Kesla proG 20 User manual

GRAPPLE proG
20, 25, 25E, 25P, 26, 26E
OPERATION
SERVICE
SPARE PARTS
2018 09
(a translation from the original version)

GRAPPLES – USER MANUAL 1
INDEX
1.GENERALINSTRUCTIONS................................................................................................................................2
1.1.ABOUTTHEUSERMANUAL.....................................................................................................................................2
1.2.CONTACTDETAILS...................................................................................................................................................3
1.2.WARNINGANDINSTRUCTIONDECALS....................................................................................................................3
2.IMPORTANTSAFETYINSTRUCTIONS................................................................................................................5
3.INTRODUCTIONOFTHEMACHINE...................................................................................................................8
4.INSTALLATIONINSTRUCTIONS........................................................................................................................9
4.1.INSTALLINGTHEGRAPPLE.......................................................................................................................................9
4.2.SAFETYGLASSESOFTHEBASEMACHINE.................................................................................................................9
4.3.INSTALLATIONOFTHEHYDRAULICS......................................................................................................................10
5.OPERATIONINSTRUCTIONS..........................................................................................................................11
5.1.SAFETY...................................................................................................................................................................11
6.MAINTENANCE.............................................................................................................................................12
6.1.SAFETYINMAINTENANCE.....................................................................................................................................12
6.2.GENERALINSTRUCTIONS.......................................................................................................................................12
6.2.1.Spareparts....................................................................................................................................................12
6.2.2.Cleaning.........................................................................................................................................................12
6.2.3.Welding.........................................................................................................................................................12
6.3.REGULARSCHEDULEDMAINTENANCE..................................................................................................................13
6.3.1.Afterthefirst20hours..................................................................................................................................13
6.3.2.Dailymaintenance(orafterevery20hours).................................................................................................14
7.HYDRAULICSYSTEM–FUNCTIONANDADJUSTMENTS..................................................................................15
7.1.SAFETYINSTRUCTIONS..........................................................................................................................................15
7.2.HYDRAULICOIL......................................................................................................................................................15
7.3.BIODEGRADABLEHYDRAULICOILS........................................................................................................................16
8.TROUBLESHOOTING...........................................................................................................................................17
8.1.GENERAL...............................................................................................................................................................17
8.1.1.Mechanicalfaults..........................................................................................................................................17
8.1.2.Electricfaults.................................................................................................................................................17
8.1.3.Hydraulicfaults.............................................................................................................................................17
9.DISPOSINGOFTHEMACHINE.............................................................................................................................17
APPENDIX1:DECLARATIONOFINCORPORATIONFORPARTLYCOMPLETEDMACHINERY.......................................18
APPENDIX2:TERMSOFWARRANTY......................................................................................................................19
APPENDIX3:CERTIFICATEOFDELIVERY.................................................................................................................22
APPENDIX4:CUSTOMERFEEDBACK.......................................................................................................................24
APPENDIX5TECHNICALDATA................................................................................................................................25

GRAPPLES – USER MANUAL 2
DEAR CUSTOMER
Thank you for the confidence you have shown towards KESLA product. We wish you the
best of success in your efforts. Please read through this owner's manual carefully,
because thorough knowledge of the machine, correct adjustments and careful
maintenance will guarantee user safety and reliable operation of the machine. It is
important that every part of this manual is understood and that the instructions are
followed. In unclear situations, please contact the seller of the machine. You can also give
a feedback to Kesla by a questionary in the end of this manual or in www.kesla.com.
1. GENERAL INSTRUCTIONS
1.1. ABOUT THE USER MANUAL
This manual concerns the operation and maintenance of a
KESLA grapple. Study the manual carefully before operating the
machine. Using the machine requires also some general
knowledge and skills in forestry. This user manual is written for
persons with prior practical experience in using forestry machines.
In addition to this user manual there is also a spare parts
catalogue and specified technical data.
The KESLA grapples are intended to be installed on carriers
specially equipped for forest use. Study carefully also the user
manuals of the carrier as well as control before operating or
servicing the machine.
The warning symbol is used with a very important safety warning.
Failure to observe these instructions may result in danger of
death or personal injury.
The note symbol reminds of a risk that the product, process or
environment may be harmed.
All the descriptions, instructions and technical specifications in
this manual are based on the latest information about the
machine structure when printing the manual. The product is
constantly developed and therefore the manufacturer reserves the
right to changes in the product without prior notice.
In case of malfunctions in the machine contact the seller of the
machine or a repair shop authorised by the seller.

