2008 / 2008T
Contents
1. Gs JE e 22 r 777 3 Sy t ma oct B 4 _ S eg 52712 m d Tm care esses 2224 mm H bre M P 2411 r ipfa 7 12212 I 1 A i i fiz te 2 22222 211202 i co ll FPS l PES deti 20121 t uM Mp n c cam 2978 iw 7 X BE 145 H h 1 o Vnd Le L I CN x toe I 118 2 Gaana _ i RECEPIT lei I I f I pe 111 I z of 4d 2 4 Besat D 111 23 I Cam per I i 111 imag Doa 111 Et d 2 2 V e 3 as NE RES ME 8 2 2 ai 24 i i i hy asd AE RAE 4 4 11 i Is rl2. mm distance of the booms centre of gravity from the tipping centre mm Lr support width of the stabiliser legs form the tipping centre mm K distance the tipping centre from the stabiliser legs mm The above information is used to calculate angle angle between the vehicle centre axis and the tipping line as well as the factors A B C D and E Use a function calculator in the calculation arc tan 2 __ ___________ 2 2 Y JS LaS mm 2 u eee ee mm E nun s S mm 2 D sin Q 49 050 2 E Lpp A mm The solved numerical values shall be placed in the following formula MieD A Moe C GeB PeE 41 as KESLA COMISSIONING The machine is considered stable if the result is gt 1 4 42 COMISSIONING KESLA INSTRUCTIONS FOR THE DETERMINATION OF CRANE STABILITY BY CALCULATION 2 Vehicle with 2 or 4 axles with the crane fitted at the rear 0 0 stability factor must be according to SFS 4677 n 1 0 Stability factor is calculated with the following formula NeA Moe
3. STABILITY BY CALCULATION Formula general formula for all installation alternatives M eD NeA Moe C Mse gt n Content formula D of the perpendicular distance between the crane tipping centre and the tipping line measured or calculated perpendicular distance between the end of the boom load and the tipping line measured or calculated perpendicular distance between the centre of the rear axle and the tipping line measured or calculated measurements from the vehicle perpendicular distance between the centre of the rearmost front axle and the tipping line of the vehicle 4 axles measured or calculated measurements from the vehicle perpendicular distance between the centre of the front axle and the tipping line vehicle measured or calculated measurements from the vehicle Perpendicular distance betwe en the crane booms centre of gravity and the tipping line measured or calculated Maximum load with maximum reach on the load plate crane mass without booms possible fitting stand from the crane manufacturer weight of booms in the centre of gravity from the crane manufacturer front axle weight without load from the vehicle rear axle weight without load from the vehicle weight of the rearmost front axle without load 4 axle vehicle from the vehicle stability factor angle between the vehicle centre axis and tipping li
4. as FORESTERI 2008 20081 SERVICE SPARE PARTS KESLA OY DECLARATION OF CONFORMITY We KESLA OYJ PL 282 80101 JOENSUU FINLAND declare solely at our own risk that the following product Type Serial number is in conformity with the requirements and provisions of the following directives Machinery Directive 89 392 EEC and directive 98 37 EU supplementing it as well as Directive on Electromagnetic Compatibility 89 336 EEC amended with directives 92 31 EEC and 93 68 Before implementation of the product the installation firm fitter Shall affirm that the fitting conforms to to the requirements of the above directives as concerns fitting the product to a truck tractor or other chassis and in so far as the above is concerned a new declaration of conformity must be made and CE marking attached Vau Name Esko Paajanen Position Managing Director Date Joensuu CONTENTS GENERAL page Summary Use of the manual Crane presentation Main parts of the crane Instructions and warnings on crane Standard models and accessories Q N TECHNICAL SPECIFICATIONS Technical specifications 11 Dimensional drawing 12 Outreach diagram 13 Hydraulic schemes F130 PVG 32 14 Hydraulic schemes F130 RM 255 19 Electrical schemes 24 Grease fittings of the centralized lubrication system 26 COMMISSIONING Safety instructions at commissioning 28
5. mm The above information is used to calculate angle angle between the vehicle centre axis and the tipping line as well as the factors A C and E Use a function calculator in the calculation OL arc tan 0 5 00 000050 000 5 X Y A Y RU gt En mm B 66 X SIII mm C sin mm E Lpp A T The solved numerical values shall be placed 2 the following formula If the result is 0 75 1 0 the machine is considered stable 44 COMISSIONING KESLA Installation firm gt S Date Signature 45 KESLA COMISSIONING INSTRUCTIONS FOR THE DETERMINATION STABILITY BY CALCULATION CALCULATION EXAMPLES F2008T FORESTERI 2008T crane installed at the rear of a three axle truck on a fitting stand 6500 weight without load 5500 gt distance between bogie and front axle 3300 distance of the stabiliser legs from the centre of the stand Manufacturer s information on the Foresteri 2008 T crane 1140 kg crane weight without booms P 710 kg weight of the booms G 847 kg load with maximum reach 9650 maximum reach from the tipping centre 3693 distance of the booms centre of gravity fr
6. _ BOSH y nj a T 4 4 1344 OS am 5 14 34 018 NN ri 7 14 1 1 1 D UO 43 502 d Q 91 4 2 1 3 4 L 2 2 N 4 4 ja 5 LZ ome O m Px T m ie Us oe M WU SLX 2 3189 215414 en INANA NSS feo vig trm 8 1 1935 JHON 26 TECHNICAL SPECIFICATIONS am KESLA GREASE FITTINGS OF THE CENTRALIZED LUBRICATION SYSTEM see also drawing on the following page FILLING use only synthetic grease e g ESSO Fliessfett S 420 it is recommended use harder grease NGLI 0 1 2 in summer and a softer NGLI 000 00 0 1 in winter use a barrel pump to fill the grease pump pump grease and pull simultaneously at the lever of the stabiliser leg control valve running in of the spreading beams until the pump unit is filled The lubricant tank holds approx 1 kg of lubricant grease the pump unit has a sufficient amount of grease when the movement of the barrel pump feeding rod becomes sluggish OPERATION the centralized lubrication system gets its power from the pressure of the crane hydraulic system when the stabiliser legs are spread to
7. t 8 1 J The load plate is placed at the point of operating and notifies the max allowed working loads for different lifting radii 1 0 use If the stability factor of a combination with a rear fitting stand is 0 75 halved lifting values in the beginning of loading 8 GENERAL KESLA OYJ INSTRUCTIONS AND WARNINGS ON CRANE 4 CONTROL LEVER DECALS Background yellow text black 2 LEVER CONTROL VALVE 4 LEVER CONTROL VALVE No 328 0231 No 328 0197 Outer boom Lifting Boom slewing Grapple Outerboom Rotator The control lever decal is placed at the point of operating and is referring either to 2 lever or 4 lever control valves The decal shows the lever and pedal functions 9 KESLA GENERAL INSTRUCTIONS AND WARNINGS ON CRANE 5 CONTROL LEVER DECAL Background yellow text black No 328 0198 Left Right Spreading of the Moving the Moving of the stabilizer leg stabilizer leg stabilizer leg fitting stand bunk DOCET 378 0198 There are 2 bottom control lever decals One is placed the point of operating and one at the bottom point of operating The bottom control valve stabiliser leg valve can be used from the upper point of operating of the crane electrically with levers or mechanically by means of cable control The crane can also be controlled directly by means of the valve levers at the bottom point of o
8. 2 21 Y 25 Y 25 f I dm qud ED 20 26 26 ein 12 1949 3i 20 320 1 T 21 KESLA 23 TECHNICAL SPECIFICATIONS HYDRAULIC SCHEMES FORESTERI F2008 20081 F130 RM 255 valves OM 44 lN manufacturer ON Control valve right Control valve left Bottom control valve Rotator check pressure settings with Outer boom cylinder Boom extension cylinder Lifting cylinder Grapple cylinder check pressure settings with the grapple manufacturer Slewing cylinders Stabiliser leg cylinder Stabiliser leg spreading cylinder Stand moving cylinder Check valve Pressure controlled check valve Reducing nipple Pressure measuring nipple Pressure filter Return filter Hydraulic pump Oil reservoir Swivel Swivel Quick connector Quick connector Series connection nipple 1 circuit system Modulating valve 14 TECHNICAL SPECIFICATIONS KESLA DY HYDRAULIC SCHEME F2008 F2008T 2 LEVER 1 CIRCUIT F130 PVG 32 valves 11 05 z 175 175 25 MPn 25 MPol 25 25 MPO gt 2V1PPVES 32 11 15 as KESLA TECHNICAL SPECIFICATIONS HYDRAULIC SCHEME F2008 F2008T 2 LEVER 2 CIRCUIT F130 PVG 32 valves 10 6 9 7 8 5 230 23
9. 2 2 H i 2 28 MPa 25 MPa di ILE mud m m mum mm mm mm ee 475 MPn 175 MPo 75 MPa m i m o 224 4222 2 2 F130CF PVG32 16 TECHNICAL SPECIFICATIONS KESLA DY HYDRAULIC SCHEME F2008 F2008T 4 LEVER 1 CIRCUIT F130 PVG 32 valves 10 9 8 EEL 2342 023 21 17 ee 1i gt lt gt lt gt lt 2 TaT Fr 17 1 L d m m 21 2 de La 25 28 25 MPa um GT TE 5 4V1PPVGS F130CF PVG32 1 as KESLA TECHNICAL SPECIFICATIONS HYDRAULIC SCHEME F2008 F2008T 4 LEVER 2 CIRCUIT F130 PVG 32 valves 10 9 B 7 6 5 n 230 023 4 25 MPn 17 5 MPa 25 MPa 25 MPo 28 25 2200 022 4V2PPV05 F1300F PVG3Z 18 TECHNICAL SPECIFICATIONS KESLA HYDRAULIC SCHEMES FORESTERI 2008 2008T F130 PVG 32 valves OM 44 lN manufacturer CO ON Control valve right Control valve left Bottom control valve Selector valve Rotator check pressure setting
