Genesis GHG 125 User manual

Handling Grapple (GHG)
Models GHG 75 - GHG 125
SAFETY & OPERATOR’S MANUAL

© 2023 Genesis Attachments, LLC
Genesis GHG 75-125 Handling Grapple
2
CONTACT INFORMATION
View and download all manuals: genesisattachments.com/manuals
Patents: genesisattachments.com/products/patents
Asia Pacic Representative O󰀩ce
24 Upper Serangoon View #12-28
Singapore 534205
Phone: [phone]
E-mail:
[email protected]
Europe/Africa/Middle East
Genesis GmbH
Teramostrasse 23
87700 Memmingen, Germany
Phone: [phone]
Fax: [phone]
genesis-europe.com
E-mail:
[email protected]
Central America & Colombia
Cra 13A #89-38 / O 613
Bogota, Colombia
Phone: [phone]
E-mail:
[email protected]
Genesis Attachments
1000 Genesis Drive
Superior, WI 54880 USA
Toll Free: 888-SHEAR-IT
(888-743-2748)
Phone: [phone]
E-mail:
[email protected]

© 2023 Genesis Attachments, LLC Genesis GHG 75-125 Handling 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 product’s owner to ensure the
operator is trained in the safe operation of the product and has available this manual for review.
It is the responsibility of the operator and maintenance personnel to read, fully understand and
follow all operational and safety-related instructions in this manual. The attachment should not
be operated until you have read and fully understand these instructions. Always use good safety
practices to protect yourself and those around you.
Important
This operator’s manual must accompany the attachment at all times and be readily available to
the operator.
Manual Replacement
Should this manual become damaged or lost or if additional copies are required, immediately
contact any authorized Genesis dealer or the Genesis Service Department at 888-743-2748 or
715-395-5252 for a replacement.
Registration Form
The Warranty Registration Form must be lled out by the dealer or customer and returned to
Genesis indicating the date the attachment went into service.
Possible Variations
Genesis cannot anticipate every possible circumstance that might involve a potential hazard as
the owner’s requirements and equipment may vary. Therefore, the warnings in this publication
and on the product may not be all-inclusive, and you must satisfy yourself that the procedure,
application, work method or operating technique is safe for you and others before operating.
Public Notice
Genesis reserves the right to make changes and improvements to its products and technical
literature 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, modications or repairs performed before
authorization by the Genesis Service Department will render all warranty reimbursement
consideration null and void without exception. See page 37 for Warranty Claim Procedures.
Improper operation or improperly performed maintenance may render any warranty null and void.

© 2023 Genesis Attachments, LLC
Genesis GHG 75-125 Handling Grapple
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TABLE OF CONTENTS
CONTACT INFORMATION 2
PREFACE 3
Important 3
Manual Replacement 3
Registration Form 3
Possible Variations 3
Public Notice 3
Warranty 3
SAFETY STATEMENTS 6
OPERATIONAL SAFETY 7
Read Manual Before Operating or Maintaining the Attachment 7
Personal Protection 7
Know Your Equipment 7
Before Operating 7
Check the Equipment 8
Stability 8
Know the Work Area 9
Starting Procedure 9
Place the Load Safely 9
Safely Operate Equipment 10
Transporting the Attachment 11
Equipment Condition 11
Working Overhead 11
Power Lines 11
Use Care with Hydraulic Fluid Pressure 12
Prioritized Oil Flow 13
Emergency Situations 13
Unsafe Conditions 13
Crystalline Silica Dust 13
Process Material Safely 14
Lift the Load Safely 14
Place the Load Safely 14
ATTACHMENT MARKINGS 15
MAINTENANCE SAFETY 16
Pinch Points & Crush Points 16
Performing Maintenance 16
MAINTENANCE SCHEDULE 18
Four-Hour Checklist 18
Eight-Hour Checklist 18
Long-term Maintenance 18
LUBRICATION POINTS 19
BOLT TORQUE SPECS 20
GENERAL WELDING GUIDELINES 21
Welding Ground Clamp 21
Welding Rules 21

