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OPERATION SERVICE SPARE PARTS

1. as FORESTERI 2006 OPERATION SERVICE SPARE PARTS 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 amended with directives 92 31 EEC and 93 68 EEC 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 a CE marking attached ee Papo Name Esko Paajanen Position Managing Director Date Joensuu CONTENTS page GENERAL Summary 0 For the reader 1 2 Major loader components 3 Instructions and warnings on loader 4 Standard models and accessories 7 TECHNICAL DATA Technical data 9 Dimensional drawings and allowed loads 10 Reach diagram 12 Hydraulic schemes 13 FITTING AND COMMISSIONING Safety instructions at commissioning 16 Preparing for installation 17 Mounting the loader 18 Inspections 22 Instructions for determination of stability by calculation loader 24 cranes 31 Instructions for determination of stab
2. FITTING AND COMMISSIONING as KESLA INSTRUCTIONS FOR THE DETERMINATION OF STABILITY BY CALCULATION LOADER CRANES 2 A vehicle with 2 or 3 axles with the crane mounted in the back of the chassis D 0 the stability coefficient shall according to SFS 4677 be 1 0 the stability coefficient is calculated with formula N e A C If the result is gt 1 0 crane is considered stable If the result is 0 75 1 0 the stability must be examined by test Y _ NNNS NNN FIGURE 3 FIGURE 4 33 KESLA FITTING AND COMMISSIONING INSTRUCTIONS FOR THE DETERMINATION STABILITY BY CALCULATION LOADER CRANES 2 A CHANE MOUNTED BEHIND THE VEHICLE pict 3 and 4 Vehicle information needed for calculation Ms rear axle weight less load kg rearmost front axle weight less load kg 0 if there is axle X wheel base mm X front wheel base mm Y distance from rear axle to crane stabiliser legs mm Manufacturer s information on Foresteri cranes N crane weight less booms kg P weight of booms kg G load with max reach kg L max reach from slewing centre mm distance between centre of gravity of booms and slewing centre mm Lr support width of stabiliser legs from slewing centre mm K slewing centre distance from stabiliser legs mm The angle a the angle between the centre line of t
3. Stop working immediately if there is any risk of danger Make sure that there is sufficient working light 47 as KESLA TRAFFIC ON PUBLIC ROADS Comply with all the statues and decrees of the Road Traffic Law when driving on public roads If the load area is empty lower the end of the lift boom and the closed grapple on a bolster When the load space is full leave enough space in the centre for the boom so that no part of the loader will rise above the permitted transport height Retract the stabiliser legs and the outrigger beams into transport position and secure them with lock pins Disconnect the hydraulic pump during transport drive Secure the load carefully with load straps Lock the detachable rear installation console mechanically to the vehicle chassis Do not exceed the permissible axle and total loads or transport dimensions Check the lights reflectors tyre pressure trailer connection etc before driving off Adjust the travelling speed to the situation Make sure of full control of the vehicle at all times Observe the height of the vehicle when driving under electric lines telephone lines and bridges 48 SERVICE KESLA OYJ SAFETY INSTRUCTIONS WHILE SERVICING Start by becoming familiar with the service instructions because faulty or inadequate service might damage loader During service maintenance or cleaning support the
4. 14 TECHNICAL SPECIFICATIONS as KESLA HYDRAULIC SCHEME P2006 4 LEVER 1 CIRCUIT Pressures MPa EE i lt re oy 13 as KESLA OY TECHNICAL SPECIFICATIONS HYDRAULIC SCHEME P2006 2 LEVER 1 CIRCUIT Pressures MPa ev fo E sc MC F TR i lt AAA m m w A s mman mmm m m eee 12 TECHNICAL SPECIFICATIONS as KESLA REACH DIAGRAM P2006 Ts _ eM SS P y 9 KESLA OY TECHNICAL SPECIFICATIONS The technical specification gives the main functional measures as well as the lifting power and pressure settings TECHNICAL SPECIFICATION P2006 Lifting capacity gross kNm net kNm 65 7000 Stroke of boom extension mm 1200 Slewing torque gross Nm kg Slewing angle Weight less oil grapple and rotator 1550 Pump recommendation working pressure MPa bar 23 230 flow 1 pump l min 60 80 power input 1 pump kW 23 31 Height fastening level upper link of 2160 pillar mm Transport width mm 2200 ACCESSORIES ROTATORS GV11 2 Slewing torque 20 kNm 1 4 2 2 MPa Weight kg TIMBER GRAPPLES Hultdins SG 260 Jaw pressure at the tips Weight kg 10 as KESLA TEC
5. back end of the outer boom Finally extend the extensions fully and oil or brush grease on the top bottom and sides 49 as KESLA DYJ SERVICE DISMANTLING THE SLEW MECHANISM Refer to Safety instructions while servicing 1 Slew the booms to their center position 2 Drain the oil from the slew mechanism into a vessel by opening the draining and filling plugs 1 3 Remove the cylinder barrels 2 and drain the oil into a vessel The rack bar 3 and its thrust bearing 4 can be removed without removing the pillar 4 The pillar 5 can be lifted away by removing the locking ring 6 from the lower end and the hoses going through the pillar The pillar can be lifted away without removing the slewing cylinders and the rack bar 5 Mount in the opposite order and finish by adding hypoid oil 80W90 into the slew mechanism to the oil gauge 7 v FILLING HOLE 1 OIL GAUGE DRAINING e 1 C S 6 N 7 7 Y N fs AS 1 24 7 5 aN 6 0 50 SERVICE as KESLA OYJ DISMANTLING THE OUTER BOOM 1 Drive out the extension about 30 cm 2 Remove the extension cylinder from the outer boom as well as the hydraulic hoses 3 Remove all glide pads from the mouth of the outer boom 4 The whole extension package can be pulled out from the outer boom ADJUSTING THE HORIZONTAL CLEARANCE Remove the locking screw 1