10. MOUNTING DIMENSIONS KESLA TECHNICAL SPECIFICATIONS OUTREACH DIAGRAM F2008 F2008T 14 TECHNICAL SPECIFICATIONS KESLA DY 2 2008 _ GN 5 KESLA GENERAL INSTRUCTIONS AND WARNINGS ON CRANE The prints on loader have warnings instructions informing of hazards or operational directives see picture from the previous page numbers 1 5 Follow these to avoid unnecessary accidents and malfunctions 1 RISK ZONE DECAL Background yellow text black No 328 0275 RISK ZONE 25 m A large decal on both sides of the outer boom notifies the risk zone during operation Ensure that the risk zone is clear of unauthorised persons when operating the crane 2 WARNING DECAL Background yellow text black No 328 0264 WARNING VARNING STAYING WITHIN THE RISK ZONE IS STRICTL FORBJUDEN CLEAR OF OVER HEAD POWER WIRES DIG FOR SPANNINGSFORANDE LEDNINGAR Nominal voltage Minimum distance Minimum distance from from insulated uninsulated wire wire Nominell Minimiavstang spanning Minimiavstang fron fron isolerad oisolerad ledning ledning 6 GENERAL KESLA OYJ The decal is placed at the point of operating and absolutely forbids persons loitering within the risk zone when loading risk zone 25 m The decal warns of live electrical conductors
11. Clean the crane thoroughly with e g a pressure washer NOTE Never clean electric components with a pressure washer Lubricate all service spots after washing to remove any possible water from the bushings and to prevent corrosion Oil the visible piston rods and valve levers with e g spray Check the oil quantity of the slew mechanism and add if necessary Drain some oil from the draining plug to eliminate possible condensed water Drain some oil from the quick coupling If the storage temperature will rise winter gt summer the oil volume will increase and the system will get pressur ized Brush paint on the spots where it is cracked or worn 69 KESLA DY SERVICE Repair all faults and defects to ensure that the crane will be in faultless tion when retaken into use STORING Store the crane with the slew mechanism in upright position and support it properly to prevent it from tipping over It will be of advantage to store the crane away from sunlight preferably under root When retaking the crane into use clean the piston rods check the slew mechanism oil the mounting bolts of the crane and the safety equipment func tion 9 DISCARDING When the crane is coming the end of its service life is no longer repair able it shall be withdrawn in a way which will cause no needless harm to the environment 1 Deliver the machine scrapped goods treatm
12. If you must work or drive under such conductors always follow the minimum safe approach distances given in the table GENERAL KESLA INSTRUCTIONS AND WARNINGS 3 SAFE WORKINGS LOAD PLATE we we we we we lt lt a 1 ON Ut f E 4 ui v NE _ a i h 4 1 i rit fii Ic 1147 1 212311 TIA _ 4 L Vig exis Wali 164 1 1 e lt gt Se ise Qo 62 15 8 6 CN L or yi si 6 IC A f debili rfr it 1 UN co Ww lt 2 k lt WI esr 5 NM PII 2 N ki A dE zi L_ 485 4 i D 5 Ay f 2 p 2 MP 1 9 QRA m 1 32 1441 130 4414 4 idee e
13. Record files Record forms for start up and periodical inspections are supplied with the crane During every inspection such a form must be filled out and filed with the loader for at least 5 years Please refer to national safety regulations Safety instruction The same safety instructions apply to inspections as to normal operation 1 START UP INSPECTION The inspection shall be carried out immediately after mounting prior to taking the combination into use The procedure is given in the record of start up inspection enclosure 1 including the determination of stability of the combination according to Finnish standard SFS 4677 and operational test according to Finnish standard SFS 4261 2 AFTER SALES SERVICE An authorized service centre shall carry out the procedure given in the after sales service record enclosure 2 The continuation of a full warranty requires that this overhaul is done within 30 days from the installation of the crane 3 PERIODICAL INSPECTION An operating loader must be inspected within a period of one year and also test run according to standard SFS 4261 every four years Please refer to national regulations as they may rule differently The inspection procedure is given in the records for periodical inspection enclosure 3 During the inspection special attention must be payed to fatigue of material wear corrosion and other damage caused by operation No structural changes are allowed especially from th
14. DY SERVICE INTO A VESSEL AND SEND IT AWAY FOR FURTHER TREATMENT 56 SERVICE KESLA DY SERVICE PROCEDURE interval h General 1 10 i crane 0 Dail Daily Check hoses and hose cou 5 olings Clean load bearing structures and check their condition 250 Grease bushings with grease gun Tighten mounting bolts 250 1200 Nm Initially after 50h 7 Checkoilquantity Change oil 1000 11 21 50 Booms Grease bushings with grease gun 10 10 Checkbushings 250 1 Check the position cylinder mouth pieces 250 and pins needed Extensions 12 Grease bushings with greasegun 10 Brush grease on extensions 50 needed Check vertical clearance 250 Adjust if needed with Check chain tension and adjust if needed 50 50 1 Check mounting bolts 250 Change pressure filter 500 3 Change return filter 1000 Change if needed 17 Lubricate chains 50 shims Tighten if needed Initially after 50h Initially after A No 8 5 S seel 94 57 SERVICE ______ 5 ____ 24 Change hydraulic oil 1000 At least 2 25 Grease At least 1 x conditions month 28 SERVICE TROUBLE SHOOTING CHART KESLA The chart shows the most probable malfunctions with causes and how to rect them Contact the service department for more information Do not ig
15. UNIVIS 32 he service centre shall affix to the vehicle or crane a machine plate where following information is given name and address of service centre year of mounting serial number of crane registration number of the vehicle and CE marking he crane can be fitted on a movable rear fitting stand or with a fixed installation on a trailer behind the cabin or at the rear of the truck 1 FITTING THE CRANE ON A MOVABLE FITTING STAND Fit the truck with fastening muffs 2 to enable the mounting of the stand 3 follow the instructions of the truck manufacturer importer 31 KESLA COMISSIONING The fitting stand 3 is lifted into the fastening muffs 2 The stand can be equipped with a moving cylinder 5 in which case the truck is equipped with a suitable mounting set with locking As an option the moving cylinder may be mounted on the truck and the mounting set on the stand 32 COMISSIONING KESLA FITTING THE CRANE 1 FITTING THE CRANE ON A MOVABLE REAR FITTING STAND Lift the crane 1 on the fitting stand 3 and fit six M30 stud bolts 4 into the outer holes of the stand Tighten the bolts in pairs with a torque wrench to 1200 Nm 122 kpm N a M447 4 NOTE Use safety chain to prevent the fitting stand from falling down Connect the return and pressure hoses of the crane to the hydraulic system of the truck Replace the quick releas
16. end of the cable and run lubri cant mixture into the cable It is also possible to fully detach the cable 62 SERVICE KESLA POINTS OF LUBRICATION 1 SLEW MECHANISM Few strokes of the grease gun is enough Grease the top bearing of the slew mechanism 2 grease nipples regularly The other parts of the slew mechanism are oil immersed Check oil quantity through the oil gauge with the machine standing on even ground Add if needed hypoid oil SAE 80W 90 The slewing link at the upper end of the stabiliser leg has 2 grease nipples and the front beam 1 grease nipple 2 MAIN LIFTING BOOM Grease the bushings with so many strokes that you see old grease moving out The bushing in the upper part of the slew pillar has 1 grease nipple bushing the link between the main lifting boom and outer boom has 2 grease nipples Grease the bushing in the main lifting boom links from the grease nipple b cated at the lower side of the boom he intermediate links have 3 grease nipples Grease the spherical bearings 4 pcs of the main lifting and outer cylinder regularly 3 BOOMS Grease the rear glide pads of the extension from the grease nipple top of the outer boom Keep the extensions retracted In a double extension model grease the bushings of the chain gear 2 pcs from the grease nipple at the pin end with the extensions retracted All the grease nipples of t
17. extreme caution during the test The machine 15 considered stable if no more than one of the machine fulcrum points looses its hold from the ground during the test If more than one support point looses its hold put a load of 25 of the max permissible load in the load area and repeat the test In such a case add in the load plate halved load values and the text vehicle without load with load lt 25 Stability determined by the installation firm 4 KESLA COMISSIONING Installation firm Date Signature 48 KESLA OPERATING AND SAFETY INSTRUCTIONS Do not let an operator who has not become familiar with the operating and safety instructions operate the loader Always have the parking brake engaged when loading Place parking blocks in front of and behind the wheels if necessary Ensure that the rear fitting stand is locked with a chain to the vehicle Feed oil with a three way valve when needed to the control valve of the crane or the valve operating the stabiliser legs The stabiliser legs are operated by a valve fixed to the base or by remote control from the point of operating Spread the stabiliser legs as wide as possible to ensure good stability If this is not possible start the loading with minor loads Ensure that the ground under the stabiliser legs is firm enough Use additional plates if necessary The stabiliser