© 2023 Genesis Attachments, LLC Genesis GHG 75-125 Handling Grapple 5
TABLE OF CONTENTS
BUILD-UP AND HARD-SURFACING 22
Hard-Surfacing Patterns 22
HARD-SURFACING 23
HYDRAULIC/ROTATION MAINTENANCE 24
Hydraulic Requirements 24
Rotation Valve Input 24
Rotation Valve Settings 24
SLEWING RING MAINTENANCE 25
ROTATION CIRCUIT 26
Rotation with Motion Control Valve 26
BLADE MAINTENANCE 27
Blade Rotation 27
GRAPPLE INSTALLATION 28
Installation Procedure 28
ROTATOR INSTALLATION 29
Rotation Circuit - Gear Pump Type 30
Rotation Circuit - Auxiliary Valve on Machine 31
GENERAL OPERATION INSTRUCTIONS 32
E󰀩cient and Productive Operation 32
HYDRAULIC START-UP 33
Start-up Procedure 33
HYDRAULIC / ROTATION MAINTENANCE 34
Mounting Bolts 34
Bolt Torque 34
Grease Slewing Ring 34
Rotate After Greasing 34
Grease Points 34
Grease Temperatures 34
TROUBLE-SHOOTING GUIDE 35
WARRANTY 37
Claim Procedure 37
PARTS ORDER POLICY AND PROCEDURE 38
Parts Orders Should Include 38
Placing Orders 38
Part Numbers 38
Shipping 38
Invoices 38
Returns 38
Return Goods Authorization 38
PARTS ORDER FORM 39
CONTACT INFORMATION 40
For bolt torque specs, see the Genesis Fastener Manual.
genesisattachments.com/manuals
NOTICE

© 2023 Genesis Attachments, LLC
Genesis GHG 75-125 Handling Grapple
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SAFETY STATEMENTS
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.
This statement is used where serious injury or death
could result if the instructions are not followed properly.
!WARNING
This statement is used where minor or moderate injury
could result if the instructions are not followed properly.
!
CAUTION
This statement is used where property damage could
result if the instructions are not followed properly.
NOTICE
!DANGER
This statement is used where serious injury or death will
result if the instructions are not followed properly.

© 2023 Genesis Attachments, LLC Genesis GHG 75-125 Handling Grapple 7
!WARNING
Serious injury or death could result if appropriate
protective clothing and safety devices are not used.
Personal Protection
Use protective clothing and safety devices appropriate for the working conditions. These may
include but are not limited to:
3Hard hat
3Safety glasses, goggles or face shield
3Hearing protection
3Safety shoes
3Heavy gloves
3Reective clothing
3Respirator or lter mask
Know Your Equipment
Know your attachment’s capabilities, dimensions and functions before
operating. Inspect your attachment before operating and never operate
an attachment that is not in proper working order. Remove and replace
any damaged or worn parts.
Before Operating
3Warn all others in the area that you are about to start operation.
3Perform the Check the Equipment steps outlined in this manual.
3Check 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.
3Be properly seated in the operator’s seat.
3Do not attempt to operate until you have read and fully understand this manual and the
OEM manual for the carrier.
OPERATIONAL SAFETY
Read Manual Before Operating or Maintaining the Attachment
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 and maintenance of the attachment, operators and maintenance
personnel must read this manual.

© 2023 Genesis Attachments, LLC
Genesis GHG 75-125 Handling Grapple
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Check the Equipment
Before use, check the equipment to ensure it is in good operating condition.
Check the following:
3Grease ttings. Pump grease at all tting locations, see page 19.
3Hydraulic uid level. Add hydraulic uid as required.
3Hydraulic hoses and hose connections for wear or leaks. Repair or replace any damaged
hoses or connections.
3All control levers for proper operation.
3Rotation bearing. Visually check for loose or damaged bolts. If
repair is required, refer to qualied personnel.
3Grease rotation bearing and pinion gear.
3Check for loose or missing pin retaining bolts.
3Check cylinders for dents (barrel) or dings (rod).
GOOD
CONDITION
3
!WARNING
Serious injury or death could result if warnings or
instructions regarding carrier stability and the work area
are not followed properly.
Stability
Your Genesis attachment is sized for carrier stability. However, improper operation, faulty
maintenance or unauthorized modications may cause instability.
3Know the working ranges and capacities of the carrier to avoid tipping.
3Use the recommended carrier counter weight.
The following conditions a󰀨ect stability:
• Ground conditions
• Grade
• Weight of attachment
• Contents of attachment
• Operator judgement
For greater stability, knuckle the attachment to bring the load closer to the center of rotation
(center of gravity) while lifting. Use extra caution during reaching to avoid tipping.
OPERATIONAL SAFETY