GRAPPLES – USER MANUAL 3
1.2. CONTACT DETAILS
www.kesla.com
ORDERING OF SPARE PARTS [email protected]
MAINTENANCE AND WARRANTY ISSUES [email protected]
SPARE PART AND MAINTENANCE SERVICES tel.[phone]
1.2. WARNING AND INSTRUCTION DECALS
Warning and instruction decals have been attached to the grapple
to warn for possible risks caused by operation or to give
instructions for use. Following them will help avoiding accidents
and machine breakage.
DECAL NR 1: MACHINE IDENTIFICATION PLATE
Weight: Includes the weight of the grapple without any
optional equipment or accessories.
Type: Model name
Serial No: Individual identification number
Year: Manufacturing year
Fill the information on the machine identification plate in the
picture below.
When ordering spare parts or asking for repair instructions, tell the
seller or repair personnel the information given in the machine
identification plate. This way you can speed up getting help
regarding malfunctions and ensure that you get the right spare
parts as quickly as possible.

GRAPPLES – USER MANUAL 4
DECAL NR. 2: READ THE USER MANUAL
This label reminds the user to study carefully the user manual
before using, installing, servicing or repairing the grapple.
If the machine has several operators, the owner / keeper must
guide them in using, installing, servicing or repairing as well as
make the operators to study the user manual.
The owner / keeper must return to an authorised re-seller a filled
in delivery certificate and assurance certificate about familiarising
himself with the user manual, at the latest 14 days after the
delivery of the grapple to the client (see terms of warranty).
Mailing address for the delivery/assurance certificate:
Kesla Oyj, Metsolantie 2, FIN-59800 Kesälahti, Finland.
There is no storage place for the user manual in grapple so the
user must store the manual in the cabin .The user manual must
always be available to the user.
DECAL NO. 3: DANGER OF CRUSHING
The machine in operation has a risk zone of 25 metres. The
operator is responsible for ensuring that no bystanders enter the
risk zone.
2.

GRAPPLES – USER MANUAL 5
2. IMPORTANT SAFETY INSTRUCTIONS
DE-PRESSURIZING GRAPPLE:
After stopping the engine there may remain some pressure in
hydraulic components of the grapple. This pressure may cause
spraying of high-pressure oil. RISK OF SERIOUS INJURY!
BEFORE ANY MAINTENANCE DE-PRESSURIZE THE
GRAPPLE
These safety instructions do not cover all possible operating
conditions, but are helpful in avoiding dangerous situations and
accidents.
In addition to the given instructions, follow the legal safety
instructions and occupational safety regulations. Observe also the
instructions given in the user manuals of the base machine . The
dealer and owner of the machine have to make sure to comply
with all the local rules and regulations.
Familiarise yourself with the functions, controls and operating
instructions of the grapple before using the machine.
Follow all the precautions and instructions related to grapple use.
This way you may avoid accidents when working with the grapple.
Do not operate, service or repair the grapple under the influence
of alcohol or drugs.
Using the grapple is allowed only when all the safety equipment
and protections are appropriately in place and in good condition.
When operating, servicing or repairing the grapple, wear personal
safety equipment such as safety boots and helmet, ear protection
and safety goggles. Use well-fitting clothes with no long hanging
parts. Loose clothes can cause a danger of entanglement.
Note the danger of slipping when working near the grapple.
Check that no bystander is within 25 m of the grapple when you
start the engine and start operating. When necessary, place
warning signs around the logging site.
Pay attention to phone and power lines. Be extremely careful
when working close to high voltage power lines. Check safety
distances from the local electrical safety regulations. When
necessary, contact the telephone and power company.