18. return hose is not properly connected the control valve will be damaged When starting the truck hydraulic pressure shall not be connected to the crane 55 as KESLA DY OPERATION 56 as KESLA CRANE OPERATION COMMISSIONING Check that the crane levers are in middle position and that they also return to the middle position Refer to Daily overhaul prior to operation CRANE OPERATION Start the pump and set its flow to about 70 90 l min one circuit pump 2 x 60 80 I min two circuit pump If necessary consult the pump manufacturer for the flow settings corresponding to different operating speeds At low temperatures start the work by letting the oil circulate freely for a while through the valves with a small flow Then carry out all working motions slowly back and forth so that the seals will limber up before they have full pressure The lowest recommended working temperature for the crane is 25 The crane can be used even at a temperature of 35 C if this is tolerated by the hydraulic system of the base machine Notice that the hydraulic seals wear sooner hoses are more likely sustain damage and the steel constructions are more exposed to brittle fracture at low temperatures At working temperatures below 25 C it is more favourable to lift smaller loads than normally to avoid unnecessary damage Equally in very warm conditions make sure that the hydraulic oil do
19. G AND SAFETY INSTRUCTIONS Take a firm grip of the load and always as close to the centre of gravity as possible Do not exceed the max loads given in the safe working load table Do not try to lift with the telescopic extension out Instead pull the extension in and then Avoid quick lifting and lowering movements with the booms in max reach also swinging movements before the load is in the air Never drive the booms to their limits with great speed Follow extreme caution when working close to live electrical conductors Make the safety distances to such conductors clear to yourself and follow them Refer to WARNING decal Minimum safe approach distance to electrical conductors 5 m if voltage gt 110 kV vin Orme i S ge E qum 7 2 eG GN yoy B OL we When you have finished loading lower the crane firmly against the base machine and turn off the pump before driving off Follow extreme caution when connecting the crane to and disconnecting the crane from the vehicle Danger of tipping over Prevent the turning of the stabiliser legs with a locking pin Support the booms carefully to the ground The ground has to be firm and even Ensure that there are no unauthorized persons on danger zone additional extensions shall be mounted without the manufacturer s permission Never use a faulty crane Never
20. If the result is gt 1 0 the machine is considered stable If the result is 0 75 1 0 stability must be determined by test 22 MW N NN FIGURE 3 FIGURE 4 43 as KESLA COMISSIONING INSTRUCTIONS FOR THE DETERMINATION STABILITY BY CALCULATION 2 CRANE INSTALLED AT THE REAR OF A TRUCK figures 3 and 4 Information from the vehicle for calculation rear axle weight without load kg rearmost front axle weight without load kg Ms 0 if there is no such axle C c pasa Nellm mm Y distance between rear axle and crane stabiliser legs mm Manufacturer s information on the Foresteri crane N crane weight without boomrs kg P WEIGNT OF kg load with maximum reach kg L maximum reach from the tipping centre mm distance of the booms centre of gravity from the tipping centre mm support width of the stabiliser legs mm K distance of the tipping centre from the stabiliser legs
21. Preliminary preparations at introduction 29 Fitting the crane 30 Inspections 33 Instructions for the determination of crane stability by calculation 34 Instructions for the determination of crane stability by test 41 CONTENTS as KESLA DY OPERATION page Operating and safety instructions 42 Safety equipment 44 Crane operation 45 Traffic on public roads 47 SERVICE Safety instructions while servicing 48 Hydraulic oils 49 Oils and lubricants 52 Tensioning torques 53 Service procedure 54 Trouble shooting 56 Service procedure lubrication points 57 Dismantling the slew mechanism 59 Dismantling the outer booms 60 Adjusting the chain tension 61 Adjusting the horizontal vertical clearance 61 Replacing the sliding bearing replacing hydraulic components 62 Repair weldings 63 Pressure measuring 63 Storing 64 Discarding 65 Terms of warranty 66 Start up inspection record Periodical inspections record 1 KESLA GENERAL SUMMARY 1 2 10 As the very first step read the manual Check that the hydraulic system of the base machine matches with the specification and the stability has been verified and is in accordance with regulations Follow the fitting instructions The seller and the manufacturer will be pleased to give you further information if needed Do not forget the inspections provided in law Always work with good judgement Do not forget to warm up the hydraulic system in freezing conditions G
22. TS OF THE CRANE Rotator boom Uv gt 4 S 5 Aw NN 5 D VN oo o LA gt O LJ gt al N J a v o D L c Dh QNA Y AN Ww 5 gt lt LLI 2 im X lt T pA U 15 2 A 7 4 gt r LJ ACY J D D im SLewing cylinder 4 1 4 E e C srabiLizer Leg equipment Valve for stabilizer Leg quiding 28 COMISSIONING KESLA SAFETY INSTRUCTIONS AT COMMISSIONING The Foresteri loader is designed for timber loading shall be operated only by a person familiar with its use Get familiar with the crane design function controls and user manual before introduction Do not operate the loader without having read and understood the manual and safety instructions Follow all instructions warnings on the loader to avoid unnecessary damage Ensure the stability of the combination in all circumstances see the instructions on determining crane stability by calculation Make sure that the loader is properly fitted refer to Fitting the loader Do not start the truck unless the hydraulic pressure to the crane is disengaged Observe special caution when connecting the crane to and d
23. anufacturer s instructions for cold Start If the oil temperature does not rise above 70 C in summer winter oil can be used all year round The manufacturer has filled the crane with oil ESSO UNIVIS N 32 Foremost follow the recommendations of the base machine manufacturer or the supplier of the hydraulic system when choosing hydraulic oil 64 SERVICE as KESLA The oil capacity of the crane is about 50 I depending on the size and therefore at the oil change a large amount of the oil will remain in the hydraulic system Therefore pay special attention to the compatibility of the remaining and the new 65 KESLA DY SERVICE TENSIONING TORQUES Forester 2008 2008 T L Bolt thread Fitting of crane 9001 3950 Fitting of slew 9001 3836 M 30 MECHANISM Piston nut 302 0026 M24 NYLOC 71 Lifting cylinder mouth 2839 7202 M129 5 x2 2839 7201 M50x2 1200 122 Outer cylinder mouth 2839 7202 2847 7202 M129 5 x 2 idi i 2839 7201 M50x2 1200 122 Boom extension cyl single ext mouth 2824 6202 2820 1202 M64x2 idi piece 302 0008 302 0009 M20 UNF 1 00 71 Piston nut nyloc Boom extension cyl double ext 2831 1202 70 2 302 0041 M30x2 nyloc 700 71 Piston nut Stabiliser leg cyl mouth piece 2838 2202 M104x2 dui Piston nut 302 0119 55 2 KM1 1 200 20 Widening of stabiliser leg 2833 202 M55x2 700 71 Piston nu
24. ar gt 1 0 If the calculated factor is lt 1 stability must be determined by test f the factor is n 0 75 1 0 25 of the permissible working load can be taken into account in stability calculation of a crane fitted at the rear of atruck This load must be added to the axle multiple axle load In this case there must be halved load values in the load plate and the text vehicle without load or with lt 25 load The following points are used as points of vertical intersection of the tipping lines Support points of stabiliser legs wheel centres midpoint of a pair of wheels midpoint of front axle of a crane fitted at the rear of a truck It is not possible to know beforehand all the factors needed in and affecting the calculation of crane stability Crane stability must therefore be determined separately in each case depending on the make of the vehicle vehicle construction crane type and place of installation on the basis of actual measured or calculated measurements and weights If you have any problems or questions regarding the determination of crane Stability and can not find answers in the vehicle service manual registration book please contact the nearest dealer or importer of the vehicle Regarding the 36 COMISSIONING KESLA rear fitting stand please contact its manufacturer and regarding the crane Kesla Oyj 3 KESLA COMISSIONING INSTRUCTIONS FOR THE DETERMINATION
