NPK Genesis GSD Series User manual

Severe-Duty Grapple (GSD)
SAFETY, OPERATOR’S & PARTS MANUAL

© 2020 Genesis Attachments, LLC
Genesis GSD Grapple
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CONTACT INFORMATION
View and download all manuals: genesisattachments.com/manuals
Patents: genesisattachments.com/products/patents
Asia Pacic Representative Of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]

© 2020 Genesis Attachments, LLC Genesis GSD 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 con-
tact 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 Gen-
esis 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, applica-
tion, 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 litera-
ture 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 authoriza-
tion by the Genesis Service Department will render all warranty reimbursement consideration null
and void without exception. See page 23 for Warranty Claim Procedures.
Improper operation or improperly performed maintenance may render any warranty null and void.

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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
Safely Operate Equipment 10
Transporting the Attachment 11
Equipment Condition 11
Working Overhead 11
Power Lines 11
Prioritized Oil Flow 12
Emergency Situations 12
Unsafe Conditions 12
Crystalline Silica Dust 12
Process Material Safely 13
Lift the Load Safely 13
Place the Load Safely 13
ATTACHMENT MARKINGS 14
PAD INSTALLATION 15
GRAPPLE INSTALLATION 16
Grapple Removal 16
MAINTENANCE SAFETY 17
MAINTENANCE SCHEDULE 18
Eight-Hour Checklist 18
Grease 18
BOLT TORQUE SPECS 19
STRUCTURAL MAINTENANCE 20
Tine Tips 20
GENERAL WELDING GUIDELINES 21
Welding Ground Clamp 21
Welding Rules 21
HARD-SURFACING 22
Hard-Surfacing Patterns 22

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WARRANTY 23
Claim Procedure 23
Blade Warranty 23
PARTS ORDER POLICY AND PROCEDURE 24
Parts Orders Should Include 24
Placing Orders 24
Part Numbers 24
Shipping 24
Invoices 24
Returns 24
Return Goods Authorization 24
PARTS ORDER FORM 25
PARTS LISTS 26
Wear Parts GSD 10-70 27
Wear Parts GSD 90-250 28
CONTACT INFORMATION 29
TABLE OF CONTENTS
For bolt torque specs, see the Genesis Fastener Manual.
genesisattachments.com/manuals
NOTICE

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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 instruc-
tions involving your personal safety or the safety of oth-
ers. 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.

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!WARNING
Serious injury or death could result if appropriate protec-
tive 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 direc-
tions, 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 per-
sonnel must read this manual.

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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.
3Hydraulic uid level. Add hydraulic uid as required.
3All control levers for proper operation.
3Warning decals, special instructions and operators manuals. Make
sure they are legible and in the proper location.All control levers for
proper operation.
GOOD
CONDITION
3
!WARNING
Serious injury or death could result if warnings or instruc-
tions regarding carrier stability and the work area are not
followed properly.
Stability
Your Genesis attachment is sized for carrier stability. However, improper operation, faulty mainte-
nance 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 affect stability:
• Ground conditions
• Grade
• Weight of attachment
• Contents of attachment
• Operator judgment
OPERATIONAL SAFETY

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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 hydrau-
lic system.
To shut down:
3Return your Genesis attachment to a rest position on the ground.
3Shut off 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.
OPERATIONAL SAFETY

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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 trafc rules and ow. When
in doubt on any safety issue, contact your supervisor or safety coordi-
nator 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

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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 under-
ground 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 neces-
sary 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 move-
ment. 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 affect 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 instruc-
tions regarding working overhead are not followed prop-
erly.
!DANGER
Serious injury or death will result if warnings or instructions
regarding power lines are not followed properly.
OPERATIONAL SAFETY

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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 col-
lection (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 op-
erations 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 affect 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 respira-
tory disease.

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!WARNING
Using your Genesis attachment in unauthorized applica-
tions may create an unsafe situation and will void the war-
ranty.
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.
Lift the Load Safely
• Make sure the load is held securely in the jaws. Do not move a loaded attachment if the load
is loose or dangling. Make sure the load is pinched between the jaws – never cradle a load.
• Use extra caution during reaching to avoid tipping.
Place the Load Safely
• Do not move the attachment, or anything held in the jaws, over people, equipment or build-
ings. 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

© 2020 Genesis Attachments, LLC
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Decals are necessary for safe operation and maintenance. To reorder, contact your Genesis
dealer or call 715-395-5252.
ATTACHMENT MARKINGS
Model Number
Logo Decal
Serial Number
(welded on two tine jaw)