GRAPPLES – USER MANUAL 6
In case of accident with phone or power lines, consider what to
do. When you have to leave the machine, do not touch the
machine and the ground at the same time. Exit outside the
electrical field jumping both feet together.
Always stop the engine of base machine and take care that no
one connects power when servicing the grapple. Make sure that
hydraulic pressure is released from all parts of the grapple. Note
that the grapple head may fall down if the boom lowers or the
base machine moves.
Perform maintenance activities with due consideration and calm.
When changing components, connectors and hoses, use only
spare parts with sufficient pressure classification.
The hydraulic pressure measurement and adjustment can only be
performed by a service engineer familiar with hydraulics, using
great care and consideration.
The engine must be stopped when connecting pressure gauge,
adjusting valves, repairing the grapple etc., because service
engineer is close to the moving parts of the grapple. While
measuring pressure, the persons must be out of reach of the
moving parts of the grapple.
Raising the pressure settings out the range specified by
manufacturer will cause an overload situation which can break the
grapple. Danger of accident!
Keep the hydraulic hoses in good condition. Change the broken
ones immediately. High-pressure oil spray from a broken
hydraulic hose or connector may penetrate under skin and cause
serious infection. In case of accident, contact physician
immediately.
When finishing work or stopping the engine always lower the
grapple head onto the ground or onto some other stable surface.
Notice that unwanted lowering of the crane may cause the
grapple falling down.
Staying under a hanging grapple is always prohibited without an
exception.
When finishing work, switch off the grapple. Switch off the main
power switch of the machine (if exists) when leaving the machine.
A blown fuse may be replaced only with a fuse of same size and
type.

GRAPPLES – USER MANUAL 7
When operating or maintaining the machine, avoid skin contact
with oil or grease. The oil and grease may contain additives which
can be harmful when frequently contacted with the skin. Always
follow the manufacturers’ and authorities’ instructions and
regulations when handling these substances.
Be careful of hot oil!
Use appropriate protective clothes, protective skin lotions or
appropriate gloves when handling oils and greases. Use safety
goggles as well.
Do not use lubricants or greases to clean your hands. Possible
metal flakes and additives in lubricants may damage your skin.
If the oil or grease causes changes to the skin, contact a
physician immediately.
Waste oil released in servicing or repair as well as oily hoses are
harmful for environment and must be taken to appropriate
treatment.

GRAPPLES – USER MANUAL 8
3. INTRODUCTION OF THE MACHINE
The KESLA grapples are designed to be installed on cranes
specially equipped for forestry use. Before mounting make sure
your grapple is suitable for the base machine size.
The grapple is used for the handling of felled, delimbed and cut-
to-length timber as the loading device of a timber loader.
Grapple is designed only for mounted hanging free.
The heads are intended to process trees, all other use is
prohibited.
Never use the grapple for handling stones, scrap, etc., and never
use it as a hammer.
Pushing the grapple hard against the ground may damage it.
When handling fragile goods, note that there is a risk that the
goods can be damaged.