25. boom 4 Open the tightening nuts of the chain pairs and pass the back chain including clamps through the opening and then out through the mouth of the outer boom At the same time the whole extension package can be pulled out from the outer boom 5 The outer extension can be dismantled in the same way remove all glide pads and the chain gear from the mouth of the inner extension Guide out the chain via the mouth of the opening 6 Remove the extension cylinder and the tightening fork of the back chain and pull out the extension 7 For a model with single extension perform steps 1 3 8 Assemble in reverse order in 10mm distance between the fastening ADJUSTING THE CHAIN TENSION models with double extension Extend the extensions fully and then retract them some so that the visible chain becomes slack Tighten both chains equally The tension is correct when the chain will flex about 2 3 cm when pushing downward at the center of the chain by hand 65 KESLA DY SERVICE ADJUSTING THE CHAIN TENSION models with double extension In praxis the chain loading and stretching will be highest inside the booms because it pulls the extension Retract the extensions and adjust the fastening space between the outer and inner extension fastenings with nuts 4 to about 10 mm f tightened too much the chains and chain gear bushings will wear A too slack chain may break when it gets to run
26. clogging up oil channels or jamming valve spools and worst of all component damage 4 AVOID ENTRY OF IMPUHRITIES INTO THE OIL Do not store the oil vessels outdoors risk of water condensing in the oil Store the oil the original closed vessels Pump or pour the oil directly from the barrel into the tank Use clean vessels when handling the oil Make sure that the plugs funnels sieves and filling holes are clean 61 as KESLA DY SERVICE HYDRAULIC OILS Clean the place to be repaired and the surroundings prior to work Make sure that no grinding or welding work is done close by when the hydraulic system is opened Keep the working place hands and tools clean Use correct tools Avoid repairing the hydraulic system outdoors or in dusty conditions Try to locate the area where the fault is as well as possible to avoid opening the system too much Make sure that the dismantled parts and the place of repair are well covered not open the spare parts packages before the moment of installation Clean filters and replace filter cartridges according to service instructions Prior to installation blow the hydraulic hoses and pipes with air and wash them when necessary Wash the parts with kerosene or white spirit Always use high class oils with correct viscosity produced by well known manufacturers Secure reliable crane function and avoid unnecessary malfunctions by following the service instruct
27. e couplings of the truck if necessary crane can also be fitted at the rear of the truck with a fixed mounting see paragraph 2 NOTE the start up inspection shall be carried out at this stage 33 KESLA OYJ COMISSIONING FITTING THE CRANE 2 FITTING THE CRANE BEHIND THE CABIN N NN Lw MIU num Install the sides the truck suspension member frame two 10 plates 2 with welded bushings for bolts M30 3 Follow the fitting instructions of the truck manufacturer importer Truck manufacturers do not recommend U bolt connections which put pressure on the frame beams or welding directly into the frame Lift the crane 1 on the mounting plates 2 NOTE not to be supported by the body beams and fit the six stud bolts M30 3 into the bushings Tighten the stud bolts gradually to 1200 Nm 122 kom with a torque wrench Install the grapple assy link 4 rotator 5 grapple 6 and the hydraulic hoses if not factory mounted Connect the return and pressure hoses to the hydraulic system of the truck NOTE The start up inspection shall be carried out at this stage 34 COMISSIONING as KESLA INSPECTIONS Inspector The start up and periodical inspections shall be carried out by a person with sufficient knowledge of loader design operation and inspection Please refer to national safety regulations as to the qualifications of the inspector
28. e safety point of view 4 DAILY OVERHAUL PRIOR TO OPERATION Check the oil quantity of the hydraulic system and the slew mechanism and add if needed Lubricate the crane if necessary refer to Maintenance procedures a visual inspection of the loader s fitting screws lockings hoses and any possible leakage Check the function of controls and the safety equipment by driving the functions to their limits and repair possible faults and defects immediately Ensure that the EMERGENCY STOP button works 35 KESLA COMISSIONING INSTRUCTIONS FOR THE DETERMINATION STABILITY BY CALCULATION Crane stability is determined at the start up inspection by e g an authorized installation firm or installer NOTE Determination by calculation is not required if crane stability is determined by test Determination by test is necessary also if calculated stability is lt 1 0 The formulas and the example given are based on the Finnish standard SFS 4677 Quotations with permission of SFS The crane is considered stable when the sum of tilting moments multiplied by the stability factor is smaller than the sum of sustaining moments The crane is under static load on a horizontal surface in the most unfavourable direction regarding the tipping line The vehicle is without load The stability factor with a crane fitted behind the cabin must be n 1 4 and with a crane installed at the re
29. end Also check that possible lubricating holes are opposite each other Prior to pin mounting check its condition and lubricate the new bearings ac cording to recommendations REPLACING HYDRAULIC COMPONENTS When replacing hydraulic components like hoses pipes seals etc make sure that the new components correspond with the factory installed ones Original spare parts are the best insurance for safe and undisturbed function Keep the hydraulic system of the crane in good condition and replace defect parts e g hoses pipes etc in good time 67 KESLA REPAIR WELDINGS Do not ever modify the crane structure or weld supplementary parts it without the manufacturer s permission If modifications or repairs are done by welding observe following The welder must be fully qualified quality class mA edi J Remove paint and grease from the area to be welded gt y4 Always connect the earth connector to the part 2 to be welded joints in between ge 2 The suitable electrode is 48 30 equal gt Use dry electrodes Use 12 51 equal for welding PRESSURE MEASURING Refer to Safety instructions while servicing When checking the pressure the hydraulic system must be in normal working temperature and producing a normal flow about 60 l min 1 System pressure P1 Connect the gauge to the p
30. ent plant where it will be dismounted under surveillance 2 If dismounted by yourself Drain all the oil from the hydraulic system and slew mechanism and send the oil to a waste oil treatment plant Remove the hydraulic hoses and send them to a waste recycling rubber collecting place Send the metal parts to a capital scrap collector 66 TERMS OF KESLA DY KESLA OYJ gives a manufacturer s warranty for Foresteri truck loaders as stated below Tvelwe 12 months from the date of delivery to the end user The warranty is valid for new products only for the above stated time while in the possession of the first owner The warranty will cover any defects in the machine or its accesso ries due to structural failures faulty raw materials or workmanship The defective part in the machine or accessory is replaced free of charge with a new or reconditioned part by the guarantor The warranty shall apply to hydraulic hoses their connectors or hydraulic oil seals For purchased components Kesla will pass on a warranty that is equal to the warranty given by the subject component s manufacturer to Kesla 5 The warranty shall not apply to any faults or defects arising from normal wear negligence or improper operation faulty installation or incorrect or inadequate care and maintenance 5 will assume any liability for any economical losses which the purcha
31. es not overheat lt 70 An oil temperature too high can damage the seals and furthermore shorten the operating life of the oil Use stabiliser legs to set the crane pillar in an utmost upright position Observe the positions where the loader or the load can hit the cab or other parts of the truck Stop the loader working immediately if there is any risk of danger Always make sure you have sufficient working light 27 as KESLA DY OPERATION TRAFFIC ON PUBLIC ROADS Comply with all the statutes and decrees of the Road Traffic Law when driving on public roads If the load area is empty lower the main lifting boom end on the bolster and the closed grapple against the frame A End me rl c EC When the load is full leave empty space where the boom fit along the centre on top of the load to avoid any part of the crane to rise above the permitted transport hight Pull the stabiliser legs and their widenings to transport position and lock them For the time of driving disengage the hydraulic pump e Secure the load carefully with load lines The removable rear fitting stand has to be locked mechanically with a chain to the frame of the truck Do not exceed the allowed axle or total weight or transport dimensions Before driving off check the lights reflectors tyre pressure trailer connection etc Adjust the travelling s