6. overheats when loading Hydraulic system overheated Worn pump internal leakage Check flow at high pressure while the oil is hot Heplace the pump if needed Too high back pressure Check back pressure in return Pump flow exceeds the max line work with smaller flow flow of the control valve Not enough oil in hydr system Add oil Valve spindles get stuck Overheated hydraulic oil Refer to above Dirt in valve Check if oils and filters have been changed acc to instr Studs connecting the slices Check tightening torques too tight or too loose Oil leaking from the slew Slew oylinder seals leak Change seals if needed housing the seals might let some oil by especially if oil is very cold Radial seal leaking Tighten by turning axle seal spring replace axle seal if needed 47 as KESLA DYJ SERVICE SERVICE PROCEDURES LUBRICATING POINTS NOTE LUBRICATE THE SPHERICAL BEARINGS AND BUSHINGS AT BOOMS WITH BLACK GREASE MOLYBDENUM SULFIDE CONTENT 2 USE UNIVERSAL YELLOW GREASE FOR OTHER POINTS NOTE SHORTEN THE LUBRICATION INTERVALS IF WORKING CONDITIONS ARE UNFAVOURABLE E G DUSTY Lubricating point Procedure Lubrication interval 1 Slew mechanism oil gauge 10 2 Slew mechanism lower plug 1 Drain water 1000 draining 2 times year Slew mechanism upper plug Spherical bearings and bushings Outer of extensions 6 Inner surfaces
7. 51041101 10114 5 as KESLA OYJ GENERAL INSTRUCTIONS AND WARNINGS ON CRANE The loader has warning and instruction decals informing of hazards or operational directives Follow these to avoid unnecessary accidents and malfunctions 1 RISK ZONE DECAL Colour combination yellow and black 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 Colour combination yellow and black WARNING WARNUNG STAYING WITHIN THE DANGER ZONE IS STRICTLY FORBIDDEN WHEN THE LOADER IS IN OPERATION KEEP CLEAR OF OVER HEAD POWER WIRES AUFENTHALT IM GEFAHRENBEREICH WAHREND DES HEBEVORGANGS STRENGSTENS VERBOTEN ACHTEN SIE AUF STROMFUHRUNDE LEISTUNGEN NOMINAL VOLTAGE MINIMUM DISTANCE MINIMUM DISTANCE FROM UNINSULATED FROM INSULATED WIRE WIRE MINDESTABSTAND VON NENNSPANNUNG MINDESTABSTAND VON ISOLIERTEN LEITUNGEN NICHT ISOLIERTEN LEITUNGEN m 2 3 5 he is delivered with the manual and shall be placed in front of the operator The decal absolutely forbids persons loitering within the risk zone when the loader is working risk zone 25 m 6 GENERAL as KESLA he decal warns of live electrical conductors you must work or drive under such conductors always follow the minimum safe approach distances given in the table as KESLA OY GENERAL 3 SAFE WORKING LOAD
8. PLATE Colour combination yellow and black The load plate is placed in front of the top seat and notifies the max permissible loads for different lifting radii f the stability coefficient of a rear installed unit is 0 75 1 0 use 50 percent lowered lifting values when starting to load 4 CONTROL LEVER DECALS Colour combination yellow and black 2 LEVER CONTROL VALVE 4 CONTROL VALVE BN boom On Boom slewing N Rotator CHO ORE nt The control lever decal is placed in front of the top seat and is according to the control lever system either for 2 or 4 levers he decal shows the lever and pedal functions 8 GENERAL as KESLA INSTRUCTIONS AND WARNINGS ON LOADER 5 STABILIZER CONTROL LEVER DECALS Colour combination yellow and black LEFT RIGHT OUTSPREADING MOVING THE SLIDING STABILIZER STABILIZER OF STABILIZER CONSOLE BOLSTER LEG LEG OR FREE OR FREE There are 2 decals one by the top seat the other by the stabilizer control valve The stabilizer control valve can be controlled from the top seat electrically with switches or mechanically with levers and cables It can also be controlled directly from the ground with valve levers The stabilizer leg control valve may have 3 5 functions depending on how the loader is mounted and the vehicle equipped Examples moving bolster in the trailer gt a5 spindle valve for stabilizer leg control fixed mounting with
9. PeE a arctan0d 5e arc tan 0 5 3085 9 9 X Y 5500 3300 A X Y K sin a 2 55004 3300 198 e sin 9 9 1479 mm B L A 7000 1479 5521 mm sina 5500 sin 9 9 946 mm Lpp A 2450 1479 971 1080 1479 6500 e 946 1 40 910 55214510 971 36 FITTING AND COMMISSIONING as KESLA n gt 1 0 the crane 15 considered stable 37 KESLA FITTING AND COMMISSIONING INSTRUCTIONS FOR THE DETERMINATION OF STABILITY BY TEST LOADER CHANES Safety instruction Observe extreme caution when testing danger of tipping over Make sure that all loader cylinders are vented before the test Sudden movements Make sure that the ground is firm enough to withstand the loads of the wheels and other points of support TEST CONDITIONS During the test the vehicle shall be in normal running order less load Remove the accessories or weigh them as a part of the test load accoraing to the table Incline the vehicle 5 in the direction of the tipping over line during the test PERFORMING THE TEST The test is carried out with the most unfavourable reach in regard to the Stability and using an overload of 10 Observe extreme caution when driving all the movements as normally driven with the loader during the test a 2 8 s 8 loader is considered stable if no more than one of the 5 points of su