GRAPPLES – USER MANUAL 9
4. INSTALLATION INSTRUCTIONS
4.1. INSTALLING THE GRAPPLE
Remove the corrosion protection from the hydraulic cylinder.
Clean the rotator mounting face.
The strength class of fixing bolts must be at least 8.8 and that of
nuts at least 8. Check tightening torque table 6.3.1
After the first 20 working hours please check and tighten.
After installed the grapple, check the stability of the combination
according to standard EN12999 both by calculation and
experimentation.
Because of the risk of hitting objects the basic machine shall be
equipped with windscreen qualifying the local safety regulations!
4.2. SAFETY GLASSES OF THE BASE MACHINE
For forest use, the base machine must be equipped with safety
glasses because of the risk of timber hitting the cabin.
In excavators where the cabin turns with the boom, it is normally
enough to change the front windscreen and the sunroof. In
machines where the boom turns to the side of the cabin, also the
side windows and when necessary also the back window must be
changed.
In the EU, the minimum requirement is defined in ISO8084
standard. Safety regulations may vary and they must be checked
locally.
KESLA recommends using a minimum of 12 mm thick hard-
surfaced polycarbonate in the windows of grapple base machine.
When working always remember the 25 m safety distance from
other persons.

GRAPPLES – USER MANUAL 10
4.3. INSTALLATION OF THE HYDRAULICS
Use hoses of proper diameter and pressure class.
Take care of cleanliness in all hydraulic installations.
Check hydraulic pressure. The pressure must not exceed the
value given on the machine plate.
When installing hoses, make sure that the hoses do not rub
against each other or against other parts of the grapple’s
structure. Check this by opening and closing the grapple jaws
several times.
Removal of air from cylinders:
Fully open the jaws. Carefully open the hose coupling on the rod
side and allow air to escape (Note! Air is always in the upper part
of a cylinder), then tighten the hose coupling. Close the grapple
jaws, and repeat the procedure for the coupling at the bottom.
Repeat this until no further air is released.
Air in the cylinder may damage seals.
Adjust pressure to suit the grapple. See the correct model-specific
pressure from the technical specifications of the grapple.
Do not exceed specified pressure values. Risk of an
accident!
Grapple cylinder must be protected by pressure relief/ anti-cav
valve. Use shock valves in both A and B ports of the directional
valve of the crane.
Choose pressure set of the shock valves 2Mpa higher than max
pressure of the grapple.

GRAPPLES – USER MANUAL 11
5. OPERATION INSTRUCTIONS
5.1. SAFETY
Familiarize yourself well with the operation and safety
instructions before starting to operate the grapple and follow
them during operation.
Use of the grapple to handle persons, live animals, or hazardous
substances is strictly forbidden.
Lifting loads above or in the immediate vicinity of people or
animals is forbidden.
Ensure the stability of the machine when working on soft ground
or slope and lock the parking brake during timber handling.
Before starting the engine, make sure that there is no one inside
the danger zone. DANGER ZONE is 25 m.
Make sure that you can see the entire working area without
obstacles.
Stop the engine when leaving the cabin.
Un-trained persons are not allowed to manoeuvre the machine.
As a user you are responsible for the machine not causing harm
to others.

GRAPPLES – USER MANUAL 12
6. MAINTENANCE
6.1. SAFETY IN MAINTENANCE
BEFORE ANY MAINTENANCE DE-PRESSURIZE THE
GRAPPLE
Note the risk of grapple falling down when the boom lowers or the
machine moves.
6.2. GENERAL INSTRUCTIONS
6.2.1. Spare parts
Always state the individual machine identification number (serial
no.) given in the machine identification plate when ordering spare
parts.
Use only original KESLA spare parts.
6.2.2. Cleaning
Be careful when cleaning the grapple with pressure washer.
Seals, bearings and electric cables can be damaged by high-
pressure water.
6.2.3. Welding
In case you have to weld the grapple or the base machine,
disconnect the cables from the electronic units of the base
machine, according to the instructions given by the manufacturer.
Clean the weld area of oil, paint and dirt.
Ground as close to the weld area as possible.
Take care that electrical components, cables and hydraulic hoses
are not heated.
Wear appropriate welding mask and protective clothes.
Keep a fire extinguisher available during welding.