32. goes down under load and cylinder is overheating when loading Change seals Measure pressure while the oi is hot Replace with new pump if needed Measure back pressure run the pump at lower speed Add oil Refer to above Check if oil and filters have been changed acc to instr Check tensioning torques Change seals if needed the seals might let some oil by when oils are very cold Tighten by winding the pin 59 KESLA DY SERVICE valve spring replace with new pin valve needed 60 SERVICE KESLA DY SERVICE PROCEDURE LUBRICA TION POINTS NOTE LUBRICATE THE SPHERICAL BEARINGS AND BUSHINGS OF BOOMS WITH GREASE MOLYBDENUM CONTENT 2 UNIVERSAL GREASE WILL DO FOR OTHER POINTS NOTE SHORTEN THE LUBRICATION INTERVALS IF WORKING CONDITIONS ARE UNFAVOURABLE E G DUSTY f olug times year Slew mechanism upper Oil change add if neede 1000 oluo Spherical and bushings 20 22 Grease with grease gun 5 Outer surfaces of exten Greasing oil 50 SAE 10W50 sions d Inner surfaces of exten Greasing oil 50 SAE 10W50 sions Chains double exten 50 SAE 10W50 61 KESLA lsin __ 8 Bottom control cables At least 1 month Lubrication of the bottom control cables Lubricant mixture of non freezing solution and water 50 50 96 Open the plug of the fixing bushings at the upper
33. he crane can be lubricated at a time by turning the outer boom with the extensions retracted in an inclined position under the main lifting boom In this position the inner surfaces of the extensions and the inner chain will be lubricated through the back end of the outer boom Finally extend the extensions fully and lubricate or brush grease on the upper lower and side surfaces of the extensions 63 KESLA DY SERVICE DISMANTLING THE SLEW MECHANISM Refer to Safety instructions while servicing Slew the booms to center position Drain the oil from the slew mechanism into a vessel by opening the draining and filling plugs 1 Remove the barrels 2 and drain their oil into a vessel The rack bar 3 and the thrust bearing 4 can be removed without removing the pillar The pillar 5 can be lifted away by removing the base plate 8 the locking ring 6 in the bottom side and the hoses going through the pillar The pillar can be removed without removing the slew cylinders and rack bars Assemble in reverse order and finish by adding hypoid oil 80W90 into the slew mechanism to the oil gauge 7 FILLING HOLE OIL GAUGE DRAINING 64 as KESLA DISMANTLING THE OUTER BOOMS models with single and double exten sions 1 Extend the extensions about 30 cm 2 Detach the extension cylinder from the outer boom and the hydraulic hoses 3 Remove all glide pads from the mouth of the outer
34. ies when handling these substances If oil or grease have caused rash or inflammation or they have got into the eyes immediately contact a physician Wear gloves protective skin cream eye protectors proper protective clothing when handling oils and greases Never wear oily or greasy clothes and never keep oily tools or other oily objects your pockets Never clean your hands with oils or greases Waste oil from service and repairs shall always be sent to a plant where it can be duly treated 59 as KESLA DY SERVICE HYDRAULIC OILS Choose an oil suited for the hydraulic system of the crane and handle and service it correctly 1 HYDRAULIC SYSTEM To function the crane needs a hydraulic system consisting of a power unit pump oil reservoir filters and other hydraulic equipment needed The oil in the hydraulic system works both as a power transmitter and a lubricant A high class oil is the first conditon for the undisturbed function of the crane Connect the crane to an absolutely clean hydraulic system equipped with a pressure and return filter The system must also have a breather filter which prevents the entry of larger impurities into the hydraulic system Despite the breather filter small foreign particles enter the oil reservoir with the air sucked into it Foreign particles can cause damage the long run as the pump and valves work with minimum clearences Due to
35. if 2 1 1 u I I if d C s I i ri gus i i i a 004411 zc lani tame L h I 4 CNI T 1 I I iy b 1 1 li 3 11501 I i i E f i on r E ME BUR l D UON I YT K 95 12 i r 1 i L ST o EL oo c HEEL SN emu i LS ta EAE lt i i vue A 9 67 I i d 544 23 I 1 1 i Lea ts LI _ i i i i CA A amp adn i d gy fr 1 ia momen Jm 13 U 1 ___ i 1 I I TEE Q i MR i i I Lb od d LI x Lb 3 i LI r al f I C c unt b ee _ X ri a 77 SE LI LI LI LI 24 SUE 5 I m k ii d EP i i m 29s Ih
36. ions and keeping things clean during hydraulic installations 5 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 pump seals hoses Biodegradable oils are divided into three main classes 1 Hydraulic oils based on vegetable oils HE TG e g rape oils 2 Synthetic hydraulic oils based on polyglycols HEPG 3 Synthetic hydraulic oils based on esters HEE 62 SERVICE KESLA NOTE Before using hydraulic oil consult your oil dealer when choosing a suitable oil type and clarify its suitability for the pump seals and other hydraulic components 63 as KESLA DYJ SERVICE OILS AND LUBRICANTS The table below shows some hydraulic oils lubricants and greases suited for the crane Oil brand Hydraulic system Grease nipples summer winter N 46 N 32 22 80W 90 GR MOLY MOBIL DTE 16 DTE 15 13 MOBILUDE HD MOBILUX EP 2 80W 90 MOBIL GREASE MP SPECIAL T 46 OIL T 32 22 80W 90 GREASE 2 OIL 46 OIL 32 22 80W 90 EP MDS NESTE HYDRAULI MULTIHYDR HYPOIDI MP GREASE 46 AULI 22 80W 90 YGREASE SUPER 32 When starting the machine follow the pump m
37. isconnecting the crane from the truck the ground must be sufficiently strong and even turning of the stabiliser leg must be prevented with a locking pin danger of tipping over the rear fitting stand must be locked to the truck with a chain Always connect the return hose before the supply hoses Check for proper connection or the control valve may be damaged When connected to the hydraulic system for the first time there may be air in the hyaraulic lines which can cause sudden and uncontrolled movements Vent the system by driving carefully all cylinders to their limits 4 5 times Before connecting pressure to the loader check that all control levers of the crane are in middle position and also return there 29 KESLA OYJ COMISSIONING PRELIMINARY PREPARATIONS AT INTRODUCTION The Foresteri cranes are delivered from the factory fitted and equipped with operating valves pressure filters and hydraulic equipment The rear fitting stand grapple slewer etc are delivered as accessory The transport base is made of 100x100 timber and can be reused or burned A lifting capacity of min 29 3000 kg is needed for handling the loader A fork lift can be used for lifting it from under the transport base NOTE Danger of tipping over Do not remove the transport base before the loader is in the place of fitting Then remove all transport fastenings and bindings The visible piston rods are protec
38. legs are equipped with pressure controlled return valves and therefore they will hold in case of overloading or hose damage The turning of the stabiliser legs can be prevented with a locking pin E g a crane installed on a stand is disconnected from the truck to stand on its stabiliser legs When the crane in operation the locking pin is usually not needed Note that when increasing the load most of the weight will be on the stabiliser legs as the truck springs have been disengaged by the stabiliser legs Therefore it is recommended to shorten the stabiliser legs in the middle of the loading process in order to move the weight onto the truck wheels Avoid loading on sloping ground However if it is necessary to load on sloping ground follow extreme caution and lift only smaller loads When loading from the upper side of the machine remember that the relief valve of the slewing cylinders can be overloaded causing the load to escape in the down hill direction and leading to a dangerous situation The stability of the machine unit is at its weakest when the load area is empty If the machine starts to tip over lower the load immediately to the ground Do not drop the load by opening the grapple Ensure that the work area is clear of persons that you have an unobstructed view over the whole area 49 as KESLA OPERATION Never lift the load above people 50 KESLA OPERATIN