10. based on vegetable oils HETG e g turnip rape oils 2 Synthetic hydraulic oils based on polyglycols HEPG 3 Synthetic hydraulic oils based on esters HEE ALERT Before starting to use biodegradeable oil consult your dealer when choosing a suitable oil type and clarify its suitability for the pump seals and other hydraulic components 15 KESLA TECHNICAL SPECIFICATIONS HYDRAULIC SCHEMES PATU 2006 1 Control valve 2 3 Stabilizer control valve 4 5 Rotator check the pressure settings from the manufacturer 6 Outer boom cylinder 7 Extension cylinder 8 Lift cylinder 9 Grapple cylinder check the pressure settings from the manufacturer 10 Slewing cylinders 11 Stabilizer leg cylinder 12 Outrigger beam cylinder optional accessory 13 Check valve with adjustable restriction anti cavitation valve 14 15 Pilot pressure operated check valve 16 Restrictor nipple 17 Pressure gauge connector 18 Pressure filter 19 Return filter 20 Hydraulic pump 21 Oil tank 22 Swivel 23 Swivel 24 Quick connector 25 Quick connector 26 27 28 Relief valve 250 bar hydraulic system of vehicle 16 FITTING AND COMMISSIONING KESLA OYJ SAFETY INSTRUCTIONS AT COMMISSIONING The Foresteri loader is designed for timber loading and shall be operated only by a person familiar with its use Get familiar with the loader design functions controls and user manual before taking the loader in
11. loader registration number of vehicle and CE marking The loader can be fitted at the back of the truck behind the cab or front centre or back of a semi trailer 1 MOUNTING IN THE BACK OF THE VEHICLE ON A DETACHABLE CONSOLE Fit the truck with the sleeves 2 for console 3 mounting follow the instructions of the truck manufacturer importer Lift the rear installation console 3 into the sleeves 2 The detachable console is normally fitted with a transfer cylinder 5 A Slotted pocket where the flange of the transfer cylinder rod engages to must be attached to the truck frame As an alternative the transfer cylinder can be fitted to the truck frame and the pocket to the detachable console Lift the loader 1 on the console 3 and place the studs M30 4 6 pcs in the outer holes of the console as illustrated in the base drawing page 117 Tighten the studs equally with a torque wrench to torque of 1200 Nm 122 safety chain must fitted between the truck frame the console to prevent the loader from falling off 20 FITTING AND COMMISSIONING as KESLA FITTING IHE LOADER yr Connect the return and pressure hoses of the loader to the hydraulic system of the truck If needed replace the quick couplings of the truck Also a fixed mounting of the loader behind the truck is possible refer to item 2 21 KESLA FITTING AND COMMISSIONING FITTING T
12. must not be connected to the loader Check that the control levers of the loader are in middle position and that they return there when released Refer to Daily overhaul prior to operation 46 OPERATION KESLA OYJ LOADER OPERATION Connect the pump and adjust the flow to about 60 80 l min 1 circuit If you are working in freezing conditions let the oil circulate for a while through the valves with small flow Then carry out all the working motions slowly back and forth so that the seal will limber up before they are set under full pressure The lowest recommended working temperature for the loader is 25 C The loader be used even at a temperature of 35 if the truck s hydraulic system tolerates that Notice that the hydraulic seals wear sooner hoses are more likely to be damaged and the steel constructions are more exposed to brittle fracture in extremely low temperatures In working temperatures below 25 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 does not overheat lt 70 C Excessive oil temperature can damage the seals and furthermore shorten the operating life of the oil Use the stabiliser legs to get the pillar of the loader in as upright position as possible Observe the positions where the grapple or the boom can hit the cab or other vehicle constructions
13. side of the pillar The crane cab is moved hydraulically up and down p 11 as KESLA GENERAL STANDARD MODELS AND ACCESSORIES Loader controls are placed in crane cab The control valves are controlled either mechanically with levers connected straight to the spindles or electrically he alternative accessories of the loader are the same for standard loaders As standard the crane cab is equipped with e g heater 2 wind screen wipers washers inner light working light set of 5 seat arms safety glass wind screen and a safety glass sun roof Accessories Timber grapple e g Foresteri 28 36 Hultdins SG 260 Rotator 4 link set e g Indexator GV11 2 MR8AF Working light set 2 4 or 5 working lights Heated seat Raised seat back Central lubrication system e g Safematic Weighing system e g KA 60 Detachable fitting console Transfer cylinder for console etc 17 as KESLA OY FITTING AND COMMISSIONING PREPARATIONS BEFORE INSTALLATION truck loaders are delivered from the factory as complete units with control valves pressure filters and hydraulic lines as well as other hydraulic fittings Grapple rotator etc are delivered as accessories The transport base is made of 100x100 mm timber and can be reused or burned For handling the loader a lifting capacity of min 29 kN 3000 kg is needed A fork lift c
14. 0 in gear pumps 52 SERVICE as KESLA OYJ 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 loader Never use motor oil in the hydraulics Even a new hydraulic oil contains contaminant particles which due to their size can cause disturbances 3 CONTAMINANTS IN OIL Storing and transport tanks accumulate dirt An operating loader creates due to component wear metal and other particles which enter the hydraulic system During loader maintenance contaminants enter the system With component damage greater quantities of contaminant can get into the circulation at one time Contaminants in oil can lead to a faster than normal component wear temporary malfunctions e g clogging up oil channels or jamming valve spindles and worst of all component damage 4 AVOID ENTRY OF CONTAMINANTS INTO THE OIL Do not store the oil vessels outdoors risk of water condensing in the oil Store the oil in closed original vessels If possible pour the oil directly from the vessel into the tank Use clean vessels when handling the oil Make sure that the plugs funnels sieves and the filling pipes are clean 53 KESLA SERVICE HYDRAULIC OILS Clean the surroundings and the place to be repaired prior to work Make sure that no grinding or welding work