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Preparation of the excavator prior to attachment delivery will make installation safer and
easier. Contact Genesis or your Genesis dealer for assistance.
Curl the excavator stick under so the bottom of the stick is facing upward.
Use the mounting dimensions provided on your installation drawing to locate the correct place-
ment of the stabilizer pad on the bottom of the stick. The stabilizer pad must be centered on and
parallel to the stick.
Before Welding:
Disconnect battery ground cables or shut off master bat-
tery switch to avoid damage to the excavator’s onboard
computer systems. Connect welding ground clamp directly
to the parts being welded. Connecting to any other area
may cause arcing between moving parts such as bearings
or cylinder parts.
Weld the pad to the stick using E7018 low hydrogen elec-
trode or equivalent. Weld per instructions provided on your
Installation Drawing.
Install the stabilizer arm to the pad in the factory recom-
mended position.
Enlarged view of stabilizer pad
PAD INSTALLATION
!WARNING
Removing any connecting pin may be hazardous. To
remove a connecting pin, position the attachment on the
ground and properly support.
!WARNING
Particles may y when a pin is struck. Use a drift pin or
mallet when striking pins. Keep all personnel at a safe
distance.
Moving the stiff arm back one hole, further from the
grapple, from the factory recommended position, may
result in linkage and/or grapple toggle and damage to
the bucket cylinder.
!
CAUTION

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Remove the bucket following the manufacturer’s proce-
dure. Retract the bucket cylinder. The grapple must be on
a rm, level surface with the jaws closed.
Position the excavator behind the grapple and carefully
line up the stick connection of the excavator and grapple.
(Diagram A)
Install pin. (Diagram B)
Raise the grapple slightly off the ground and extend the
bucket cylinder. Connect power link of excavator to the
grapple. (Diagram C)
Align the stabilizer arm with the lower grapple jaw by mov-
ing the stick and operating the bucket cylinder. Pin the arm
to the grapple. (Diagram D)
Check all connections to ensure mounting pins are prop-
erly retained.
Stiff arm should be mounted in factory recommended pin
position.
Grapple Removal
To remove the grapple with the stiff arm attached and set
the stiff arm on a heavy object. Remove the pin from pad.
Slowly raise the grapple to allow stiff arm to hang. Move the
grapple to a storage position. (Diagram E)
Lower the grapple to the ground. Close the jaws to prevent
grapple movement after the link pin is removed.
Remove the grapple mount pins.
Diagram D
Diagram A
Diagram B
Diagram C
Diagram E
GRAPPLE INSTALLATION
!WARNING
Make sure all personnel stand clear. Lifting the grapple will
cause the jaw to move and the stabilizer bar to swing.
!WARNING
Make sure all personnel stand clear. Removing the pin
from the pad will cause the jaw to move and the stabilizer
bar to swing.

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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 or mechanical operation of the attachment. Doing so may cause a dan-
gerous 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 mainte-
nance 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 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, immedi-
ately shut down the equipment and report the situation to the proper authority.

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Performing scheduled maintenance will promote safe, reliable operation of your shear. Inspect and
grease components every eight hours of operation, as indicated on the following checklist. 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:
• Bolts - check for loose bolts, replace if damaged
• Bracket pivot for wear and pin retainers
• Entire grapple for cracks (visual check)
Grease:
• Bracket pivot
• Main shaft/pivot (both sides)
• Excavator stick tip and linkage joints per excavator OEM instructions
• Both ends of stiff arm
Jaws:
• Check tines for wear
• Build-up and hard-surface as required
Grease
Use a lithium-based premium EP #2 in normal conditions above 32° F (0° C). Use Grade 0 in tem-
peratures below freezing.
Grease all ttings every eight hours of operation. Grease all locations until grease extrusion is vis-
ible.
MAINTENANCE SCHEDULE

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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

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Before performing maintenance, read, fully understand and follow the safety rules outlined in this
manual.
Always wear personal safety equipment including gloves, safety glasses, safety boots and proper
clothing.
Tine Tips
At the end of each shift, check tine tip condition.
Tines may be built up and hard-surfaced.
Replace tine tips if the weld is gone or the plate is worn down from excess wear, as shown below.
Contact the Genesis Service Department at 715-395-5252 for additional information regarding
proper tine tip maintenance, wear and build-up procedures.
Weld
Wear
Wear
Side View Front View
STRUCTURAL MAINTENANCE