© 2023 Genesis Attachments, LLC Genesis GHG 75-125 Handling Grapple 9
Know the Work Area
Check clearances in the work area. Keep all bystanders at a safe distance. Do not work under
obstacles. Always check your location for overhead and buried power lines or other utilities before
operation.
Check ground conditions. Avoid unstable or slippery areas. Position the carrier on rm level
ground. 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).
Starting Procedure
Before operating, walk completely around the equipment to make certain no one is under it, on it
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:
3Make sure all controls are in the center (neutral) position.
3Be properly seated.
3Slowly operate all functions to check for proper operation and to bleed air from the
hydraulic system.
To shut down:
3Return your Genesis attachment to a rest position on the ground.
3Shut o󰀨 the carrier engine.
3Work controls in all directions to relieve hydraulic pressure, per excavator manufacturer’s
instructions.
!WARNING
Serious injury or death could result if warnings or
instructions regarding safe operation are not followed
properly.
Place the Load Safely
Do not move the attachment, or anything held in the jaws, over people, equipment or buildings. Do
not throw or drop the contents. Operate the controls smoothly and gradually.
OPERATIONAL SAFETY

© 2023 Genesis Attachments, LLC
Genesis GHG 75-125 Handling Grapple
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Safely Operate Equipment
Do not operate equipment until you are trained by a qualied operator in its use and capabilities.
See your carrier’s manual for these instructions.
3Operate only from the operator’s seat. Check the seat belt daily and replace if frayed or
damaged.
3Do not operate this or any other equipment under the inuence of drugs or alcohol. If you
are taking prescription medication or over-the-counter drugs ask your medical provider
whether you can safely operate equipment.
3Never leave equipment unattended with the engine running or with the attachment in a
raised position. Apply the brakes before exiting the equipment.
3Do not exceed the lifting capacity of your carrier.
3Avoid conditions that can lead to tipping. The carrier can tip when operated on hills, ridges,
banks and slopes. Avoid operating across a slope which could cause the carrier to overturn.
3Reduce speed when driving over rough terrain, on a slope, or when
turning to avoid overturning the carrier.
3Never use the attachment as a work platform or personnel carrier.
3Keep all step plates, grab bars, pedals and controls free of dirt, grease,
debris and oil.
3Never allow anyone to be around the equipment when it is operating.
3Do not operate poorly maintained or otherwise faulty equipment. Inform the proper authority
and DO NOT resume operation until the problem has been xed.
3Do not alter or remove any safety features.
3Know your work site safety rules as well as tra󰀩c rules and ow.
When in doubt on any safety issue, contact your supervisor or safety
coordinator for an explanation.
3A heavy load can cause equipment instability. Use extreme care during travel. Slow down
on turns and watch out for bumps. The equipment may need additional counter-weights to
counterbalance the weight of the attachment.
OPERATIONAL SAFETY

© 2023 Genesis Attachments, LLC Genesis GHG 75-125 Handling Grapple 11
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 of any kind with any part of the carrier
or attachment. Always contact the appropriate utility when operating near
power lines. The lines should be moved, insulated, disconnected or de-
energized and grounded before operating in the area.
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.
Working Overhead
Avoid handling material overhead whenever possible. Safety glass and wire mesh
cab guarding must be installed to protect the operator from ying 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.
Transporting the Attachment
3Travel only with the attachment in a safe transport position to prevent uncontrolled
movement. Drive slowly over rough ground and on slopes.
3When driving on public roads use safety lights, reectors, Slow Moving Vehicle signs, etc.,
to prevent accidents. Check local government regulations that may a󰀨ect you.
3Do not drive close to ditches, excavations, etc., as cave-in could result.
3Do 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.
Equipment Condition
Never operate poorly maintained equipment. When maintenance is required, repair or replace
parts immediately.
!WARNING
Serious injury or death could result if warnings or
instructions regarding working overhead are not followed
properly.
!DANGER
Serious injury or death will result if warnings or instructions
regarding power lines are not followed properly.
OPERATIONAL SAFETY

