Related Manuals for Kesla 2009S
Summary of Contents for Kesla 2009S
- Page 1 TIMBER HANDLING CRANE 2009S 2009ST USER MANUAL MAINTENANCE SPARE PARTS (a translation from the original version) KESLA 2009S GB 2020 02...
- Page 3 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...
-
Page 5: Table Of Contents
PURPOSE OF THE CRANE.................... 4 RECOMMENDED OPERATING CONDITIONS ............... 4 PROHIBITED USAGE AND CONDITIONS OF USE ............4 GENERAL WARRANTY TERMS FOR KESLA PRODUCTS ........... 5 THE INFORMATION AND WARNING SYMBOLS IN THE MANUAL ....... 7 1.7.1 Warning symbols ...................... 7 CONTACT INFORMATION ..................... - Page 6 CONTENTS 4.7.3 Performance of test ....................38 WORKING WITH THE CRANE ................39 GENERAL INFORMATION ................... 39 5.1.1 Safety instructions ....................39 THE CRANE'S OPERATING PRINCIPLE ..............40 WORKING METHOD ....................40 5.3.1 Special Safety Instructions ..................40 5.3.2 Practice ........................41 CRANE COMMISSIONING ...................
-
Page 7: Introduction
GENERAL INFORMATION 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. -
Page 8: General Information
GENERAL INFORMATION 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. -
Page 9: Machine Plate
GENERAL INFORMATION 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. -
Page 10: Purpose Of The Crane
GENERAL INFORMATION 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! -
Page 11: General Warranty Terms For Kesla Products
Kesla factory. For spare parts the warranty period is 6 months from the date of purchase. Kesla shall supply spare parts, produced by Kesla, for a period of ten (10) years, af- ter the manufacturing of the Product has been stopped. - Page 12 Kesla Oyj or if hydraulic system is ad- justed exceeding allowed tolerances or reference values.
-
Page 13: The Information And Warning Symbols In The Manual
Black symbol in a red circle describes a prohibited action Direction sign White symbol on blue background describes an action that must be per- formed in order to avoid danger. CONTACT INFORMATION www.kesla.com SPARE PART ORDERS spare.parts@kesla.com SERVICE AND WARRANTY ITEMS after.sales@kesla.com Spare parts and services tel. -
Page 14: Safety Instructions
SAFETY INSTRUCTIONS 2 SAFETY INSTRUCTIONS GENERAL SAFETY INFORMATION Please read and understand the operation, maintenance, and safety in- structions before operating or servicing the cranes. Operation, mainte- nance and adjustment may only be carried out by people qualified for op- erating and servicing the specified device. -
Page 15: The Biggest Security Risks When Operating And Maintaining The Crane
SAFETY INSTRUCTIONS THE BIGGEST SECURITY RISKS WHEN OPERATING AND MAIN- TAINING THE CRANE DANGER PINCH HAZARD Hands or other parts of the body can be trapped inside the de- • vice's framework or under the load resulting in death or serious injury. -
Page 16: Safety Instructions
SAFETY INSTRUCTIONS DANGER TIPPING HAZARD! Instability of the device may cause its unexpected movement that • could result in death or serious injury. Never exceed the maximum slope angles when parking or operat- • ing the machine. Noise emission exposure made by the machines can cause weak- •... -
Page 17: Danger Zones During Use
SAFETY INSTRUCTIONS - the surface must be sufficiently strong and steady. - rotation of the stabilizer leg must be prevented with a locking pin (against tipping hazard)! - check that the rear mounting bracket has been locked to the vehicle with a chain. * Always connect the return hose before the pressure hoses. -
Page 18: Safety Devices
SAFETY INSTRUCTIONS * The crane is supplied with a label regarding safety distances from live wires. The label must be affixed to a location where it is easily readable when using the crane. * The label is placed to the control position and strictly forbids the presence of people in the danger zone during lifting (danger zone 25 m). -
Page 19: Emergency Stops
SAFETY INSTRUCTIONS 1. The main release prevents the working pressure to rise too high. There is one on each pressure control valve over each pressure connection. If the pressure of oil coming to the control valve exceeds the set value, oil will be discharged to the tank channel until the set pressure level has been reached once again. -
Page 20: Caution And Warning Signs On The Crane
SAFETY INSTRUCTIONS 2.3.5 Caution and warning signs on the crane The crane has warnings and instructions attached to various spots, regarding the danger or in- structions related to its use. By following them you can avoid accidents and machine breakdowns. If the machine's warning labels become detached or torn, they must be immediately repaired. - Page 21 SAFETY INSTRUCTIONS LABEL NO. 2 WARNING LABEL * The label is placed to the control position and strictly forbids the presence of people in the danger zone during lifting (danger zone 25 m). * The label warns about live electrical wires. If you need to work or to drive under a power line, follow the minimum distances given in the table.
