koller KFS20 User manual
Utility model granted!
English
Operating Manual
Mechanical Felling Wedge
Version with internal stop ‘Version 2022’
Issue: 2022 version 1
(Valid from model year 2022)
KOLLER GmbH
Kufsteiner Wald 26
A-6334 Schwoich / Austria
Tel.: +43 5372 63257
Fax +43 5372 63257 7
www.kollergmbh.com
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Important notice for operating manual
This operating manual is intended to allow proper and safe use of mechanical felling wedge.
The operating manual must be read and applied by each person, who is responsible for the
operational procedures of the felling wedge.
Improper operation of the device, in particular the non-observance of safety instructions and
warnings may result in personal injury or death.
For commercial application, in addition to the operating manual, the statutory regulations, standards
and laws, applicable on site or in the country of use, for safe and professional work must be observed.
All documents are protected under copyright law. The disclosure, as well as the reproduction of
documents, including excerpts, as well as utilisation and communication of its contents is not
permitted without express written authority.
The operating manual is an integral part of the device. The operating manual must be included in the
purchase of the felling wedge.
If you still have any questions after reading this operating manual, please contact Koller GmbH.
The importance of keeping this operating manual safe
The operating manual must always be available and must be kept near to hand by the equipment.
Signs and symbols in this operating manual
DANGER
A signal word that is used to indicate an imminently hazardous situation which, if not
avoided, can result in serious injury or death.
WARNING
A signal word that is used to indicate a potentially hazardous situation which, if not
avoided, could result in serious injury or death.
CAUTION
A signal word that is used to indicate a potentially hazardous situation which, if not
avoided, could result in slight or moderate injury.
NOTE
Indicates risk of damaging the machine.
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Table of Contents
1General 6
1.1 Identification 6
1.2 Modification of products 6
1.2.1 Warranty commercial use 6
1.2.2 Warranty private use 6
1.2.3 No warranty 6
2Product Description 7
2.1 Technical data 7
2.1.1 Overall view 7
2.1.2 Application 7
2.1.3 Performance Characteristics, Dimensions and Weight 8
2.1.4 Surroundings 8
2.1.5 Delivered condition 8
2.1.6 Optional Accessories 8
2.1.7 Identificaton 8
3Basic Saftey Instructions 9
3.1 Saftey Instructions 9
3.2 Warning notices 11
3.3 Product saftey 11
3.4 Intended use 11
3.5 Foreseeable misuses 12
3.6 Danger zones when felling 13
3.7 Emergency information 13
3.7.1 Emergencies at arborist work 13
3.8 Marking and fencing of hazardous areas 13
4Configuration and Function 14
4.1 Layout 14
4.1.1 Performance Characteristics, Dimensions and Weight 14
4.2 Functional description 15
5Operation 16
5.1 Saftey instructions for operation 16
5.2 Warning notices for operation 16
5.3 Operation of the device 17
5.3.1 Inspection before starting daily felling operations 19
5.3.2 Maintenance by operators 19
5.4 Faults 19
6Maintenance 20
6.1 Safety information for maintenance 20
6.2 Maintenance work 20
6.2.1 Care and cleaning work 20
6.2.2 Lubrication / greasing / control 20
6.2.3 Function check 22
6.3 Customer Service Information 22
7Storage 22
7.1 Storage conditions 22
7.1.1 Before a prolonged shutdown 22
7.1.2 Commencing use again after storage 22
8Transport 23
8.1 Saftey instructions for transport 23
8.2 Transport 23
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1 General
1.1 Identification
Translation of original operating manual for mechanical felling wedge with internal stop
Version 2021
Language: English
Product
Series:
felling wedge (wide)
felling wedge narrow
Type:
mechanical felling wedge
mechanical felling wedge
Number:
KFS20
KFS20s
Year of manufacture and No.:
see rating plate
see rating plate
Manufacturer
Koller GmbH
Kufsteiner Wald 26
A-6334 Schwoich
Tel.: +43 5372 63257
Fax: +43 5372 63257-7
Email: office@kollergmbh.com
www.kollergmbh.com
1.2 Modification of products
Modifications or additions to the felling wedge by the customer are prohibited.
