Kesla 2009S User manual

(a translation from the original version)
KESLA 2009S GB 2020 02
TIMBER HANDLING CRANE
2009S
2009ST
USER MANUAL
MAINTENANCE
SPARE PARTS

EC DECLARATION OF CONFORMITY FOR MACHINERY
Manufacturer: Kesla Oyj
Kuurnankatu 24, FI-80100 JOENSUU, FINLAND
Name and address of the person authorized to compile the technical file:
Riku Väyrynen
Kuurnankatu 24, FI-80100 JOENSUU, FINLAND
Herewith we declare that
Timber handling crane KESLA 2009S, 2009ST
Serial number:_____________________
•is in conformity with the relevant provisions of the Machinery Directive (2006/42/EC)
•is in conformity with the provisions of the following other EC-Directives
2014/30/EC
And furthermore, we declare that
•the following (parts/clauses of) European harmonised standards have been used
SFS-EN ISO 12100
SFS-EN-12999
Place, time: Joensuu 2/7/2020 Signature: ____________________
Managing Director Simo Saastamoinen
(a translation from the original version)
Kesla Oyj
Registered office:
Joensuu
Business ID
0168715-8
Kesälahti factory
Metsolantie 2
59800 KESÄLAHTI
tel. [phone]
fax. [phone]
Joensuu factory
Kuurnankatu 24
80100 JOENSUU
tel. [phone]
fax. [phone]

CONTENTS
EC DECLARATION OF CONFORMITY
1INTRODUCTION ..................................................................................................1
1.1 GENERAL INFORMATION .............................................................................................2
1.1.1 Storing the manual ...................................................................................................2
1.1.2 Manual contents.......................................................................................................2
1.2 MACHINE PLATE............................................................................................................3
1.3 PURPOSE OF THE CRANE............................................................................................4
1.4 RECOMMENDED OPERATING CONDITIONS...............................................................4
1.5 PROHIBITED USAGE AND CONDITIONS OF USE .......................................................4
1.6 GENERAL WARRANTY TERMS FOR KESLA PRODUCTS ...........................................5
1.7 THE INFORMATION AND WARNING SYMBOLS IN THE MANUAL............................... 7
1.7.1 Warning symbols......................................................................................................7
1.8 CONTACT INFORMATION .............................................................................................7
2SAFETY INSTRUCTIONS ....................................................................................8
2.1 GENERAL SAFETY INFORMATION...............................................................................8
2.2 THE BIGGEST SECURITY RISKS WHEN OPERATING AND MAINTAINING THE
CRANE ...........................................................................................................................9
2.3 SAFETY INSTRUCTIONS.............................................................................................10
2.3.1 Danger zones during use .......................................................................................11
2.3.2 Safety devices........................................................................................................12
2.3.3 Emergency stops ...................................................................................................13
2.3.4 Priorities and dimension drawings.......................................................................... 13
2.3.5 Caution and warning signs on the crane ................................................................14
2.4 HYDRAULIC SYSTEM ..................................................................................................19
2.5 SAFETY INSTRUCTIONS FOR HANDLING CHEMICALS............................................ 20
2.6 WELDING THE CRANE ................................................................................................21
2.7 INSTALLING ACCESSORIES AND MODIFYING THE DEVICE STRUCTURE............. 21
2.8 SAFETY PRECAUTIONS ON THE ROAD ....................................................................22
2.9 USER’S MANUAL KESLA CE -EQUIPMENT ................................................................ 23
3ABOUT THE CRANE .........................................................................................26
3.1 CRANE'S MAIN COMPONENTS................................................................................... 26
3.2 CRANE OPERATION....................................................................................................27
3.3 CRANE EQUIPMENT OPTIONS...................................................................................27
3.3.1 Basic crane models................................................................................................27
3.3.2 Crane accessories .................................................................................................28
4COMMISSIONING ..............................................................................................29
4.1 SAFETY INSTRUCTIONS FOR THE CRANE’S COMMISSIONING.............................. 29
4.2 PREPARATIONS FOR CRANE COMMISSIONING ...................................................... 29
4.3 CRANE MOUNTING .....................................................................................................30
4.3.1 Installation to a movable stand behind a truck........................................................31
4.3.2 Installing the crane behind the cabin ...................................................................... 32
4.3.3 Installation of the rotator and its hoses in Keslink: ..................................................33
4.3.4 Hose connections...................................................................................................34
4.4 INSTALLER...................................................................................................................35
4.4.1 Safety instructions..................................................................................................35
4.5 INSPECTIONS ..............................................................................................................35
4.5.1 Commissioning inspection......................................................................................35
4.5.2 Warranty service ....................................................................................................35
4.5.3 Periodic inspections ...............................................................................................36
4.5.4 Thorough periodic inspection .................................................................................36
4.5.5 The crane's daily inspection ...................................................................................36
4.6 INSTRUCTIONS ON HOW TO CALCULATE THE CRANE'S STANDING STABILITY.. 37
4.7 INSTRUCTIONS ON HOW TO DETERMINE EXPERIMENTALLY THE CRANE'S
STANDING STABILITY.................................................................................................38
4.7.1 Safety instructions..................................................................................................38
4.7.2 Test conditions.......................................................................................................38