- Page 22 SAFETY INSTRUCTIONS LABEL NO. 4. CONTROL CHART LABELS Two-lever control valve (No. 3280231) Four-lever control valve (No. 3280197) * The control chart label is located at the crane's control position and has, according to the control valve, either 2 or 4 levers. * The label shows the functions of levers and pedals.
- Page 23 SAFETY INSTRUCTIONS LABEL NO. 5 CHASSIS CONTROL CHART (background: yellow, text: black, no.: 3280198) * There are 2 label with the chassis control chart. One is located at the crane's control position and the second at the chassis control position. * The chassis control valve (=stabilizer leg valve) can be used from the crane's top control position electrically by lever switches or mechanically with cable control.
- Page 24 PLATE NO. 6 * Machine plate * The product plate shows the manufacturer's name and address, and the crane's designation of type (e.g. KESLA 2110T), as well as the serial number and year of manufacture. * CE: A pan-European approval.
-
Page 25: Hydraulic System
SAFETY INSTRUCTIONS HYDRAULIC SYSTEM • Follow the safety instructions regarding the hydraulic system when connecting and using the loader's hydraulic system. • The hydraulic system can be maintain and repaired and the related components can be installed only by trained operators. •... -
Page 26: Safety Instructions For Handling Chemicals
SAFETY INSTRUCTIONS RISK OF ACCIDENTS! • Due to commissioning, repair, maintenance or other reasons, air may have entered the hydraulic system, which can cause unpredictable movements. These movements can result in death or serious injury. • Be especially careful when starting the crane. •... -
Page 27: Welding The Crane
• If changes and corrections are made without Kesla's permission that hamper the machine's operation, safety and usability, the manufacturer is not liable for any events causing death, inju- ry or material damage, which is the result of such changes or repairs. -
Page 28: Safety Precautions On The Road
SAFETY INSTRUCTIONS SAFETY PRECAUTIONS ON THE ROAD • Do not ever exceed the permitted shaft weight and total weight and the transport dimensions. • Ensure that the aggregate's controllability during travel is main- tained in all situations. Also take into account the increased braking distance. -
Page 29: User's Manual Kesla Ce -Equipment
SAFETY INSTRUCTIONS 2.9 USER’S MANUAL KESLA CE -EQUIPMENT 2.9.1 Load indicator There is a signal light at the post of the pilot of the crane, indicates the load in use to the user (Fig- ure 1.1or 1.2). The system is based on the measure of the lifting pressure. The signal light has three colors, each of which indicates a different situation. - Page 30 SAFETY INSTRUCTIONS 2.9.2 Height indicator The lifting beam is equipped with a sensor which controls the angle of the beam and indicates if the maximum height is passed, in this case the red signal light turns on at the driver’s post. The signal light must be taken into account if the crane is positioned at the rear of the truck on top of the load during transportation.
- Page 31 SAFETY INSTRUCTIONS Before starting to drive the driver has to make sure that the height of the vehicle does not exceed the authorized maximum height. If the loading is done on a slope or on an uneven surface, you must not rely on the indica- tion of the signal light, instead you must measure the eight of the vehicle.