© 2023 Genesis Attachments, LLC
Genesis GHG 75-125 Handling Grapple
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Use Care with Hydraulic Fluid Pressure
Hydraulic uid under pressure can penetrate the skin and cause serious injury or death.
Hydraulic leaks under pressure may not be visible.
3Keep unprotected body parts, such as face, eyes and arms as far away
as possible from a suspected leak. Flesh injected with hydraulic uid may
develop gangrene or other permanent injuries.
3If injured by injected uid see a doctor immediately.
3Wear safety glasses and protective clothing and use a piece of cardboard
or wood when searching for hydraulic leaks.
Do Not Use Your Hands!
See illustration below.
3Hydraulic 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 appropriate protective
clothing and safety equipment. If burned, seek immediate medical attention.
!WARNING
Serious injury or death could result if warnings or
instructions regarding hydraulic uid pressure are not
followed properly.
OPERATIONAL SAFETY

© 2023 Genesis Attachments, LLC Genesis GHG 75-125 Handling Grapple 13
OPERATIONAL SAFETY
IMPORTANT: Concrete and masonry products contain silica sand.
Quartz, which is a form of silica and the most common mineral in the
Earth’s crust, is associated with many types of rock.
Some activities that may have silica dust present in the air include
demolition, sweeping, loading, sawing, hammering, drilling or planing of
rock, concrete or masonry.
It is recommended to use dust suppression (such as water) or dust
collection (such as a vacuum) along with personal protective equipment
if necessary during the operation of any attachment that may cause high
levels of silica dust.
Prioritized Oil Flow
Equipment operators must ensure there is prioritized oil ow to the main valves in overhead
operations or high reach conditions.
Emergency Situations
Always be prepared for emergencies. Make sure a re extinguisher is available.
Be familiar with its operation. Make sure to inspect and service the re extinguisher
regularly. Make sure a rst aid kit is readily available.
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 a󰀨ect your safety and the safety of those around you. Always use common
sense while operating and be alert to unsafe conditions.
Crystalline Silica Dust
It is recommended to use dust suppression, dust collection and if necessary, personal protective
equipment during the operation of any attachment that may cause high levels of dust.
!DANGER
Exposure to respirable crystalline silica dust along
with other hazardous dusts may cause serious or fatal
respiratory disease.

© 2023 Genesis Attachments, LLC
Genesis GHG 75-125 Handling Grapple
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!WARNING
Using your Genesis attachment in unauthorized
applications may create an unsafe situation and will void
the warranty.
Process Material Safely
• Do not pull down structures with your Genesis attachment. 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 material.
Lift the Load Safely
• The hydraulic system has been preset and tested by your dealer. Do not alter hydraulic
settings without consulting an authorized Genesis dealer or the Genesis Service Department.
Doing so will void the warranty and may cause structural damage, accidents or tipping.
• Make sure the load is held securely in the tines. Do not move a loaded attachment if load is
loose or dangling. Make sure the load is pinched between the tines – never cradle a load.
Place the Load Safely
• Do not move the attachment, or anything held in the tines, over people, equipment or
buildings. Place the load gently. Do not throw or drop the contents.
• Operate the controls smoothly and gradually. Jerky controls are hazardous and may cause
damage to the carrier.
• Avoid re hazards. Keep the area clean. Remove all ammable materials from the area during
any welding or heating process. Have a re extinguisher nearby and know how to use it.
• 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.
• Use your Genesis attachment only as directed in this manual. Do not use the attachment to lift
and move other objects. Doing so may cause instability and tipping.
OPERATIONAL SAFETY

© 2023 Genesis Attachments, LLC Genesis GHG 75-125 Handling Grapple 15
ATTACHMENT MARKINGS
Serial Number
(Weld On)
Product
Model
Logo

© 2023 Genesis Attachments, LLC
Genesis GHG 75-125 Handling Grapple
16
MAINTENANCE SAFETY
Only trained and authorized persons should perform maintenance on the attachment. To be
qualied, you must understand the instructions in this manual, have training, and know the safety
rules and regulations of the job site.
Do not alter the physical, mechanical or hydraulic operation of the attachment. Doing so may
cause a dangerous situation for yourself and those around you and will void the warranty.
Do not attempt repairs you do not understand. If any questions arise regarding a safety or
maintenance procedure, contact Genesis or your Genesis dealer.
Read this entire manual. All personnel must understand the maintenance and safety procedures.
Use factory authorized parts. The use of unauthorized parts may compromise safety, performance
and durability of the attachment and may void the warranty.
Follow the daily checklist and maintenance schedules in this manual. Extreme conditions may
dictate shorter maintenance intervals.
Do not exceed bolt torque specications. See the Genesis Fastener Manual.
Do not weld on structural components without consulting Genesis. Doing so may cause structural
failure and void the warranty.
Do not operate an attachment without the case-drain line properly installed if the attachment uses
a rotation system that requires a case drain. Doing so will cause immediate failure of the rotate
motor and gearbox.
Do not work on the attachment before ensuring it will not move. Completely lower the boom to the
ground or a rest position and relieve hydraulic pressure.
Never operate poorly maintained equipment. When maintenance is required, repair or replace
parts immediately.
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.
Pinch Points & Crush Points
During maintenance or servicing, lifting the attachment by the top pins may cause the attachment
to unexpectedly close, creating a crushing point. The grapple and tines must be properly blocked
during maintenance. With the grapple hydraulic system drained of oil, this condition may cause
the unexpected movement.
Performing Maintenance
Prior to maintenance, make sure the attachment is properly blocked to prevent accidental
rotation. Do not rely on the rotation motor or other rotation components to inhibit movement during
maintenance or servicing. Always perform appropriate Lockout/Tagout procedures.