15. 677 and operational test according to Finnish standard SFS 4261 2 WARRANTY SERVICE This service shall be performed by an authorised service shop according to the warranty service records enclosure 2 For the warranty to apply in full the service must be carried out within 30 days of mounting the loader 3 PEHIODICAL INSPECTIONS An operating loader must be inspected within a period of one year and also tested according to the Finnish standard SFS 4261 every 4 years Please refer to the national regulations as they may rule differently The 25 KESLA FITTING AND COMMISSIONING inspection procedure is given in the record for periodical inspection enclosure 3 During the inspection special attention must be paid to fatigue of material wear corrosion and other damage caused operation No structural changes are allowed especially from the safety point of view 4 DAILY OVERHAUL TO OPERATION Check the oil quantity of the hydraulic system and the slew mechanism and aad if needed Lubricate the loader if necessary refer to Maintenance procedures Make a visual inspection of the loader s fitting screws pin lockings hoses and any possible leakage Check the functions of controls and the safety equipment by driving the functions to their limits and repair possible faults and defects immediately Check that the emergency stop switch works 26 FITTING AND COMMISSIONING as KESLA INS
16. An experienced operator drives many loader movements simultaneously adjusting different speed of movements to his liking Naturally the speed of the loader movements will decrease when the same oil flow is directed to many cylinders An experienced operator manages the control levers calmly and softly and avoids jerks and sudden stops to make the work safe and effective and on a long term to eliminate unnecessary repairs It is beneficial for an inexperienced operator to adjust the pump flow down thus making it easier to avoid sudden movements Get familiar with the loader by lifting smaller loads at the beginning COMMISSIONING OF THE LOADER Refer to Safety instructions atcommissioning Never connect the hoses to the loader before the hydraulic system of the vehicle has been cleaned The hydraulic system of the loader is cleaned and tested by the manufacturer Test loading according to SFS 4261 has been carried out by the manufacturer Check that the hydraulic oil tank is full any possible closing valve in the suction hose of the pump is open and that the pressure and return filters are in place Always start with cleaning the quick couplings Connect the return hose before the pressure hoses Assure yourself of proper connection of quick couplings Should the return hose by mistake not have been connected the control valve may be damaged 45 as KESLA OPERATION When starting the engine the hydraulic pressure
17. HE LOADER 2 FITTING THE LOADER BEHIND THE p il JL 5 3 Fa INR E 222 HE Gss A 2 1 Fit 10 mm steel plate with screws 2 to the sides of the auxiliary frame chassis of the truck Sheaths for the studs M30 3 are welded the plates Follow the mounting instructions of the truck manufacturer dealer The truck manufacturers do not recommend either clamp mounting that presses the frame members or welding directly on the frame members Lift the loader 1 onto the fixing plates 2 ALERT do not let rest on frame members and put the studs M30 3 6 pcs in the sheaths Tighten the studs equally with a torque wrench to torque 1200 Nm 122 Mount the accessories link 4 rotator 5 grapple 6 hydraulic hoses if not done by the loader supplier Connect the return and pressure hoses of the loader to the hydraulic system of the truck 22 FITTING AND COMMISSIONING as KESLA FITTING THE LOADER Please note that the slewing arc of the crane is 415 If not differently specified when the order was placed the centre position is on the outrigger side of the pillar and the boom stops are on the pendulum side The loader may be fitted depending on the make and model of the truck with the pendulum and the boom steps towards the cab as illustrated on the previous page or with the pendulum facing the rear of the truc
18. HNICAL SPECIFICATIONS 11 KESLA DYJ TECHNICAL SPECIFICATIONS DIMENSIONAL DRAWING hydraulic spreading ALLOWED LOADS hydraulic spreading 2006 sylinteriLevitys 7000 Hydraulic spreading 5 M 1050 2450 max 1535 C min 2209 c 4 10017234 0 8 12 TECHNICAL SPECIFICATIONS as KESLA DIMENSIONAL DRAWING mechanical spreading ALLOWED LOADS mechanical spreading 2160 038 600 0 3 5 5 7 42 SERVICE as KESLA OYJ OILS AND LUBRICANTS The table below shows some hydraulic oils lubricating oils and greases suited for loader use Oil brand Hydraulic system Grease nipples gt L 3 QJ 2 pop Sliding surfaces 9 Chain Summer Winter ENERGOL SHF ENERGOL SHF 32 HYPO GEAR 80W 90 ENERGREASE LS EP2 46 22 EP L21M UNIVIS N 46 UNIVIS N 32 22 GEAR OIL GX 80W 90 BEACON EP 2 MULTIPURPOSE GR MOLY MOBIL DTE 16 DTE 15 13 MOBILUDE HD 80W 90 MOBILUX EP 2 MOBIL GREASE MP SPECIAL SHELL TELLUS TELLUS SPIRAX HD ALVANIA EP OIL T TX 46 OIL T TX 32 22 80W 90 GREASE 2 RANDO RANDO HDZ MULTIGEAR MARFAK HDZ 46 32 HYDRAULIC LUBRICIANT EP 80W 90 MULTIPURPOSE 2 OIL HD 5W MOLYTEX GREASE 2 Follow the pump manufacturer s cold start instructions when starting the machine If the oil temperature does not rise ab