-
Page 32: About The Crane
ABOUT THE CRANE 3 ABOUT THE CRANE CRANE'S MAIN COMPONENTS... -
Page 33: Crane Operation
CRANE EQUIPMENT OPTIONS 3.3.1 Basic crane models KESLA timber handling cranes are delivered from factory as complete tested assemblies with sev- eral options for standard equipment from which the customer can choose the most suitable one. - Basic crane * Controls can be mounted directly behind the tower or to its side. -
Page 34: Crane Accessories
(located in the cabin) or electronically (located in the tower). * The crane's equipment options are the same as for the basic crane. 3.3.2 Crane accessories Several accessories are available for the KESLA timber handling crane making it’s use even more comfortable. -
Page 35: Commissioning
SAFETY INSTRUCTIONS FOR THE CRANE’S COMMISSIONING * The KESLA crane is designed for loading with a grapple and it can be used only by a person familiar with its use. * Operation with hooks is not allowed! * Acquaint yourself with the crane’s structure, operation, control devices and use instructions be-... -
Page 36: Crane Mounting
COMMISSIONING * The crane will be transported on its carrier block to the mounting location where the fasteners and clamps for transporting will be removed. * Visible cylinder shafts are protected. Remove the protective substance (for example with petrole- um) as the impurities that adhere to it could damage the seals. •... -
Page 37: Installation To A Movable Stand Behind A Truck
COMMISSIONING 4.3.1 Installation to a movable stand behind a truck * Fastening sheaths (2) should be mounted to the truck for the installation of the bracket (3). - follow the truck manufacturer's/distributor's instructions. * The rear mounting bracket (3) should be lifted to the fastening sheaths (2). * The rear mounting bracket can be fitted with a stand manoeuvring cylinder (5), in which case the truck will be fitted with an appropriate mounting kit with locking. -
Page 38: Installing The Crane Behind The Cabin
COMMISSIONING 4.3.2 Installing the crane behind the cabin * To the sides of the truck's subframe/frame bolt-on plates PL 10 (2) should be installed, with weld- ed sleeves for stud bolts M30 (3). - Follow the mounting instructions provided by the truck's manufacturer/importer - Truck manufacturers do not recommend clamp mounting that would compress the frame beams or welding directly to the frame beams. -
Page 39: Installation Of The Rotator And Its Hoses In Keslink
In- stallation differing from the instructions also considerably reduces the service life of hoses and Kesla Oyj's warranty will not be valid in case of improper installation. -
Page 40: Hose Connections
COMMISSIONING 4.3.4 Hose connections... -
Page 41: Installer
COMMISSIONING INSTALLER 4.4.1 Safety instructions Please read and understand the operation, maintenance, and safety in- structions before operating or servicing the cranes. Operation, mainte- nance 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. -
Page 42: Periodic Inspections
COMMISSIONING 4.5.3 Periodic inspections Periodic inspections and a related test run should be carried out to a used crane once every one year and a related test run according to the standard SFS EN 12999 or equivalent should be done once every four years. -
Page 43: Instructions On How To Calculate The Crane's Standing Stability
* If, when determining the standing stability, any parameters or questions appear that are not men- tioned in the truck's maintenance/registration book, please contact the nearest dealer or importer of the truck make in question. Or Kesla Oyj regarding the crane. -
Page 44: Instructions On How To Determine Experimentally The Crane'sstanding Stability
COMMISSIONING INSTRUCTIONS ON HOW TO DETERMINE EXPERIMENTALLY THE CRANE'S STANDING STABILITY 4.7.1 Safety instructions * The test has to be carried out with special caution: danger of tipping over! * Check before the test that all the crane cylinders are deaerated: sudden movements! * The surface must be flat and sturdy enough to withstand the load of wheels and other support points 4.7.2 Test conditions... -
Page 45: Working With The Crane
5 WORKING WITH THE CRANE GENERAL INFORMATION The safe and effective use of the device requires good knowledge of the device and extensive practical experience. Each crane model has different trajectory, speed and characteristics, so even experienced users are encouraged to thoroughly acquaint themselves with the operation of the new crane before its actual commissioning. -
Page 46: The Crane's Operating Principle
* The aggregate's standing stability is at its weakest when the load space is empty. When the ag- gregate begins to fall, lower the grapple immediately to the ground. Do not drop the load by open- ing the grapple. * Make sure that there are no people in the grapple's operation area and that you can see freely the entire operation area. -
Page 47: Practice
* Never leave the crane boom up without supervision! * When loading is complete, lower the crane firmly against the base and turn off the pump before driving off. * Use great caution when attaching or detaching the crane from a vehicle: DANGER OF TIPPING! •... - Page 48 * Check that all the crane’s control levers are in the middle position and that they also return to the middle position. * Refer to the crane's daily inspection. * Start the pump and adjust its output according to the crane's requirements (refer to specifica- tions).