Any modification of the felling wedge will invalidate the declaration of conformity.
Therefore, changes or additions are only permitted after consultation with Koller GmbH.
1.2.1 Warranty commercial use
The purchaser has statutory warranty entitlements during a warranty period of 12 months from
transfer of risk.
The seller should always be afforded the opportunity to rectify errors within an appropriate period.
Further claims, especially claims for damages due to consequential damages are excluded, as far
as legally permissible. Defects must be immediately notified against the seller in writing.
1.2.2 Warranty private use
The purchaser has statutory warranty entitlements during a warranty period of 24 months from
transfer of risk.
1.2.3 No warranty
The manufacturer will not accept liability in the following cases:
For any components that are subject to natural wear. These include such items as bearings etc.
For defects that are based on the weather, chemical, physical, electrochemical or electrical
influences, insofar as they are not the fault of Koller GmbH.
For defects caused by failure to follow the rules on handling, care and maintenance of the device
according to the operating manual.
For defects caused by failure to use original spare parts of Koller GmbH or incorrect assembly
by the purchaser or third parties or by faulty or negligent treatment.
For the consequences of modifications that are improper and performed without the consent of
Koller GmbH, or repair work by the purchaser or third parties.
For defects that are due to unsuitable or improper use.
For damage or performance limitations that are caused by use of non-original parts and
accessories.
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2 Product Description
2.1 Technical data
2.1.1 Overall view
2.1.2 Application
The wide version of the mechanical felling wedge is used in harvesting of large and medium diameter
trees.
The narrow version is used in harvesting of small and medium diameter trees.
Compared to traditional felling wedges, the potential to unscrew and reposition the wedge, when the
spreading height is too low, represents a significant improvement and simplification of the workflow.
The trimming of tree tops, such as required at the erection of intermediate supports at cable yarding
systems or arborist work, is much safer compared to conventional wedge work, due to the impact-
free and simple operation.
The impact-free wedging considerably reduces the risk of falling dead wood.
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2.1.3 Performance Characteristics, Dimensions and Weight
Series:
Felling wedge (wide)
Felling wedge narrow
Weight:
2,80 kg
2,20 kg
Weight with ratchet:
3,40 kg
2,80 kg
Length / Width / Height:
310 mm / 95 mm / 90 mm
310 mm / 65 mm / 90 mm
Stroke per Rotation:
2,5 mm
2,5 mm
Max. torque:
250 Nm
250 Nm
Max. stroke:
30 mm
30 mm
Max. compressive force:
20 t
15 t
Timber thickness:
Large diameter timber
Small diameter timber
2.1.4 Surroundings
The felling wedge is designed for central European temperatures and can be used between -15 °C
(5 °F) and +40 °C (104 °F).
2.1.5 Delivered condition
Mechanical Felling Wedge
Ratchet
Operating Manual
2.1.6 Optional Accessories
Telescopic ratchet (without swivel), Item No.: V-0800139, weight 1,10 kg / 2.43 lbs, (only for wide
version)
NOTE
The telescopic ratchet must only be used with wide felling wedge Item No. 060-029-000!
2.1.7 Identificaton
060-0XX-000
20 to
X,X kg
20XX / XXX
Type
Max compressive force
Net weight
Model year / No.
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3 Basic Saftey Instructions
3.1 Saftey Instructions
Statutory safety instructions (e.g. "Forestry" accident prevention regulations) must always be
observed as a priority, regardless.
Only mentally and physically capable persons, who are accordingly trained and instructed, should
be employed. Employment restrictions for persons not of full age must be observed.
The operator must be trained in felling and forest work. Completion of a qualified course is
recommended in this connection.
The employer shall instruct the employee prior to commencement of work on the hazards and
preventative safety measures. This instruction must be repeated at least once per year, as well as
after accidents and near misses, and when changing the tools and working methods.
This training must be held in a form comprehensible to the workers (if necessary in their native
language). The employer must also be certain that the employee has understood the training.
The employer must keep a written record (certificates) of the instruction. The employees must follow
the instructions of the employer and use the protective equipment provided properly, and treat it with
care.