19. NS Avoid quick lifting and lowering movements with fully outstreched boom also swinging movements before the load is in the air Never drive the booms to their limits with great speed Observe extreme caution when working close to electric lines Make the safety distances to electric lines clear to yourself and follow them Refer to WARNING decal Minimum safe approach distance to electric line 5 m if voltage gt 110 kV m 8 4 7 N ANZ 5 2 8569 3 TN N 1 a 9 4 N Z e X 5 8 peg te aoe 2 FEE I Z 98 PITE IRL 0 N F Cae eO g t 6026 EIS SS Never leave the booms hanging above ground without supervision After having completed the loading lower the loader firmly against a rest and disconnect the pump before starting to drive Observe extreme caution when mounting or dismounting the loader to or from the vehicle s back Danger of tipping over Prevent the stabiliser legs from folding with pin locking Support the booms firmly on the ground Make sure the ground is firm and even Ensure that the risk zone is clear of any unauthorised person additional extensions shall be mounted onto the loader without the manufacturer s permission Never use a faulty loader Never use the loader for towing Never use the loader for lifting persons 41
20. TRUCTIONS FOR DETERMINATION OF STABILITY BY CALCULATION LOADER CRANES The stability must be determined in connection with the start up inspection and performed e g by an authorised service centre Determination by calculation is not necessary if the stability is determined by test Also when the calculated stability is 1 0 the determination by test shall be carried out The formulas and calculation are based on the Finnish standard SFS 4677 Please refer to national regulations as they may differ The loader is considered stable when the sum of the tipping moments multiplied with the stability coefficient does not exceed the sum of the stabilising moments loader is set under a static load on a horizontal plane in a position most unfavourable in relation to the tipping line The vehicle must be empty The stability coefficient for a loader mounted behind the cab shall be gt 1 4 and for a loader mounted in the back of the chassis gt 1 0 If the calculated coefficient is n lt 1 the stability must be examined by test f the coefficient n 0 75 1 0 25 of max permitted effective load can be added when calculating stability of a loader mounted behind the chassis This load is added to the axle bogie weight In this case the safe working indicate also load plate shall indicate 50 load values and the text Vehicle empty or a lt 25 load Following points used as points of vertical in
21. an be used for lifting it from under the transport base ALERT danger of tipping over Lift the loader from its transport base to the mounting place and remove there all the transport fastenings and bindings The visible cylinder piston rods are protected against corrosion Clean off the protective grease using e g kerosene because impurities can damage the seals Do not install the loader unless necessary components like hydraulic pumps oil tank and hydraulic pipes first are installed on the truck ALERT Always check that the hydraulic system of the truck Suites the loader When fitting the sub frame and the fitting base crane follow instructions of the truck manufacturer dealer 18 FITTING AND COMMISSIONING as KESLA Before mounting the loader check the stability of the machine unit by calculation refer to Instructions for determination of stability by calculation loader cranes 19 KESLA FITTING AND COMMISSIONING FITTING THE LOADER A Only a service centre or person authorised by the manufacturer AX is permitted to perform the fitting All loader functions have been test run and hydraulic pressures measured by the manufacturer First filling oil SHF 32 class API SD The service centre shall affix to the vehicle a machine plate where following information is given name and address of service centre year of mounting serial number of
22. as KESLA OPERATION 42 OPERATION as KESLA SAFETY EQUIPMENT For safety at work the loader hydraulics are fitted with different chock valves The valve settings may not be altered without the manufacturer s written permission The manufacturer will not be responsible for any damage if the pressure and flow settings have been altered without permission truck s pressure lines s should have relief valves fitted with an opening pressure exceeding the loader s main relief valve with at least twenty 20 bar 1 The three way globe valve is located in the pressure connection of the right side control valve and leads the pressurised oil either to the control valve or the stabiliser leg valve This prevents the unintentional use of the stabiliser leg valve during loading 2 Ihe main relief valve prevents the working pressure from rising too high and is located at the inlet section of each control valve If the pressurised oil coming to the control valve is exceeding the pressure settings the oil will flow through the return channel to the oil tank until it has reached the set pressure 3 Port relief valves prevent the pressure from rising too high in different cylinders If the load on the cylinder exceeds the pressure setting the oil will flow from the cylinder via the relief valve until the permitted pressure is reached 4 The check valves with adjustable restriction are located in the lift and outer boom cyli