-
Page 49: Emergency Stop Measures
EMERGENCY STOP MEASURES The crane's control system must be equipped with a STOPswitch located in the crane's control position. It can be used to cut off crane's oil supply (e.g. by an electrically controlled valve) or, al- ternatively, the electric current to the pilot-operated control valve. Also the stopping of the drive unit is considered as a STOPPING - operation, if it can be done from the control position.. -
Page 50: Additional Instructions
ADDITIONAL INSTRUCTIONS 6 ADDITIONAL INSTRUCTIONS WAREHOUSING AND STORAGE If the crane remains idle for a prolonged period of time, it is necessary to take the following steps: * Clean the crane thoroughly for example with a pressure washer. • Washing the electrical components with a pressure washer is prohibited. -
Page 51: Road Traffic
ADDITIONAL INSTRUCTIONS ROAD TRAFFIC * Obey all road traffic rules and regulations when driving on public roads. * When the load space is empty, lower the lifting boom's head to the bunk and set the closed grap- ple against the base. * When the load space is full, you might want to leave space for the boom to the centre, so that no part of the crane exceeds the allowable transport height. -
Page 52: Troubleshooting
TROUBLESHOOTING 7 TROUBLESHOOTING The operational failure table below shows the possible most common faults, their causes, and the measures that can be taken so the interference can be eliminated. 7.1.1 Safety instructions * When carrying out repairs and measures to remove the cause of the failure, all the instructions issued on the crane operation and safety should be strictly adhered to. -
Page 53: Maintenance Instructions
MAINTENANCE 8 MAINTENANCE INSTRUCTIONS This part of the Maintenance Instructions will walk you through the routine maintenance and the necessary checks and adjustments. SAFETY INSTRUCTIONS Washing the electrical components with a pressure washer is • prohibited. *Disassembly of the crane or its parts, during the warranty period should be assigned to the manu- facturer's authorized service person. -
Page 54: Daily Inspections
MAINTENANCE * KESLA crane maintenance tasks do not require any special tools that have not been supplied with the machine. Thus, the crane operator him/herself can perform almost all of the maintenance tasks. * The valves' pressure values should not be changed without the permission of the manufacturer due to the hydraulic circuit values. -
Page 55: Hydraulic System
MAINTENANCE 8.3.4 Hydraulic system - Check if the changes endangering the safety have been made in the hydraulic system, such as the hoses are original and in their pressure class. MAINTENANCE SCHEDULE The frequen- Maintenance Measure cy of mainte- Note! object nance/h General... -
Page 56: Turning Device
MAINTENANCE TURNING DEVICE 8.5.1 Lubrication of the turning device - For lubrication a couple of squeezes with a grease gun is enough. * The top bearing of the turning device (2 grease nipples) should be lubricated regularly. * The turning device is in other respects oil flooded. Check the oil level on the level surface through the oil eye. -
Page 57: Positions Of The Turning Device
MAINTENANCE 8.5.2 Positions of the turning device Center positions of the turning device Marked with points on the turning device. When the marks are aligned, the turning device rotates in both directions equally. The extreme position of the turning device: Marked with the label (3281523). -
Page 58: Opening Of The Turning Device
MAINTENANCE 8.5.3 Opening of the turning device * Turn the boom to its central position. * Lower the oil of the turning device into the container by opening the drain plugs and the filler plugs (1). * Remove the cylinder pipes (2) and drain the oil in them into the container. The rack (3) and the support bearing of the rack (4) can be removed without lifting the column from its position. -