Personal protective equipment (depending on the respective activity):
Safety helmet, suitable hearing protection, work gloves, safety footwear, upper body clothing in signal
colour, fall protection, chainsaw protection trousers.
Working alone is prohibited!
First aid kit: A first aid kit (package) according to country-specific standard must be present.
Each person involved must have appropriate training and knowledge of first aid.
The forestry rescue chain must be implemented.
Follow country specific requirements for marking and fencing of hazardous areas, as well as the
obligations for notification and authorisation.
All persons must act in a manner so that they do not endanger third parties or themselves. All
measures must be taken immediately to avoid injury or damage, in the case of imminent danger.
Drinking alcohol, even in small amounts, is strictly forbidden.
The participants have to keep constant call or visual connection with each other.
Each chainsaw operator is responsible for the tree he cuts.
Each tree must be brought down completely before the next tree is felled. Hanging trees are to be
brought down immediately and professionally. If this is not possible, the hazardous area must be
marked, if necessary shut off. The same applies to hewn, grained and sawed trees.
Store not used machinery and equipment in a way nobody is endangered.
When working on slopes, you may only work one below the other when the workplaces are offset
laterally so that persons working deeper are not endangered by falling or rolling material.
The contractor must ensure that felling work is carried out only in daylight and not in case of sight
obstruction or strong wind. In bad weather, felling work must be stopped.
On steep slopes, in the case of clear ice, on frozen or frosted ground, felling work may only be
carried out if a secure standing position is ensured.
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The employer must ensure that felling work is not started until it has been ensured that only
persons who are involved in felling trees are in the felling area. Before the felling cut the saw
operator has to give a warning sign. A warning sign is for example the call "Attention, tree falls!"
In order to ensure that only persons who are part of the operation actually stay in the working area,
a comprehensive overview should be provided additionally to the warning sign.
Consistent compliance and control of safety distances.
The falling area of a tree and consequently the direct area of danger is basically the circular area
with a radius of at least twice the tree length around the tree to be felled.
Due to special danger situations for example on slopes, it may be necessary to extend the fall area
and danger area beyond twice the tree length during felling
Place tools against the direction of fall within a tangible distance. Do not block the escape routes.
Fallbacks are obstacle-free evasive options or escape routes that are generally intended to run
obliquely backwards to the falling direction.
When determining the direction of fall, the tree to be felled and its surroundings must be critically
assessed for possible hazards. Special attention is to be paid to cracked and dry branches or
crown parts (dead wood), to trunk rot and to the fibre orientation in the area of the stump. Never cut
the tree to be felled on standing dry, dead trees.
Always pay attention on safe footing.
Signalling: All signals must be explained by the plant manager before commencing work.
In the event of disruptions or threats to third parties, the operation must be discontinued and may
only be resumed after clarification of the situation.
Failure to comply with the safety instructions and warnings can result in serious injury or death.
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3.2 Warning notices
DANGER
Lethal voltages!
Working too close to electrical overhead lines will result in death or serious injury from
electrical shock.
Verify the location of the overhead lines.
Never touch an overhead line. Never assume that an overhead line is not energized.
Inquire about the operating voltage of the overhead lines.
Inquire about protective distances to overhead power lines and make sure you keep
to them.
Follow the safety precautions of the relevant operator of the overhead line.
DANGER
Danger of injury or death through rough terrain!
Carelessness can result in serious injury or death.
Never stand with your back to an obstacle.
Never walk backwards.
Always pay attention to the subsoil and the environment.
Establish your escape route before beginning to fell a tree and keep it clear.
When the tree begins to fall, immediatly leave to the escape route.
3.3 Product saftey
Although the felling wedge is state-of-art technology and meets recognised safety regulations, there
are still potential risks.
Only use the felling wedge under sound and proper conditions and pay attention to proper
maintenance.
Make sure you fully observe the safety instructions of the operating manual and the warning notices.
3.4 Intended use
The mechanical felling wedge is used in harvesting large and medium diameter logs.
In order to avoid overload due to gusts of wind, at least one additional ordinary plastic felling wedge
must always be inserted into the felling cut and repositioned regularly during spreading of the
mechanical felling wedge!
Use for other materials or purposes is not permitted.