23. booms against a rest Never leave the booms supported only by the hydraulics Disconnect the pump and motor if the loader is not to be used during service tis forbidden to open tighten etc a pressurised hydraulic system Entry of air in to the opened hyaraulic system can cause sudden unanticipated movements when retaking the loader into use When handling the loader or its components use an overhead crane and proper lifting accessories with sufficient lifting power Never stand under the load when working or lifting Avoid skin contact with oil or grease during work and service They contain solvents and additives that can be harmful by repeated skin contact dry and chapped skin Old and dirty oils and greases are more harmful than new ones Follow the instructions of the manufacturers and authorities when handling these substances f oil or grease have caused rash or inflammation or they have got into the eyes immediately contact a physician Always wear proper gloves protective skin cream eye protectors and proper protective clothing when handling oils and greases Never wear oily or greasy clothes and never keep oily tools or other oily objects in your pockets Never clean your hands with oils or greases 49 as KESLA OYJ SERVICE Waste oil from service and repairs shall be sent to a waste treatment plant 50 SERVICE KESLA OYJ HYDRAULIC OILS Choose an oil suited for the hydrauli
24. c system of the loader and handle it correctly 1 HYDRAULIC SYSTEM To function the loader needs a hydraulic system consisting of a power unit pump oil tank filter and other hydraulic equipment needed The oil in the hydraulic system works both as a transmission and a lubricant A high class oil is the first condition for the undisturbed function of the loader Connect the loader only to a thoroughly cleaned hydraulic system equipped with a pressure filter and a return filter The system must also have a breather filter which prevents the entry of larger contaminant particles into the hydraulic oil Despite the breather filter contaminant particles enter the oil tank with the air sucked into it Foreign particles are a risk factor as the pump and valves work with very small plays Due to temperature changes water condenses in the hydraulic system Especially in winter time the water may cause malfunction Therefore change the oil often enough according to service recommendations at least twice a year in the spring and in the fall Replace filters often enough according to service recommendations and always when changing oil The oil tank can be washed with paraffin or white spirit never with diesel oil 2 THE CONDITIONS FOR A GOOD HYDRAULIC OIL 51 as KESLA OY SERVICE Solidification temperature below 50 viscosity may not drop below 1 5 ES 50 in piston pumps and 2 5 ES 5
25. eezing Oil spray with teflon oroblems 46 SERVICE as KESLA OYJ FAULT FINDING CHART The chart shows the most common problems and their reasons as well as the procedures to eliminate them Contact the service department for more information Always follow the safety instructions during repairs MALFUNCTION POSSIBLE REASON ACTION The loader is not moving Empty oil tank Add oil Pressure hose connector not Check the connection and connected or faulty replace with new quick coupling Pump does not generate Check pressure at the inlet pressure section of control valve check the relief valve of loader moves some oris Return hose connector not Check connection measure powerless connected or faulty back pressure of return line Defective or dirty main relief Check pressure at the inlet valve or dirty or faulty pump section replace relief valve if relief valve If fitted needed One function powerless Relief valve at the particular Check pressure of this spool faulty or dirty function replace with new relief valve if needed Boom goes slowly down with Relief valve of this particular Replace relief valve normal load function leaks Cylinder seal leaks Change seals This particular function goes down under load and cylinder is overheating when loading Valve spool leaks of particular function does Change the spindle or whole not hold and the valve slice segment
26. fully in Hold the control lever back Head the system pressure Compare with the main pressure in the hydraulic scheme Release the lever to their middle position and read the back pressure 2 CYLINDER PRESSURES P 2 he pressure of each working movement main lift outer boom slew extension grapple rotator is reached by driving each function toward its limit with the control lever If the pressure setting of the port relief valve is less than the pressure the valve should open The opening pressure may exceed the hydraulic scheme setting with max 5 26 Functions having a higher pressure settings in their port relief valves than the main pressure can be measured by changing to a 250 bar main relief valve before measuring Also the frame line relief valve in the truck If fitted must have a setting of 250 bar during measuring Perform the measuring and compare the result with the hydraulic scheme Replace the relief valve if needed AN Never raise the pressure settings of the control valve It can cause overload and break the loader 53 as KESLA DYJ SERVICE STORING THE LOADER CRANE If the loader is to be stored for a longer period carry out following preparations Clean the loader thoroughly with e g a jet sprayer Lubricate all lubrication points after washing to remove any possible water from the bearings and thus to prevent corrosion Oil the piston rods and the control lever
27. he oil by opening the draining and filling plugs Incline the loader in the direction of the draining plug When rnining the tank 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 INTO A VESSEL AND SEND IT TO A WASTE TREATMENT PLANT 45 as KESLA OY SERVICE SERVICE PROCEDURES Maintenance Procedure Maintenan Note point ce interval h General 3 Check condition of hoses couplings 50 Clean load bearing structures and check their Slew Lubricate bearings with a grease gun mechanism t Tighten fitting bolts 1200 Nm Initially after 50h 7 Checkoilquantty 10 ui Change oil Initially after 50h Booms 9 Lubricate bearings with agreasegun 10 10 Check bearings 250 Check the mounting of cylinder bushes and pins need Extensions 12 Lubricate bearings withagreasegun 10 Brush grease on extensions 14 Check horizontal clearance of glide need with shims 50h Chains 17 Lubrcatechans 50 78 Check chain tension and adjust if needed 50 19 Clean chains need a need Change pressure filter 50h Change return filter Initially after 50h 2 x year Control cables 25 Lubricate cables When At least Mixture of antifreeze and water 50 50 fr