39. nd operation manual manual l Waning decals 117 T Movement of vate spook pumos and wawawa 77 syst oft stab F a Pressure andum mes _ cuit Tte amount amount oro nsew _____ WORK AND TRIAL RUN 1 Lubrication of links bearings and cables 11 2 Air venting from the system by driving all cylinders to their extreme positions without load 4 5 times S Trial run according to Finnish standard 888 4261 __ 4 Correct movements ofthe levers and orane L 5 Al crane movements go to extreme positions Checking the operation ofthe reet valves 7 Booms do notlowerbythemseves L 8 Operation of the emergency stop system ___ _ INSPECTIONS AFTER TRIAL RUN 1 No oil leakages 2 2 Hydraulic oil temperature does not rise excessively oil temperature does rise excessively 3 Fitting has been performed according to directives and standards and the CE mark has been attached to the vehicle 4 crane operator familiar with the instruction manual REMARKS Date Installation firm Client s signature Installator s signature KESLA PERIODICAL INSPECTION The periodical inspection shall be ca
40. ne calculated on the basis of measured values 38 COMISSIONING KESLA On the following pages you will find formulas for different crane vehicle combinations 39 KESLA COMISSIONING INSTRUCTIONS FOR THE DETERMINATION STABILITY BY CALCULATION 1 Vehicle with 2 or 3 axles with crane behind the cabin Stability factor must be according to SFS 4677 1 4 crane stability is calculated with the following formula M eD NeA MoeC If result is gt 1 4 the machine is considered stable FIGURE 1 FIGURE 2 40 COMISSIONING as KESLA INSTRUCTIONS FOR THE DETERMINATION STABILITY BY CALCULATION 1 CRANE INSTALLED BEHIND THE DRIVER S CABIN figures 1 and 2 Information from the vehicle M front axle weight without load kg M rear axle weight without load kg PG EEE AAN S Y distance between rear axle and crane stabiliser legs mm Z distance between rear wheel centres wheel track Manufacturer s information on the Foresteri crane N crane weight without boomrs kg P welgni Of TAC kg G load with maximum reach kg L maximum reach from the tipping
41. nore the safety instructions when repairing MALFUNCTI POSSIBLE CAUSE MEASURE ON The crane 18 not moving The crane moves some Or IS powe r less One function powerless Booms Stay up under normal load Hydraulic system overheats Valve spools get stuck Oil leaking from the slew housing Empty oil tank Pressure hose connector not properly connected or faulty Pump does not generate pressure Return hose connector not properly connected or faulty Main relief valve or pump relief valve defective or dirty Relief valve at the particular section faulty or dirty Relief valve of this particular function leaking Cylinder seal leaking Valve spool leaking Leakage in the pump Pump flow too high for the control valves Not enough oil in hydraulic system Overheated hydraulic oil Dirt in valve Studs connecting the valve sections too tight or too loose Slew cylinder seal leaking Too much oil in the mechanism Radial seal leaking Add oil Check the connector replace with new quick coupling if needed Measure pressure from the pump section of control valve check the relief valve of pump Check connector measure back pressure Measure pressure from the tank section end check and if needed replace with new relief valve Measure pressure of this function replace new valve if needed Replace relief valve This particular function
42. om the tipping centre 3550 support width of the stabiliser legs K 236 distance of the tipping centre from the stabiliser legs n NeA M C formula a 0 5 7 arc tan 0 5 3550 11 4 X 5500 3300 X Y K sin 5500 3300 236 sin 11 4 1693 mm B L A 9650 1693 7957 mm C X e sin 5500 sin 11 4 1087 mm E Lpp A 3693 1693 2000 mm 1140 1693 6500 1088 847 7957 710 2000 n gt 1 0 machine considered stable 46 COMISSIONING as KESLA INSTRUCTIONS FOR THE DETERMINATION STABILITY BY TEST SAFETY INSTRUCTION Follow extreme caution when proceeding with the test Danger of tipping over Make sure before the test that air has been removed from the entire hydraulic system Uncontrolled movements Make sure that the ground is firm enough to withstand the loads of the wheels and other support points TEST CONDITIONS During the test the vehicle shall be in normal running order without load Remove possible grapple assy or weigh it as part of the test load according to the table Incline the vehicle 5 in the direction of the tipping line during the test PERFORMING THE TEST Carry out the test with the most unfavourable reach in regard to the stability and using an overload of 10 Drive all crane movements as normally driven Observe
43. on from the machine plate This will soeed up the process and assure that correct information parts will be supplied Copy the information on the machine plate onto the picture below 3 KESLA GENERAL FIN S0101 Joensuu Finland KESLA oY 973 682 841 Tyyppi Paino Type Weight Valm No O Valm V Tillv nr Tillv r Serial Nosturil Kranklass Loader class 4 GENERAL as KESLA CRANE PRESENTATION FIELD OF APPLICATION The Foresteri truck crane is designed for professional loading of cut to length timber The crane is also suitable for loading scrap sand fertilizers etc when suitable grapples are used It is forbidden to use the loader for lifting persons o m Fi 11 rrrrrrr nna OPERATING PRINCIPLE To be in working order the crane needs a power unit with attached hydraulic pump and necessary hydraulic equipment among others oil reservoir filters hydraulic pipes All working motions are hydraulic Separate functions slewing of booms boom lifting grapple closing etc are achieved by leading pressurized oil with the contro valve to the desired hydraulic cylinders If needed the operator can drive several functions simultaneously 5 KESLA GENERAL MAIN PAR
44. on the edge of the chain gear ADJUSTING THE HORIZONTAL CLEARANCE OF BOOM EXTENSION Remove the locking screw 1 of the side glide pad Turn the glide pad clamp 2 clockwise equally on both sides of the boom until there is gap If this does not eliminate the gap the glide pad 3 is worn out and must be replaced Loosen the clamp 2 back to previous lock position Put back the lock screw 1 and lock with nut 4 66 SERVICE KESLA DYI ADJUSTING THE VERTICAL CLEARANCE OF BOOM EXTENSION in models with single and double extension Open fixing bolts 5 If needed add adjusting shims 7 between the glide pad clamp 6 and the upper surface of the boom use 1 or 2 shims There is no adjusting space left when the bottom glide pads 8 are worn to almost the same level as the lock plates 9 If so change the glide pads NOTE The glide pads must have a small working clearance to allow the exten sions to move Overtightening will only cause excessive wear REPLACING THE SLIDING BEARING Refer to Safety insturctions while servicing The booms are equipped with so called thin box sliding bearings which are long lasting if correctly lubricated When the bearing is so worn that there is a distinct gap in the link remove the pin and the old bearings by opening them at the seam with e g a wedge Use a suitable mandrel when installing a new bearing to prevent damaging the bearing
45. ory tested and adjusted before delivery Never use a faulty crane but repair even minor faults and defects before they cause damage refer to Daily overhaul prior to operation The tables Service procedure for periodical inspections and service and Trouble shooting for fault locating will make these measures easier for you The persons responsible for the use and service of the crane must be familiar with these instructions 2 OIL CHANGE Change the hyaraulic system oil in the spring and in the fall or every 1000 operating hours When all the hyaraulic piston rods are pulled back the oil volume of the crane is at its smallest Then empty the oil reservoir and clean it if needed and replace the filter cartridges Fill the reservoir with hydraulic oil to the upper mark refer to Oils and lubricants If the oil is very dirty drain the cylinders separately as follows Hemove the hose on the rod side and put it in a waste oil vessel Drive the piston rod out and connect the hose Change the slew mechanism oil once a year and drain the water 2 times year Check the oil quantity from the oil gauge and change the oil by opening the draining and filling plugs Incline the crane in the direction of the draining plug When the reservoir is empty screw the draining plug back and fill hypoid oil into the slew mechanism to the upper edge of the oil gauge refer to Oils and lubricants ALWAYS DHAIN THE WASTE OIL 55 KESLA
46. peed to the situation Make sure you have full machine control at all times Observe the combination height when driving under live electrical conductors telephone lines and bridges 58 SERVICE KESLA SAFETY INSTRUCTIONS WHILE SERVICING Start by becoming familiar with the service instructions faulty or inadequate service might damage the crane NOTE Never use a pressure washer when washing the electric components Dismounting of the crane or its components during the guarantee period must be done by a service company or person authorized the manufacturer When servicing repairing or cleaning support the boom against the frame Never leave the boom supported by the hydraulic cylinder only Disconnect the pump and turn off the engine if the crane is not to be used during service Never try to open tighten etc a pressurized hydraulic system Entry of air into the opened hydraulic system can cause sudden unanticipated movements when retaking the crane in use When handling the loader or its component use lifting equipment with capacity Never stand under the load when working or lifting Avoid skin contact with oil or grease during work or service They contain solvents additives that can be in repeated skin contact dry and cracked skin Old and dirty oils and greases are more harmful than new ones Follow the instructions of the manufacturer and authorit