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3.5 Foreseeable misuses
Only screw the wedge in up to the specified notch. If the wedge is screwed in till the maximum length
at the notch, further rotation will damage the thread and the spreading plate!
NOTE
Since the redesign 2019 a mechanical end stop is installed, which prevents the wedge
from being screwed over the maximum insertion depth.
•Do not forcibly turn against the end stop as there is a risk of damaging the
threaded sleeve.
•Under load, it may happen that the end stop is not perceived, therefore always
pay attention to the notch for the maximum insertion depth!
The mechanical felling wedge does not replace a winch or jack hoist! Pay attention to maximum
lifting force!
The felling wedge is operated via a ratchet. Never strike the mechanical felling wedge!
HINWEIS
It is not permitted to use pipe extensions or similar devices to expand the torque! The
maximum torque of 250Nm is designed for the strength of a person at the end of the
original ratchet and must not be exceeded.
HINWEIS
In case of use of a cordless impact screwdriver instead of the ratchet, it must be limited to
a maximum torque of 250Nm!
It is not recommended to use an cordless screwdriver to drive the felling wedge!
Destruction of
the spindle
Working area of the inner
wedge
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3.6 Danger zones when felling
The falling area of a tree and consequently the direct area of danger is basically the circular area
with a radius of at least twice the tree length around the tree to be felled.
Due to special danger situations for example on slopes, it may be necessary to extend the fall area
and danger area beyond twice the tree length during felling.
3.7 Emergency information
Appropriate rescue equipment must be provided at the place of work.
The parties involved must maintain constant verbal or visual contact with each other. Working alone
is prohibited!
In the event of injuries, secure the scene of accident and provide first aid (set up the rescue chain).
If injuries can be self-treated, keep records of the used material to the bandage book.
If necessary, request safety and rescue equipment.
3.7.1 Emergencies at arborist work
Provision must be made for the rescue of a person wounded while working in treetops. Each person
involved must have appropriate training and knowledge of first aid.
Equipment requirement for arborist recovery:
- Second climbing set
- Safety rope for abseiling
- Figure eight descender with split tail or other descenders
- Two to three carabiner safety clips
- Potential for separating tether - knife or rope nip
3.8 Marking and fencing of hazardous areas
Forestry
Hazard areas must be marked in accordance with the statutory forest regulations while working.
Public roads, streets, powerlines, etc.
Marking and fencing of hazardous areas must be agreed with the appropriate authority/office, in each
case, with sufficient notice in advance, and must wait for and be implemented with the related
approvals and relevant conditions.
1 tree length
2 tree lengths
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4 Configuration and Function
4.1 Layout
NOTE
The end stop has a left-hand thread and must be fitted with a medium-strength bolt
adhesive so that it cannot come loose.
When installing the castellated nut, take care that you don´t distort the bearing point.
4.1.1 Performance Characteristics, Dimensions and Weight
Series:
Felling wedge (wide)
Felling wedge narrow
Weight:
2,80 kg
2,20 kg
Weight with ratchet:
3,40 kg
2,80 kg
Length / Width / Height:
310 mm / 95 mm / 90 mm
310 mm / 65 mm / 90 mm
Stroke per Rotation:
2,5 mm
2,5 mm
Max. torque:
250 Nm
250 Nm
Max. stroke:
30 mm
30 mm
Max. compressive force:
20 t
15 t
Timber thickness:
Large diameter timber
Small diameter timber
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4.2 Functional description
The mechanical felling wedges from Koller are operated by means of a ratchet. When felling large
diameter timber we recommend the optional a telescopic ratchet. (The telescopic ratchet only
eases the operation; the maximum torque stays the same!)
To avoid tilting effects during the rotation of the threaded spindle, it was built into the feed wedge
and thus does not protrude beyond the felling wedge.
Another advantage of this design is that there is no contamination of the hands by the greased
thread while operation or transport of the wedge. Furthermore the thread is better protected against
contamination
The lubrication of the thread and the sliding surface of the feeding wedge is provided by a lubricating
nipple, which fills a grease reservoir for the threaded spindle within the feeding wedge, thus enabling
the best possible lubrication effect.
The special design of the pinch pattern on the spreading plate generates maximum possible grip to
avoid slipping out of the wedge.