28. he vehicle and the tipping over verge and the coefficients A B C D and E of the calculation formula are calculated on the basis of the above data A scientific calculator is needed for the calculation a arc tan 0 5 LTJ X Y X Y K e sin o mm B L A mm Xe sina mm C Place the resulted numerical values into the formula 2 GeB PeE If the result is 0 75 1 0 the stability must be examined by test 34 FITTING AND COMMISSIONING KESLA Installation company Date Signature 35 KESLA FITTING AND COMMISSIONING INSTRUCTIONS FOR THE DETERMINATION OF STABILITY BY CALCULATION LOADER CRANES CALCULATION EXAMPLE PATU 2006 FORESTERI loader mounted on a console behind a 3 axle vehicle 6500 kg bogie weight less load X 5500 mm distance between bogie and front axle Y 3300 mm the loader stabiliser legs distance from the centre of the console Manufacturer s information on Patu 2006 Foresteri loader N 1080 kg loader weight less booms P 510 kg weight of booms G 910 kg load with max reach L 7000 mm max reach from slewing centre 2450 mm distance between centre of gravity of booms and slewing centre L1 3085 mm support width of stabiliser legs from slewing centre K 198 mm slewing centre distance from stabiliser legs n Mae calculation formula M3_0 GeB
29. ility by test loader cranes OPERATION Operating and safety instructions 32 Safety equipment 34 Operating the loader 35 Traffic on public roads 3 SERVICE Safety instructions while servicing Hydraulic oils Oils and lubricants Tensioning torques Maintenance procedures shooting table Maintenance procedures lubricating Dismantling the slew mechanism Dismantling the outer booms Adjusting the directional and vertical gap Replacing the sliding bearing hydraulic components Repair weldings Pressure measuring Storing the loader crane Discarding the loader Terms of warranty Certificate of fitting inspection Certificate of annual service and inspection of truck loader Certificate of warranty service CONTENTS page 38 39 42 43 44 46 47 49 50 50 51 51 52 53 53 54 55 56 57 0 GENERAL as KESLA OYJ SUMMARY 1 2 10 As the very first step read the manual Check that the hydraulic system of the truck 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 Grease often with small amounts instead of infrequently with great amounts Cleanness
30. intenance of a Foresteri loader are included in the delivery Thus the operator can carry out almost all the maintenance by himself Do not ever alter the relief valve pressure settings so that they differ from the values in the hydraulic scheme without the manufacturers permission Have an authorized service shop to do the adjustments and repairs of the valves The loader is thoroughly factory tested and adjusted before delivery Never use a loader which is out of order but repair even minor faults and defects before they cause damage refer to Daily overhaul prior to operation We have prepared the tables with Periodical checks and service procedures and Trouble shooting to make the maintenance and locating the faults easier for you 2 OIL CHANGE Change the oil of the hydraulic system in the spring and in the fall or every 1000 operating hours The oil volume of the loader is at its smallest when all the hydraulic cylinders are pushed in Empty the oil tank and clean it if needed and replace filter cartridges Fill oil tank with hydraulic oil to the upper mark refer to Oils and lubricants If the old oil is very dirty drain the cylinders separately Remove 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 oil of the slew mechanism once a year and drain the water 2 times year Check the gauge quantity from the oil gauge and change t
31. is done nearby when the hydraulic system is opened Keep the working place hands and tools clean and use correct tools Avoid repairing the hydraulic system outdoors or in dusty conditions ry to locate the fault as well as possible to avoid having to open the system too much Make sure that the dismantled parts and the place of repair are well covered Do not unpack the spare parts before the moment of installation Clean filters and replace filter cartridges according to service instructions Blow the hyaraulic hoses and pipes and wash them when necessary prior to installation Wash the parts with paraffin or white spirit before installing Always use high class oils with correct viscosity BY FOLLOWING THE SERVICE INSTRUCTIONS AND HEMEMBERING ABSOLUTE CLEANNESS DURING HYDRAULIC INSTALLATION THE LOADER WILL FUNCTION RELIABLY AND UNNECESSARY MALFUNCTIONS CAN BE AVOIDED 5 BIODEGRADEABLE HYDRAULIC OILS Instead of normal hydraulic oils oils that quicker dissolve in the environment have been developed to minimise the damage in case of oil leak Many forest management companies request the use of biodegradeable oils in machines that work in forests managed by them Normal oils cannot directly be replaced with any biodegradeable oil without altering the hydraulic equipment e g pump seals hoses Biodegradeable oils are divided into three main classes 54 SERVICE as KESLA OYJ 1 Hydraulic oils