GRAPPLES – USER MANUAL 13
6.3. REGULAR SCHEDULED MAINTENANCE
The given maintenance intervals are valid only when the machine
works at normal capacity in normal operation conditions. Shorten
the maintenance intervals if the machine is used heavily or when
working conditions are disadvantageous (very high or low
temperature, sand, dust, mud, etc.).
6.3.1. After the first 20 hours
During the first working hours with a new machine loosening of
some screws and bolts is normal. Therefore, after the first 20
working hours please check and tighten, if needed, all the bolts
and screws of the grapple.
Please see the list below for the correct tightening torque for each
screw.
Tightening torque for screws with a metric ISO thread
(unless specified separately)
Nm
8.8 10.9 12.9
M4 2.8 4.0 4.9
M5 5.7 7.9 9.5
M6 9.7 13.7 16.2
M8 23.5 33.3 39.2
M10 47.1 65.7 79.4
M12 81.4 114.7 137.0
M14 130.0 181.0 216.0
M16 196.0 280.0 333.0
M18 270.0 382.0 461.0
M20 382.0 539.0 647.0
M22 519.0 730.0 873.0
M24 662.0 932.0 1118.0
M30 1324.0 1863.0 2236.0

GRAPPLES – USER MANUAL 14
6.3.2. Daily maintenance (or after every 20 hours)
Grease all grease nipples of the grapple
Check possible oil leaks, hoses, structures, tightness of
screws and nuts as well as fastening of axles and pins.
Clean the grapple from sand, snow, ice and trash.
The given lubrication interval is valid only in normal working
conditions. Shorten the lubrication interval if the machine is used
heavily or working in difficult conditions.
Recommended lubricants:
BP LS-EP2
AGIP GRMU EP2
ESSO Beacon EP 2
MOBIL Mobilux EP2
SHELL Calithia EP 2
20 h

GRAPPLES – USER MANUAL 15
7. HYDRAULIC SYSTEM – FUNCTION AND ADJUSTMENTS
7.1. SAFETY INSTRUCTIONS
Hydraulic pressure measurement and adjustment must only be
performed by a person familiar with hydraulics.
When working at the grapple be careful of the lowering crane.
Keep unauthorised persons away from the controls. RISK OF AN
ACCIDENT!
Be careful when measuring pressure because of the high
pressure in the hydraulic system. Ruptured hoses, leakage and
opening of connectors can cause serious injuries because of oil
spraying out.
Always before any maintenance engine must be stopped, power
switched off and hydraulic system pressure-free
Remember cleanliness also when handling pressure gauge and
measuring connectors.
7.2. HYDRAULIC OIL
A mineral-based hydraulic oil is suitable for grapple use.
Check the pertinent ISO classification (ISO32 or ISO46) according
to the conditions and instructions given by manufacturer of the
base machine.
Current bio-degradable oils are unsuitable for use in Kesla
grapples.
Continuous high temperature of the hydraulic oil prematurely ages
the seals of the grapple.
Check the oil level daily!
The hydraulic oil should qualify cleanliness class 18/16/13 ISO
4406 or cleaner.
Oil temperature must be between -20 … +70 ˚C (-4 … +158 ˚F)
Oil viscosity must be 20 - 50 cSt during normal operation (15 –
2000 cSt at start-up)
The hydraulic oil must not contain water.

GRAPPLES – USER MANUAL 16
Change the hydraulic oil according to the instructions given by the
manufacturer of the base machine.
Cleanliness is of utmost importance in storing and handling
hydraulic oil.
Remember cleanliness also when handling spare parts and
hoses.
Fill hydraulic oil to the system always through a filter.
7.3. BIODEGRADABLE HYDRAULIC OILS
* Instead of normal hydraulic oils, oils that dissolve quicker in the
environment have been developed to minimise the damage in
case of oil leakage. Many forestry companies require the use ot
these oils in their machines.
* Normal oils cannot directly be replaced with any biodegradable
oil without changing the hydraulic components (e.g. hoses).
* Biodegradable oils are divided into three main classes:
1. Synthetic hydraulic oils based on esters (HEE)
2. Synthetic hydraulic oils based on polyglycols (HEPG)
3. Hydraulic oils based on vegetable oils (HETG) e.g.
rapeseed oils
*NOTE! The use of HETG oils is prohibited in Kesla products!
* NOTE! Before using a biodegradable hydraulic oil, consult your
oil dealer when choosing a suitable oil type and clarify its
suitability for the hydraulic components.