Compared to ordinary felling wedge types, the potential to unscrew and reposition the wedge, when
the spreading height is too low, represents a significant improvement and simplification of the
workflow. (Felling cut is kept open by an ordinary felling wedge while unscrewing)
Trimming of tree tops while arborist work is much safer compared to conventional wedge work, due
to the impact-free and simple operation.
Another advantage is the direction of rotation of the spindle. It is turned counter clockwise. So the
operator can ergonomically support himself against the tree and actuate the lever by pulling with his
right hand.
The mechanical felling wedge also stands out for its small size and low weight. This allows the wedge
to be transported easiely by the operator. By hooking the felling wedge on the belt (only possible with
the swivel ratchet), the hands remain free for other tools.
Due to the high forces that occur and the harsh working conditions, wear of the moving components
is unavoidable. Therefore special attention was given to simple interchangeability of the individual
components during the development.
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5 Operation
5.1 Saftey instructions for operation
Observe the basic warnings in chapter: "3 Basic safety instructions"
The operator must check the equipment before every use (visual inspection)
Each chain saw operator is responsible for the tree he fells
The chainsaw chain must never contact the felling wedge while cutting otherwise the saw may
kickback or break the chain and cause serious injury
Position at least one traditional felling wedge in time so that the cut remains open and the saw bar
does not get pinched. During wedging the saw chain should be at a standstill.
Failure to observe the safety instructions and warnings can result in serious injury or death.
5.2 Warning notices for operation
DANGER
Danger of injury or death in rough terrain!
Falls and risk of falling due to uneven forest ground, roots etc.
Falling or rolling trees, root balls or stones can cause serious injury or death.
Never stand with your back to an obstacle.
Never walk backwards.
Keep an eye on the slope above. Logs, root balls or stones can start rolling.
Always pay attention to the subsoil and the environment.
Keep escape routes free.
DANGER
Injury or death due to mental and physical stress!
Carelessness can result in serious injury or death.
Swap over activities.
Avoid stress.
Comply with the permitted daily exposure values in respect of whole-body vibration.
Take additional short breaks to perform stretching exercises within the work shift.
DANGER
Injury or death due to falling of loose branches, tree parts,
overhanging trees or deadwood!
Carelessness can result in serious injury or death.
If there is a risk that loose branches, tree parts, overhanging trees or deadwood could
fall down, slide away or topple over, the work must only be carried on when adequate
safety measures have been taken.
Keep escape routes free.
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DANGER
Danger of injury or death through incorrect handling!
A lack of knowledge or expertise can result in serious injury or death.
The mechanical felling wedge does not replace a cable winch!
The operator must be trained in felling and forest work. Completion of a qualified
course is recommended.
DANGER
Danger of injury or death through toppling trees!
If the spreading plate fractures or the wedge slips out of the notch it can cause the tree to
fall in the wrong direction.
Always take account of the required insertion depth.
Always set a backup wedge parallel to the work progress.
Always keep the spreading plate in perfect condition.
Immediately follow emergency escape route.
5.3 Operation of the device
Always apply proper felling techniques.
Open out the felling cut with a chainsaw on both sides in a wedge shape so that the spreading
plate projects into the trunk at least up to the third row of holes (5 –6 cm / 2 –2.4 in.).
NOTE
Never strike the mechanical felling wedge!
The special design of the pinch pattern on the spreading plate generates maximum possible grip
against sliding out of the wedge.
Wedge-shaped
enlargement on both sides
Push in to at least here
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Position the wedge so that the centre line of the spindle is parallel to the saw plane. This ensures
that the wedge does not rub on the cut surfaces when screwing in and that the wedge does not get
bent which can cause the wedge to break or getting bent.
NOTE
If the centre line of the mechanical wedge is set at an angle to the saw plane, it may
cause damage to the threaded spindle and other components!
Further the centre line of the threaded spindle should be pointing in the direction of the logs centre
in order to achieve an even loading of the wedge over the entire width.
NOTE
Only screw the wedge in up to the specified notch. If the wedge is screwed in till the
maximum length at the notch, further rotation will damage the thread and the spreading
plate!