47. perating The bottom control valve may have 3 5 functions depending on the fitting method of the crane and the equipment of the vehicle E g moving of the bunk bottom control valve with 5 stems Fixed mounting bunk can not be moved bottom control valve with 3 stems 10 GENERAL KESLA STANDARD MODELS AND ACCESSORIES Foresteri truck cranes have passed an operalional test after assembly and are ready to be used There are several models to be chosen from Basic crane The control equipment can be fitted directly behind the pillar or with the aid of wedges diagonally to the right or left side in which case the boom does not obstruct the view Control valve with 2 or 4 levers Bottom control valve stabiliser leg valve with 3 5 spools depending on what functions are required e g moving of the bunk moving of the fitting stand In addition it can be either electrically or mechanically controlled Outer boom alternatives single or double extensions Hydraulic system alternatives 1 circuit 1pump or 2 circuits 2 pumps In addition the system can be equipped with a fixed output pump or variable capacity pump Cabin crane The cabin is fitted on guide bars attached to the sides of the pillar and it can be hydraulically moved up and down 11 KESLA DYJ GENERAL STANDARD MODELS AND ACCESSORIES Controls with 2 or 4 levers are situated in the cabin Control valves are ope
48. rated either mechanically located in cabin or electrically located on pillar The equipment alternatives for the actual crane are the same as for the basic crane The cabin comes with e g the following standard equipment heater 2 windshield wipers washers interior light 3 working lights seat arm rests safety glasses front sun roof safety glass Accessories With the following accessories the crane is even more pleasant to use Timber grapple e g Forester 36 43 Vahva 40 Hultdins 40 Rotator link set e g Indexator GV11 2 Working light set 2 4 or 5 lights Seat heater Seat back extension Centralized lubrication system e g Safematic down to the grapple Loading scales e g KA 60 Rear fitting stand customized versions also Cylinder for moving the fitting stand fastening set pocket conical model 54 as KESLA SERVICE PROCEDURE 1 GENERAL Maintain the crane regularly to ensure its safe and troublefree function All the tools needed for the service of Foresteri cranes are included in the delivery Thus the operator can carry out almost all the service himself Do not ever without the manufacturer s permission alter the relief valve pres sure settings to settings differing from the ones given in the hydraulic scheme Have an authorized service shop do the valve adjustments and repairs he crane is thoroughly fact
49. rease often with small amounts instead of infrequently with great amounts Cleanness is essential for the hydraulic system First filling oil SHF 32 class API SD Repair even minor faults immediately to avoid serious damage 2 GENERAL KESLA USE OF MANUAL Each Foresteri crane delivery includes an owner s manual This manual is drawn up for operators with earlier practice of handling timber cranes The asterisk notifies information the subject issue The dash indicates necessary possible steps to be taken The WARNING symbol denotes a very important safety instruction NOTE The NOTE symbol notifies risk of damage for the product process or environment The content of the manual has been divided into five larger sections headed at the too of each page This together with page numbers will make the use of the manual faster and easier All descriptions instructions and technical data are based on the latest specification of the machine at the time of the manual Due to continuos product development the manufacturer reserves the right to change the product without advance notice In the case of disturbance in function the problem and its propable cause can be repaired wth the assistance of the fault finding chart If not contact the manufacturer or an authorized service centre NOTE When ordering spare parts or enquiring for service instructions always supply the informati
50. ressure meas uring coupling at the pressure end of the control valve or with a joint to the pressure hose Start the pump and engage the retract function of the extension with extensions retracted Read the system pressure Compare with the main pressure in the hydraulic scheme Release the levers to their middle position 68 SERVICE KESLA DY and read the return pressure 2 PRESSURES OF THE WORKING MOVEMENTS P2 The pressure of each working movement raising outer boom functions slew ing extension grapple rotator is achieved by driving each function toward its limit with the control lever If the pressure setting of the relief valve for the function in question is less than the crane working pressure the valve should open The opening pressure may exceed the hydraulic scheme setting with max 5 f the pressure setting of the relief valve for the function in question is higher than the crane working pressure the function can be measured by changing the main relief valve to a 250 bar relief valve for the time of measuring The setting of the pump relief valve must also be 250 bar during the measuring Compare the measuring result with the hydraulic scheme Replace the relief valve if needed Never raise the pressure settings of the control valve It may cause over load and damage the crane STORING If the crane to be stored for a longer period carry out following preparations
51. rried out once a year and the trial run according to standard SFS 4261 every 4 years An authorized installation firm must fill in the inspection record of which the first part will be given to the client and the second part remains with the installation firm The inspection record must be filed with the crane Vehicle make model and registration No Manufacturing year K a F ITI a I J A O rr 111 FF TRIAL RUN ACCORDING TO FINNISH STANDARD SFS 4261 The movements vers wor poston 1 1 Gondton a 11 REMARKS
52. s with Outer boom cylinder Boom extension cylinder Lifting cylinder Grapple cylinder check pressure settings with the grapple manufacturer Slewing cylinders Stabiliser leg cylinder Stabiliser leg spreading cylinder Stand moving cylinder Check valve Pressure controlled check valve Reducing nipple Pressure measuring nipple Pressure filter Return filter Hydraulic pump Oil reservoir Swivel Swivel Quick connector Quick connector Series connection nipple 1 circuit system 11 KESLA TECHNICAL SPECIFICATIONS The technical specification gives the constructural and functional measures as well as the lifting power and pressure settings TECHNICAL SPECIFICATIONS Lifting capacity gross Lifting capacity Slewing angle ___ 415 Less oil grapple and rotator kg 1690 1810 Pump recommendation working pressure MPa bar 24 240 flow 1 circuit l min 70 90 F130 2 circuits l min 2 x 60 80 F130 power input 1 circuit kW 27 35 2 circuits kW 45 60 Pulling force of extension 24 0 2450 20 0 2030 Height fastening level upper link of pillar 2170 Transport width 2500 GRAPPLE ACCESSORIES ROTATORS MR8AF GV11 1 2 5 Slewing torque 24 MPa 2 5 58 9 Weight kg 56 as KESLA DYJ DIMENSIONAL DRAWING 12 TECHNICAL SPECIFICATIONS CH
53. ser may incur through a failure of the product or for any consequential damage to persons or property resulting from a failure of the warranted product Warranty shall be invalidated if any repairs to the warranted product have been made by others than the manufacturer or the manufac turer s sole representative The warranty shall be invalidated also if the preset pressure settings have been altered A written warranty claim for the defective part must be submitted to the guarantor within a period of thirty 30 days at the most from the date of reparation The warranty claim form must always be filled with the following information make and model machine number date of delivery to the client date of reparation description of the defect name address and telephone number of the client 67 KESLA SERVICE reference number Bill of Material of the exchanged spare parts KESLA START UP INSPECTION The start up inspection must be performed immediately after assembly before taking the crane into use An authorized installation firm shall fill in the inspection record which shall then be signed by the inspector and the client The first part will be given to the client second part returned to the manufacturer and the third part remains with the assembly shop A R R CHECKS BEFORE TRIAL RUN 1 The crane has the correct service and 1 The crane has the correct service a