© 2023 Genesis Attachments, LLC Genesis GHG 75-125 Handling Grapple 17
Do not work on any hydraulic lines or components while they are pressurized. Escaping hydraulic
uid 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 uids under high pressure. Use a piece of cardboard to search
for leaks.
If uid is injected into the skin, seek medical assistance immediately from a
doctor familiar with this type of injury.
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.
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.
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 ammable
materials from area. Allow fumes to disperse at least 15 minutes before welding or
heating.
Avoid re hazards. Keep the area clean. Remove all ammable materials
from the area during any welding or heating process. Have a re
extinguisher nearby and know how to use it.
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.
See “Use Care with Hydraulic Fluid Pressure”, page 12
NOTICE
MAINTENANCE SAFETY

© 2023 Genesis Attachments, LLC
Genesis GHG 75-125 Handling Grapple
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Performing scheduled maintenance will promote safe, reliable operation of your attachment. 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.
Four-Hour Checklist
Inspect:
• Bolts - check for loose bolts, replace if damaged
• Fittings and hoses for damage or leaks
• Bracket pivot for wear and pin retainers
• Cylinder pivot for wear and pin retainers
• Entire attachment for cracks (visual check)
Grease:
• Cylinder pins (the ttings on the end of the cylinder)
• Pivot pins/drag link pins
Eight-Hour Checklist
Perform four-hour checklist plus the following:
Grease:
• Bracket pivot (stick pin)
• Bracket cylinder(H-link pin)
• Rotation bearing (four locations)
• Rotation bearing gear teeth
Tines:
• Check for loose or damaged bolts, retorquing loose bolts
• Build-up and hard-surface as required
Long-term Maintenance
• Check all bolts, including slewing ring bolts, after the initial 80 hours of operation
• Replace slewing ring bolts every 2000 hours
• Reseal cylinder every 4000 hours
• Reseal swivel every 4000 hours
MAINTENANCE SCHEDULE
Extreme operating conditions may require shortened
maintenance intervals.
NOTICE

© 2023 Genesis Attachments, LLC Genesis GHG 75-125 Handling Grapple 19
For normal conditions above 32˚F (0˚C), use a lithium-based, premium grade 2 extreme-pressure
grease. For temperatures below 32˚F, use a grade 0 grease.
Do not use grease containing Molybdenum (Moly).
Genesis GLG-2®anti-wear, extreme-pressure lithium grease, PN 6302601, is recommended for all
temperature conditions.
Grease all ttings every four to eight hours of operation (see maintenance schedule). Grease until
extrusion is visible.
After greasing the rotation bearing, rotate the attachment through two full rotations. The cylinder
and pivot should be greased at four hours and eight hours of operation, while the attachment is
warm. The bracket and rotation should be greased at the end of an eight-hour shift.
Grease locations:
1. H-link pin (grease through H-link) - not shown
2. Stick pin - not shown
3. Attachment cylinder rod
4. Attachment cylinder butt
5. Pivot pins
6. Rotation bearing (four locations)
7. Rotation bearing gear teeth
8. Drag link pins
LUBRICATION POINTS
!DANGER
Shut o󰀨 excavator and disable hydraulics per OEM
instructions before greasing.
8
4
5
3
6
7

© 2023 Genesis Attachments, LLC
Genesis GHG 75-125 Handling Grapple
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BOLT TORQUE SPECS
Bolt torque specs and thread treatment procedures can be found in the
Genesis Fastener Manual.
genesisattachments.com/manuals