GRAPPLES – USER MANUAL 17
8. TROUBLESHOOTING
8.1. GENERAL
When troubleshooting first find out if the fault is mechanical,
electrical or hydraulic.
8.1.1. Mechanical faults
Check that the function is not jammed.
8.1.2. Electric faults
The most common electric faults are
- bad contact in connectors (loose connector, wire became
loose from connector, moisture)
- broken wire (no contact or shortcut)
8.1.3. Hydraulic faults
Troubles in hydraulic system are often caused by foreign particles
in valve spool or restrictor, or a broken seal. Be careful to avoid
getting impurity to the oil when changing hoses and filling oil to
the system.
9. DISPOSING OF THE MACHINE
When the grapple ends its service life, it shall be disposed
appropriately. Follow these instructions to avoid unnecessary
damage to the environment.
- A grapple to be scrapped should be delivered to a scrap yard
where scrapping takes place under control.
If you cannot deliver the grapple to be scrapped, act as follows:
- Drain the oil from the hydraulic system and deliver waste oil to
a monitored waste oil collection point.
- Disconnect all hydraulic hoses and deliver them to a suitable
collection point.
- Deliver the metallic parts to metal waste collection.

GRAPPLES – USER MANUAL 18
APPENDIX 1: DECLARATION OF INCORPORATION FOR PARTLY COMPLETED
MACHINERY
Manufacturer: Kesla Oyj
Kuurnankatu 24, FI-80100 JOENSUU, FINLAND
Name and address of the person authorised to compile the relevant technical documentation:
Riku Väyrynen
Kuurnankatu 24, FI-80100 JOENSUU, FINLAND
Herewith declares that for the Partly Completed Machinery
Grapple head KESLA proG 20, 25, 25P, 26, 28, 30, 35, 40, 46, 50, 50L, 25E, 26E, 30E, 40E,
40E3, 50E, 50E6
Serial number:______________________
The following essential requirements of the Machinery Directive (2006/42/EC) are applied and
fulfilled: 1.1.1, 1.1.2, 1.3.2, 1.3.4, 1.3.6, 1.3.7, 1.3.8, 1.4.1, 1.5.3, 1.5.4, 1.5.11, 1.6.1, 1.6.2,
1.7.1, 1.7.1.1, 1.7.3, 1.7.4, 1.7.4.1, 1.7.4.2, 1.7.4.3
The relevant technical documentation is compiled in accordance with part B of Annex VII and
that this documentation or parts hereof will be transmitted by post or electronically in response
to a reasoned request by the national authorities
And that this partly completed machinery is in conformity with the provisions of the following
other EC-Directives
And furthermore, declares that
This partly completed machinery must not be put into service until the final machinery into
which it is to be incorporated has been declared in conformity with the provisions of the
Machinery Directive 2006/42/EC, where appropriate
the following (parts/clauses of) European harmonised standards have been used
SFS-EN ISO 12100
the following (parts/clauses of) other technical standards and specifications have been
used
ISO/TR 14121-2
Place, date: Joensuu 06.09.2018 Signature:_____________________
managing director, Simo Saastamoinen
(a translation from the original version)
Kesla Oyj Kotipaikka: Joensuu Y-tunnus 0168715-8
Kesälahden tehdas Metsolantie 2 59800 KESÄLAHTI puh. [phone] fax. [phone]
Joensuun tehdas Kuurnankatu 24 80100 JOENSUU puh. [phone] fax. [phone]