CONTENTS
4.7.3 Performance of test................................................................................................38
5WORKING WITH THE CRANE ..........................................................................39
5.1 GENERAL INFORMATION ...........................................................................................39
5.1.1 Safety instructions..................................................................................................39
5.2 THE CRANE'S OPERATING PRINCIPLE .....................................................................40
5.3 WORKING METHOD ....................................................................................................40
5.3.1 Special Safety Instructions .....................................................................................40
5.3.2 Practice..................................................................................................................41
5.4 CRANE COMMISSIONING ........................................................................................... 41
5.5 EMERGENCY STOP MEASURES ................................................................................43
5.5.1 Tipping hazard .......................................................................................................43
5.5.2 Emergency stop in case of rupture of hoses...........................................................43
6ADDITIONAL INSTRUCTIONS ..........................................................................44
6.1 WAREHOUSING AND STORAGE ................................................................................ 44
6.1.1 Start-up after storage .............................................................................................44
6.2 ROAD TRAFFIC............................................................................................................45
6.3 REMOVAL OF A CRANE FROM USE........................................................................... 45
7TROUBLESHOOTING........................................................................................46
7.1.1 Safety instructions..................................................................................................46
8MAINTENANCE INSTRUCTIONS......................................................................47
8.1 SAFETY INSTRUCTIONS.............................................................................................47
8.2 GENERAL MAINTENANCE INSTRUCTIONS ...............................................................47
8.3 DAILY INSPECTIONS...................................................................................................48
8.3.1 Hydraulic hoses and pipes .....................................................................................48
8.3.3 Shaft locks .............................................................................................................48
8.3.4 Hydraulic system....................................................................................................49
8.4 MAINTENANCE SCHEDULE ........................................................................................49
8.5 TURNING DEVICE........................................................................................................50
8.5.1 Lubrication of the turning device.............................................................................50
8.5.2 Positions of the turning device................................................................................51
8.5.3 Opening of the turning device.................................................................................52
8.6 THE BOOM ...................................................................................................................53
8.6.1 Lubrication of the lifting boom................................................................................. 53
8.6.2 Lubrication of the transfer booms ...........................................................................53
8.6.3 Opening of the transfer booms ...............................................................................54
8.6.4 Adjustment of the tightening of the chains (two - extension models)....................... 54
8.6.5 Adjustment of the lateral clearings..........................................................................55
8.6.6 Adjustment of the vertical gap (one and two - extension models) ........................... 55
8.6.7 Changing of the sleeve bearing.............................................................................. 56
8.6.8 Adjustment of the grapple hanger brake................................................................. 56
8.7 THE HYDRAULIC SYSTEM .......................................................................................... 57
8.7.1 Requirements set for a good hydraulic oil...............................................................57
8.7.2 Impurities in oil .......................................................................................................58
8.7.3 Avoid any impurities in the oil.................................................................................58
8.7.4 Biodegradable hydraulic oils...................................................................................59
8.7.6 Performance of oil change .....................................................................................60
8.8 PRESSURE MEASUREMENT ......................................................................................61
8.8.1 Measurement .........................................................................................................61
9LUBRICATION ...................................................................................................62
9.1 LUBRICATION TARGETS.............................................................................................62
9.1.1 Oils and Lubricants ................................................................................................64
10 ELECTRICAL DIAGRAMS.................................................................................65
10.1 POWER SUPPLY CABLE CONNECTIONS .................................................................. 70
11 ANNEXES, TECHNICAL SPECIFICATIONS ETC.............................................71

