 1055 Nm Wldt Pin P/N P/N Assembly Hose Torque Specs Ft-Lb Nm (EXT on Cylinder to CB1 on Valve Body / Manifold) Cylinder No. 1 Figure 40a - Install Cylinder No. 1 and Extend Hose P/N Assembly Hose Torque Specs Ft-Lb Nm (RET on Cylinder to CR1 on Valve Body / Manifold) Figure 40b - Install Retract Hose Genesis Attachments, LLC Genesis GSG Scrap Grapple

39 HYDRAULIC ASSEMBLY CYLINDERS NO. 2, 3 & 4 INSTALLATION Port CB2 P/N Adaptor 1/2 Straight Ft-Lb Nm Port CR2 P/N Adaptor 1/2 Straight Ft-Lb Nm Port CB4 P/N Adaptor 1/2 Straight Ft-Lb Nm Port CR4 P/N Adaptor 1/2 Straight Ft-Lb Nm Figure 41a - Valve / Manifold Fittings Cylinder No. 2 Location Figure 41b - Valve / Manifold Fittings 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 Install Cylinder No. 4 Figure 41c - Cylinders No. 2, 3 & 4 Installation 2017 Genesis Attachments, LLC Genesis GSG Scrap Grapple 39

40 HYDRAULIC ASSEMBLY SWIVEL FITTINGS AND HEAD INSTALLATION P/N Adaptor 3/4 45 Torque Specs Ft-Lb Nm Figure 42a - Install Swivel Spool Fittings Head Subassembly (1) P/N Head Wtmg (1) P/N Slewing Bearing (20) P/N F Hex Head Capscrew M16 x 2 x 80 (20) P/N F Flat Washer M16 Torque Specs 230 Ft-Lb. 313 Nm Figure 42b - Install Head Subassembly Genesis Attachments, LLC Genesis GSG Scrap Grapple

41 HYDRAULIC ASSEMBLY SWIVEL TORQUE ARM / MOTOR FITTINGS INSTALLATION P/N Torque Arm (3) P/N Hex Head Capscrew M12 x 1.75x 45 Torque Specs 92 Ft-Lb. 125 Nm Figure 43a - Swivel Torque Arm Installation Face fittings straight up Relief Valve Port DO NOT install until after the motor has been installed in grapple head P/N Adaptor 1/2 90 Torque Specs Ft-Lb Nm P/N Pinion P/N F Hex Head Capscrew 5/8-11 x 1 Torque Specs 376 Ft-Lb. 510 Nm Figure 43b - Motor Subassembly 2017 Genesis Attachments, LLC Genesis GSG Scrap Grapple 41

42 HYDRAULIC ASSEMBLY MOTOR SUBASSEMBLY INSTALLATION Motor Subassembly (4) F Socket Head Capscrew M12 x 1.75 Torque Specs 92 Ft-Lb 125 Nm Figure 44a - Install Motor Subassembly P/N Cartridge, Crossport Relief Torque Specs Ft-Lb Nm Figure 44b - Install Crossport Relief Cartridge Genesis Attachments, LLC Genesis GSG Scrap Grapple

43 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 LOWER OR SUPPORT RAISED EQUIPMENT MAINTENANCE REMOVING OUTER CYLINDER GUARD PRESSURIZED SYSTEM PINCH POINTS AND CRUSH POINTS PAGE 11 PAGE 11 PAGE 21 PAGE 21 PAGE 22 PAGE Genesis Attachments, LLC Genesis GSG Scrap Grapple 43

44 CYLINDER REMOVAL & REPLACEMENT PROCEDURE 2. Remove outer cylinder guards 3. Remove lower cylinder pin Genesis Attachments, LLC Genesis GSG Scrap Grapple

45 CYLINDER REMOVAL & REPLACEMENT PROCEDURE 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple 45

46 CYLINDER REMOVAL & REPLACEMENT PROCEDURE 6. Remove cylinder hoses and note the position of the adaptors before removing them. Retract Extend 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 (90º end) to the valve body / manifold subassembly, finger tight only. Connect the other end (straight end) to the cylinder. Tighten both ends Ft-Lbs (43-54 Nm). 10. Connect the retract hose (90º end) to the valve body / manifold subassembly, finger tight only. Connect the other end (straight end) to the cylinder. Tighten both ends 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 Genesis Attachments, LLC Genesis GSG Scrap Grapple

47 TINE HARD-SURFACING SUGGESTED TINE HARD-SURFACING PROCEDURE Do not apply hard-surfacing directly to the parent material as this could cause toe cracking, and the hard-surfacing 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. Stagger the ends of the stringer welds so they do not end in a straight line. Cap each stringer bead with one pass of GenWire or GenRod to hard-surface. Do not apply more than two layers of hardsurfacing. Peen each pass. Grind the ends of all stringer welds, with the grain to taper 1 to 1-1/2 (25-38 mm) to the parent material. See the following page for hard-surfacing illustrations and instructions specific to each area of the tines. Taper ends Grind with grain 1/4 from edge Hard-surface bead Grain Stringer bead Stagger ends Staggered stringers Crosshatch the inside roll plate with stringer beads at 45º angles to form 1 squares Genesis Attachments, LLC Genesis GSG Scrap Grapple 47

48 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 Figure 46a Angle can be used as a straight edge during installation of new tip. Edges should be straight and square. Bevel inside roll plate 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 like Fig. 46b) Figure 46b Genesis Attachments, LLC Genesis GSG Scrap Grapple

49 TINE TIP REPLACEMENT FACTORY WELDING PROCESS Tine Plate Inside Roll Plate 1/2 Note: It is important to duplicate this process when replacing the tip. Tip 1/2 3 Sides 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 2017 Genesis Attachments, LLC Genesis GSG Scrap Grapple 49

50 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, outgoing 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: Genesis Attachments, LLC Genesis GSG Scrap Grapple

51 PARTS ORDER POLICY AND PROCEDURE ORDER PLACEMENT PARTS ORDERS SHOULD INCLUDE THE FOLLOWING: q q q q q Purchase order number Model and serial number of attachment Part number and quantity needed Shipping and billing address Method of shipment or required delivery date PLACING ORDERS Orders may be placed by phone, 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. SHIPPING PARTS POLICY 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 responsibility 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 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 available to Genesis. Warranty on purchased parts other than wear components is 6 months. There is no warranty period on wear parts or components Genesis Attachments, LLC Genesis GSG Scrap Grapple 51

52 PARTS ORDER FORM Date: Customer: Phone: Shipping Address: Contact: Fax: Billing Address: Purchase Order: Model: Shipping Method: Serial Number: Quantity Part Number Description Price 52 Fax to the Genesis Parts Department at For assistance, call or Genesis Attachments, LLC Genesis GSG Scrap Grapple