Page 59: The Boom
MAINTENANCE THE BOOM 8.6.1 Lubrication of the lifting boom - The bearing is lubricated by squeezing the grease in until it is forced out. * The bearing pipe of the upper end of the turning columnhas one grease nipple. * The bearing pipe of the joint between the lifting and transfer boom has two grease nipples. * The bearing pipe of the joint in the lifting beam is lubricated from the grease nipple located below the boom. -
Page 60: Opening Of The Transfer Booms
MAINTENANCE 8.6.3 Opening of the transfer booms 1. The extensions are pushed out about 30 cm. 2. The extension cylinder from the transfer boom and the and hydraulic hoses are detached 3. All the slide parts are removed from the mouth of the transfer boom. 4. -
Page 61: Adjustment Of The Lateral Clearings
MAINTENANCE 8.6.5 Adjustment of the lateral clearings * Remove the locking screw (1) of the lateral sliding block. * Turn the bracket of the sliding block (2) clockwise equally from either side of the boom until the gap is eliminated. * If the gap is not eliminated by turning the bracket the sliding block (3) has worn out and has to be replaced. -
Page 62: Changing Of The Sleeve Bearing
MAINTENANCE 8.6.7 Changing of the sleeve bearing * In the boom has been used the so-called, thin shelled sleeve bearings, which are long-lived if proper- ly lubricated. * When the bearing is worn so that the joint has clearly a significant gap, pull the shaft and the former bear- ings for example, by wedging it open at the seam. -
Page 63: The Hydraulic System
* When replacing the hydraulic system components such as hoses, couplings, gaskets, etc., the smooth and safe operation is ensured best when using original KESLA spare parts. * For the crane's hydraulic system should be chosen a suitable oil, which must be handled and maintained properly. -
Page 64: Impurities In Oil
MAINTENANCE 8.7.2 Impurities in oil * Oil storage and transport containers will increase the dirt. *Due to wear and tear of components crane operations generate metal and other particles that come in the hydraulic system. * When repairing the crane the dirt gets into the system. * Upon component damage large quantities of impurities at the time may get into the cycle. -
Page 65: Biodegradable Hydraulic Oils
2. Synthetic hydraulic oils based on polyglycols (HEPG) 3. Hydraulic oils based on vegetable oils (HETG) e.g. rapeseed oils • The use of HETG oils is prohibited in Kesla products! Before you switch to using biodegradable oil, choose oil that is •... -
Page 66: Performance Of Oil Change
MAINTENANCE 8.7.6 Performance of oil change - The lifting, transfer, extension boom and the grapple cylinder are pushed all the way out. - Remove the hoses of the rod side of the cylinder from the cylinders and the return hose from the hydraulic system. -
Page 67: Pressure Measurement
MAINTENANCE PRESSURE MEASUREMENT WARNING DANGER OF High-pressure liquid jets! High-pressure jets of oil can shoot out of faulty hydraulic hoses • and cause serious injury when coming in contact with skin. Never try to locate a leak by palpating. • If the system has pressure accumulators, they must be depressur- •... -
Page 68: Lubrication
MAINTENANCE 9 LUBRICATION The provided lubrication intervals are valid when the crane operates with a normal load under nor- mal operating conditions. Shorten the lubrication interval if the crane is heavily loaded or when the working conditions are unfavorable, such as with sand, dust, mud, etc. LUBRICATION TARGETS •... - Page 69 MAINTENANCE LUBRICATION POINTS: Ref- Lubrication points Units Measure Lubrication inter- vals/h ence Turning device, oil eye Inspection Turning device, the lower Drain, drain the water twice a 1000 plug year Turning device, the upper Filling, adding if necessary 1000 plug Joint and plain bearings 20/22 Greasing by press The extensions of the...