GENERAL INFORMATION
1
DEAR CUSTOMER,
Thank you for choosing a KESLA product and we wish you success in your work. We ask you to
carefully read this manual as good knowledge of the machine's operation and meticulous man-
agement result in the best occupational safety conditions and the machine's productivity from day
to day. It is important that you have understood and complied with every section of this book. In
case of doubt please contact your dealer. You can also provide feedback to Kesla using the feed-
back form at the end of this manual or at www.kesla.fi.
1 INTRODUCTION
1. Read the instructions first. A prerequisite of the crane's use is a good understanding of its
safety and operating instructions.
2. Check the basic unit's compatibility with regard to hydraulics and standing stability.
3. Follow the installation instructions and, if necessary, ask more information from your dealer
or from the factory.
4. Carry out legally required inspections.
5. Practice makes perfect.
6. Always work with caution.
7. Make a slow full-scale operating movement back and forth with all the loader's cylinders to
make the gaskets more flexible.
8. Grease often and only a little bit rather than rarely and a lot.
9. Cleanliness is the most important thing in hydraulic systems.
10. Pre-loading oil: TEBOIL ECO 46
11. Repair even small defects before they can cause more serious damage.

GENERAL INFORMATION
2
1.1 GENERAL INFORMATION
This is a machine-specific instruction manual for the KESLA crane to be supplied with the crane.
This manual is intended for persons who have previous experience with the use of timber cranes.
Please read and understand the operation, maintenance, and safety instructions
before operating or servicing the crane. Operation, maintenance and adjustment
may only be carried out by people qualified for operating and servicing the specified
device. Lack of information on the device's operation and characteristics can cause
serious injury or death.
1.1.1 Storing the manual
This manual is an essential part of the product and must be maintained intact throughout the
product's service life. If any changes are made to the crane, they should be added to this manual.
Keep your manual clean and easily accessible. If the crane is sold, the manual must be handed
over to the new owner.
1.1.2 Manual contents
The operating instructions contain the following information:
•General information about the manual's purpose and content, instructions on how to read
the manual, as well as a request to provide feedback and report any possible errors.
•Safety instructions
•Daily inspections
•Operating instructions
*) The asterisk notifies information on the subject issue.
-) The dash indicates necessary / possible steps to be taken.
*All descriptions, instructions and specifications in this manual are based on the latest information
about the machine's structure on the date the manual was printed. The product is being continu-
ously developed and, therefore, the manufacturer reserves the right to change product specifica-
tions without prior notice.
*If machine malfunctions occur, the problem and its probable cause can be clarified and corrected
on the basis of the table. If you are unable to repair the machine yourself, please contact your
dealer or a service workshop authorized by the dealer.

GENERAL INFORMATION
3
1.2 MACHINE PLATE
When ordering spare parts or requesting repair instructions, communicate to your dealer or re-
pairman the information on the machine plate. This procedure will speed up getting help in case of
malfunction or ensure that you receive the correct parts as fast as possible.
Write the machine plate information to the machine plate's image below.
Machine plate location:

GENERAL INFORMATION
4
1.3 PURPOSE OF THE CRANE
KESLA timber handling crane is designed for timber loading in contracting work. The crane is also
suitable for loading scrap, sand, fertilizer, etc. when grapples fit for purpose are being used. Using
the crane for lifting persons is prohibited!
1.4 RECOMMENDED OPERATING CONDITIONS
* If work is carried out at low temperature, let oil circulate for a while through the valve system with
a low flow. Then slowly perform all the operating movements, back and forth, in order to make the
gaskets more flexible before they receive maximum pressure. The crane's lowest recommended
operating temperature is - 25°C.
* It should be noted that in lower temperatures hydraulic gaskets wear faster and the probability
that hoses and steel structures become more susceptible and steel structure's probability of brittle
fracture increases. When working in temperatures below - 25°C, it is preferable to lift smaller than
normal loads in order to avoid unnecessary damage.
* Similarly, in very warm conditions one should ensure that the hydraulic oil does not overheat
(<75°C). A too high oil temperature may cause damage to the gaskets and it also reduces oil life.
1.5 PROHIBITED USAGE AND CONDITIONS OF USE
The KESLA crane is designed for timber loading and it can be used
only by a person familiar with its use.
It is forbidden to use the crane without having studied its use and
safety instructions!
•Operation with hooks is not allowed!
•Use of the crane for towing is prohibited!
DANGER
RISK OF FALLING
•Using the crane for lifting of persons is prohibited!