54. t 302 0026 M24 nyloc 700 71 GNE mcm Control valve blocks 130 CF H170 CF 2 60 6 pipes When opened remove and replace with new nyloc nut Screw down and secure with set screw Secure with locking fluid e g LOCTITE 242 or corresponding 24 KESLA TECHNICAL SPECIFICATIONS ELECTRICAL SCHEME 5 NMO 1115 OL 9317 39 NV SNOIL23NNO2 17318133413 124 301233NN03 8119 4045 22 yes ee NS 318V3 JILSV 1d 119 1935 Z 39150 12 3 7 X 4 414 2 844408 4n 14 Vig 11 v 19 119 LHDISI DNIL4I1 LH9I1 1698 1H8 NOOS 331110 1008 1331 Wood ONAN 25 TECHNICAL SPECIFICATION KESLA ELECTRICAL 5 or 2 3 __ 2 8 Mm zT ir 1 z kU gt 4 bi AA AA EN AN 7 qd ANANG JHL ONY 15 531 931 931 JD SNAOW 211114 3azhimVis 83218 15 32119715 JHL DNIAQN 30 NIDV3HdS 11019 1111 51 NMO S OL 0333 39 1 2810313 1524 B L33NND3
55. table restriction are located in the main lifting and outer cylinders The maximum lowering speed of the booms is adjusted with these valves so that the speed is suitable and that there is enough oil coming from the pumps to these cylinders 5 The stabiliser legs are fitted with pressure controlled return valves which prevent the stabiliser leg from collapsing in case of overloading or hose damage 6 The main lifting boom outer boom and boom extension cylinders can be fitted with a hose burst valve which will lock the oil into the cylinder if the flow speed becomes too high e g case of a hose burst The hose burst valve wil open when oil is directed through it in the opposite direction 7 The crane control system shall be fitted with EMERGENCY STOP button located at the point of operation It is used either for cutting the oil flow to the crane with e g an el 53 as KESLA DY OPERATION controlled valve or alternatively the current to the control valve 7 with indirect pilot operation The button may be used also for stopping the power engine if this can be done from seat 54 KESLA The operator the loader have read understood the manual and the safety instructions before operating the loader GENERAL Good knowledge of the features as well as sound practical experience are the conditions for safe and effective
56. ted against corrosion Remove the protective grease using e g kerosene because impurities can damage the seals Before fitting the crane the truck has to be fitted with e g hydraulic pump pumps hyaraulic oil reservoir and hydraulic pipes NOTE Always check that the hydraulic system of the truck suitable for the crane 30 COMISSIONING KESLA PRELIMINARY PREPARATIONS AT INTRODUCTION Size of the pump must be chosen according to the nominal flow of the control valve for example 90 l min for F130CF valve and 120 130 l min for H170CF valve Note oversize pump will create back pressure and overheating of oil Do not use too high pump flow Recommended flow rates are available from the control valve manufacturer upon request Note The compatibility of the hydraulic system of the truck must be always veified prior to connecting the pressure to the loader he instructions of the vehicle manufacturer importer must be followed when fitting the fastening muffs of the rear fitting stand and mounting plate fixed mounting t is advisable to determine the stability of the combination by calculation See instructions for the determination of crane stability by calculation FITTING THE CRANE Only a service centre or person authorized by the manufacturer is permitted to perform the fitting All crane functions are test loaded by the manufacturer and pressures have been measured First filling oil ESSO
57. temperature changes water may be condensed in the hydraulic system Especially in winter time the water may cause disturbances Therefore change the oil regularly according to service recommendations or at least twice a year in the spring and in the fall Change new filters regularly according to service recommendations and always when changing oll Wash the oil reservoir with kerosene or white spirit not with fuel oil 2 THE CONDITIONS FOR A GOOD HYDRAULIC OIL Solidification temperature below 50 viscosity may not drop below 1 5 ES 50 in piston pumps 2 5 50 in gear pumps 60 SERVICE KESLA HYDRAULIC OILS The hydraulic oil must contain required additives in regard to the lubrication ability anticorrosion and foam prevention The oil shall be suited for the seal materials of the crane Never use motor oil in the hydraulic system Even new oil contains impurities which due to their size can cause disturbances 3 IMPURITIES IN OIL Storage and transport vessels accumalate dirt Due to wear in operation a crane creates metal and other foreign particles which enter the hydraulic system During crane repair gets into the system n case of component damage greater quantities of impurities can get into the circulation at one time Impurities in oil can lead to a faster than normal component wear temporary malfunctions e g
58. their outermost position the pump unit becomes pressurized and lubrication starts NOTE the pump unit requires a pressure of at least 100 bar to operate Check daily that the pressure gauge at the point of operating indicates a pressure of approx 160 bar during a lubrication period If the gauge does not indicate pressure rise the tank is empty or there is a leak in the main line to make sure that lubrication is effective the pressure has to be kept on for at least five seconds let the pressure drop under 20 bar before initiating a new lubrication period 27 KESLA DYJ 5 28 KESLA TECHNICAL SPECIFICATIONS GREASE FITTINGS OF CENTRALIZED LUBRICATION SYSTEM asDaJD jnulau pun ssaudpuni si ay Duiusnq asna b 14045 492110145 8 40 shulusng 10 sbBujusrig pun Ssaudpuni Si Ba N pasop 10 aui 19100 9 apis JUO Of uajuasumgm 15498 au Jo doy au apng SUND yu 40 shutusng SUUD YUN 344 4D 5 naddu asnau 5 aum doy ay sBuusng 3045 48211045 SOUILBNY 55240 puny n apis a
59. ud pajpaumgn aq un 915 10 do 2 ju apno i3 LON qowu pun SS JdpDUDU si 02511197045 au 40 Bui 950940 11400 PUD saudpuny jmpad Jn 310 950840 pun 558 0 puni 0 aq Jo 58 50 3 N Yul 40 sbuiusng 9 au jo 19 KESLA DYJ TECHNICAL SPECIFICATIONS HYDRAULIC SCHEME F2008 F20081 2 lever 1 circuit 130 RM 255 valves D 2 Q22 2V F1300F RM255 20 TECHNICAL SPECIFICATIONS am KESLA HYDRAULIC SCHEME 2008 20081 2 lever 2 circuit 130 255 valves 10 9 230 4023 n 217 16 21 KESLA DYJ TECHNICAL SPECIFICATIONS HYDRAULIC SCHEME F2008 F20081 4 lever 1 circuit 130 RM 255 valves 22 TECHNICAL SPECIFICATIONS am KESLA HYDRAULIC SCHEME 2008 20081 4 lever 2 circuit 130 255 valves 10 5 230 024 08222 2 i 2 25 x I Tn m I m 175 25 25 25 28 MPa C a E 224 220 220 222 517 1 4
60. use Every crane model has different geometry and speeds of movement and therefore even an experienced operator should thoroughly familiarize himself with the characteristics of a new crane TRAINING An experienced operator drives many crane movements simultaneously adjusting different speed of movements to his liking Naturally the speed of the crane movements will decrease when the same oil flow is directed to many cylinders Soft and effective work is achieved with soft and easy lever handling avoiding jerky movements and sudden stops this way working is safe and effective and unnecessary repairs will be avoided It is recommended for an unexperienced operator to adjust the pump flow to be low in which case it is easier to avoid sudden movements Smaller loads are also recommended when getting familiar with the crane COMMISSIONING Refer to Safety instructions at commissioning Ensure that the hydraulic system of the vehicle is cleaned before connecting the hoses to the crane he crane s hyaraulic system is cleaned and tested by the manufacturer Final inspection according to SFS 4261 has been carried out by the manufacturer Check that the hydraulic oil reservoir is filled up inlet line from tank to pump is open and that the pressure and return filters are installed Always start with cleaning the quick couplings first Connect the return hose before pressure hoses Check for secure connection of quick couplings If the
61. use the crane for towing 51 as KESLA DY OPERATION Never use the crane for lifting people 52 KESLA SAFETY EQUIPMENT For safety at work the crane s hydraulic system is fitted with various relief valves Never alter the valve settings without the manufacturer s written permission The manufacturer will not be responsible for any damage if the settings have been altered without permission The pump circuits of the truck hydraulic system have to be equipped with relief valves with relief pressure at least twenty 20 bar higher than that of the main relief valve of the crane 1 The three way safety valve is located at the pressure section of the right hand control valve It is used to feed pressurized oil 3 either to the control valve or stabiliser leg valve thus preventing unintentional use of the stabiliser leg valve during loading 2 Each control valve has at its pressure section a main relief valve which prevents the working pressure from rising too high If the oil coming into the control valve has a pressure higher than the set pressure oil will flow out to the reservoir channel until the set pressure has been reached 3 Relief valves stop the pressure from rising too high in different cylinders the load on the cylinder exceeds the pressure setting oil will flow from the cylinder via the relief valve until the permitted pressure is reached 4 The check valves with adjus
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