-
Page 70: Oils And Lubricants
MAINTENANCE 9.1.1 Oils and Lubricants The table below sets forth certain hydraulic oils, lubricating oils and greases, which are suitable for use in a crane. Oil Brand Hydraulic system Turning device The grease nipples The sliding surfaces Chains summer winter ESSO UNIVIS UNIVIS... -
Page 71: Electrical Diagrams
MAINTENANCE 10 ELECTRICAL DIAGRAMS LIGHTS OPEN TYPE... - Page 72 MAINTENANCE PVG32 CONNECTIONS...
- Page 73 MAINTENANCE P70 CONNECTIONS...
- Page 74 MAINTENANCE CE EQUIPMENT OPEN TYPE...
- Page 75 MAINTENANCE CE EQUIPMENT CABIN...
-
Page 76: Power Supply Cable Connections
MAINTENANCE 10.1 POWER SUPPLY CABLE CONNECTIONS Wire Cabin NT High seat High seat CE equipment CE Comfort +24VDC +24VDC Heater remote (+) Not used +24VDC Emergency stop (-) Emergency stop (-) +24VDC +24VDC +24VDC +24VDC +24VDC +24VDC Not used +24VDC Not used Truck rpm increase Truck rpm decrease... -
Page 77: Annexes, Technical Specifications Etc
APPENDIXES 11 APPENDIXES Contents APPENDIXES ......................71 11.1 SPECIFICATIONS..................... 72 11.2 DIMENSION DRAWING ..................73 11.3 MOUNTING DIMENSIONS ................74 11.4 PERMITTED LIFTING VALUES ................ 75 11.5 OUTREACH DIAGRAM ..................76 11.6 TIGHTENING TORQUES .................. 77 11.7 WARRANTY CERTIFICATE ................78 11.8 CUSTOMER FEEDBACK .................. -
Page 78: Specifications
APPENDIXES 11.1 SPECIFICATIONS The crane's specifications reveal its structural and functional dimensions, lifting capacity and pressure values SPECIFICATIONS KESLA 2009S KESLA 2009ST Lifting moment Reach 8050 9610 Turning moment, br (p=23MPa) 22,0 ° 415º Turning angle Stroke of boom extension 1600 2 x 1.600... -
Page 79: Dimension Drawing
APPENDIXES 11.2 DIMENSION DRAWING 2009S Gb= mass of the boom system referred to be point of load attachment. Model KESLA 2009S KESLA 2009ST 2009ST... -
Page 80: Mounting Dimensions
APPENDIXES 11.3 MOUNTING DIMENSIONS 2009S, 2009ST... -
Page 81: Permitted Lifting Values
APPENDIXES 11.4 PERMITTED LIFTING VALUES The load plate is located in the control position and indicates the maximum load with different lifting reaches. -
Page 82: Outreach Diagram
APPENDIXES 11.5 OUTREACH DIAGRAM... -
Page 83: Tightening Torques
APPENDIXES 11.6 TIGHTENING TORQUES KESLA 2009S, 2009ST Description Partnumber Bolt / thread Nm (kpm) Fitting of crane 9001 9789 M 30 1200 (122) Fitting of slew mechanism 3010794 M 30 Slewing cylinder 301 0601 M14x60, 12.9 200 (20) Piston nut 301 0601 M14x60, 12.9... -
Page 84: Warranty Certificate
APPENDIXES 11.7 WARRANTY CERTIFICATE SERIAL NUMBER VENDOR:... -
Page 85: Customer Feedback
11.8 CUSTOMER FEEDBACK In order to further develop our operations we would very much appreciate if you'd send us your feedback about a KESLA product or customer service by the form below. Customer name: Street address: Postal code / city:... - Page 86 APPENDIXES...