NOTE
Since the redesign 2019 a mechanical end stop is installed, which prevents the wedge
from being screwed over the maximum insertion depth.
•Do not forcibly turn against the end stop as there is a risk of damaging the threaded
sleeve.
•Under load, it may happen that the end stop is not perceived, therefore always pay
attention to the notch for the maximum insertion depth!
NOTE
Exceeding the maximum lever force leads to damage of the moving parts.
•Never operate the ratchet with extensions
•Do not jump onto the ratchet or operate it with two people
•Do not operate the ratchet with striking tools
Destruction of
the spindle
Working area of the inner
wedge
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CAUTION
Risk of injury from sharp edges!
The pinch pattern on the spreading plate can have sharp edges.
Operating conditions may give rise to sharp edges and burrs. There is a risk of cuts and
abrasions.
Always wear gloves when working.
To minimize the risk, (in case the felling wedge accidentally slides out from the saw cut) and to avoid
overload due to gusts of wind, always insert an additional safety wedge.
The safety wedge must be adjusted regularly with the work progress.
5.3.1 Inspection before starting daily felling operations
- Check for deformation, cracks or other damage.
5.3.2 Maintenance by operators
See 6.2.1 Care and cleaning work page 20.
5.4 Faults
Initial thread of the threaded sleeve and screw damaged by improper use:
- Re-cutting of thread in the foremost area by qualified technician.
Multiple threads of the threaded sleeve and screw damaged by improper use:
- Threaded sleeve must be replaced. Re-cutting of the thread is no longer possible.
Broken or rusted bearing through lack of maintenance:
- Bearing must be replaced.
Spreading plate is damaged e.g. due to cracks or deformation:
- Spreading plate must be replaced.
Bent screw, because wedge was inserted not in plane with the cutting gap or cutting gap was
enlarged on one side only:
- Screw must be replaced.
Limit stop broke:
- Limit stop must be replaced. In case of a damaged thread the threaded sleeve must also be
replaced.
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6 Maintenance
6.1 Safety information for maintenance
Wedges must be free of cracks and burrs.
The felling wedge must be serviced regularly and defective parts must be replaced immediately.
Repairs must not be improvised.
Use only original spare parts.
Hold a stock of wear parts.
Maintenance and repair work must be carried out in compliance with the instruction manual.
6.2 Maintenance work
Due to the high forces that occur and the harsh working conditions, wear of the moving components
is unavoidable; therefore, during development, special attention was given to simple
interchangeability of the individual components.
6.2.1 Care and cleaning work
Clean the felling wedge with a dry cloth or cleaning paper.
- Do not use abrasive detergents, as these can damage the plastic.
- Do not use any grease-dissolving agents.
- Do not use high pressure cleaners.
6.2.2 Lubrication / greasing / control
As a general rule: Always grease threads and sliding surfaces well, as this has a huge impact on the
life span and the achievable spreading force!
In order to achieve the longest possible service life, only high-quality multi-purpose greases of the
consistency class NLGI 2 with excellent adhesion and highest pressure resistance are
recommended for lubrication of the felling wedge.
Inferior multipurpose greases should not be used because their adhesion and pressure resistance
are insufficient which can result in wear of the thread and early signs of wear.
The initial lubrication of the felling wedge is done with Fuchs WSP 5040 (Koller article number V-
0700208). This grease is an extremely pressure-resistant special grease of the type "KPF" with
very good emergency running properties for the exceptionally high loads.
The use of this special grease is strongly advised as it significantly increases the lifespan and
reduces the effort required.
Since this is a heavily loaded thread, the felling wedge has to be lubricated daily with one stroke of
the grease gun via the grease nipple when retracted. Remove and discard excess and dirty grease.
The spindle has to be degreased with a grease remover (brake cleaner) in the fully extended
position regularly depending on the pollution of the grease - but at the latest weekly. This is due to
remove old grease with dirt particles and abrasion. Then the spindle must be greased again along
the entire length with clean grease (e.g. with a brush).
NOTE
Make sure that only the spindle is degreased! The grease remover must not get in
contact with the bearing and the plastic wedge!
•Carefully cover the bearing and wedge before applying the grease remover.
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