32. is essential for the hydraulic system First filling oil SHF 32 class API SD Repair even minor faults immediately to avoid serious damage KESLA OYJ GENERAL FOR THE READER Each Foresteri crane delivery includes an owner s manual This particular manual is drawn up for operators with earlier practice of handling timber cranes The asterisk notifies information on 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 he content of the manual is divided into five larger sections headed in the upper right page corner This together with page numbers will make the use of the manual quicker 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 continuous product development the manufacturer reserves the right to change the product without advance notice n the case of disturbance in function the problem and its probable cause can be repaired with the assistance of the fault finding chart If not contact the distributor or an authorised service centre NOTE When ordering spare parts or enquiring for service instructions always supply the information from the machine plate This will speed up the process and assure that correct information
33. k In the latter case you may wish to change the centre of the slewing arc to be the pendulum side To do this you must remove the two slewing cylinders and remove the piston from one side of the rack Then you must turn the crane pillar until the rack can be pulled out from the other side 1 6 the teeth are disengaged from the king post pinion Turn the crane pillar through 180 to the new end position of the slewing arc Then re mesh the rack with the king post pinion making sure that the rack support head is correctly in its place and all of the removed parts are put back in place INSTALLATION OF THE LOADER ON A TRAILER If the loader is fitted on a semi trailer it is basically done in the same manner as described earlier installation on a truck If the loader is fitted in the back or in the centre of the trailer the frame must be reinforced if not done by the manufacturer of the trailer and the support legs must be given enough space to be tilted to the position Should the loader be fitted in front of the trailer the crane will be sitting just above the rear wheels of the truck In addition to what has been said of reinforcing the frame of the trailer you may want to change the slewing arc as described above and you may also have to make the support legs swing up earlier and higher than in other installations to avoid touching the rear wheels of the truck There is a set of exchange parts available from the loader manufacture
34. nd lubricate the new bushings with grease REPLACING HYDRAULIC COMPONENTS When replacing hydraulic components like hoses pipes seals etc make sure that the new components are compatible with the original ones Original spare parts will ensure safe and undisturbed function Keep the hydraulic system of the loader in good condition and replace defective parts e g hoses pipes etc REPAIR WELDING Do not ever modify the structures of the loader or weld supplementary parts on it without permission from the manufacturer If modifications or repairs are done by welding observe following Eg The welder must be fully qualified quality class WC Remove paint and grease from the area to be welded lt Always connect the earth conductor to the lt to be welded No links in between ZI suitable electrode is 48 30 or corresponding Use dry electrodes For MAG welding use OK Autorod 12 51 or corresponding 22 SERVICE as KESLA OYJ MEASURING THE HYDRAULIC PRESSURE Refer to Safety instructions while servicing Perform the pressure measuring with the hydraulic system in normal working temperature and with normal flow about 60 l min 1 SYSTEM PRESSURE Connect the pressure gauge either to the gauge connector at the pump section of the control valve or with a connecting nipple to the pressure hose Start the pump and pull the extension
35. nders The adjustable restriction serves the purpose of setting the maximum lowering speed of the boom low enough to prevent cavitation of oil and burning of seals 5 The stabiliser legs are fitted with pilot pressure operated check valves preventing the stabiliser leg from collapsing in situations of possible overload or hose burst 6 lift and outer boom cylinder well as the boom extension cylinder can be equipped with a hose burst valve which locks the oil in the cylinder if the flow speed in the cylinder rises to high e g when a hose comes loose The hose burst valve will open when oil is directed through it in the opposite direction 7 Emergency stop button is in front of the top seat and it can be connected to stop the oil flow to the loader for example with a solenoid valve As an alternative it can be connected to 43 as KESLA OPERATION stop the engine that is running the pump 44 OPERATION as KESLA LOADER OPERATION It is forbidden to use the loader if the operator has not read and understood the manual and the safety instructions GENEHAL Good knowledge of the equipments as well as sound practical experience are the conditions for the safe and effective loader use Every loader model is different in working geometry and speed as well as response to the controls and therefore even a very experienced operator should thoroughly examine the characteristics of a new loader TRAINING
36. ne by measuring or calculation measure information from vehicle D Distance from front axle centre to tipping line by measuring or calculation measure information from vehicle E Distance from centre of gravity of the boom assembly to tipping line by measuring or calculation G Max load with max reach from safe working load plate N Mass of loader base stabilisers and pillar and detachable console i e boom assembly excluded from loader manufacturer or dealer P Mass of boom assembly at centre of gravity from loader manufacturer or dealer M Front axle weight without payload information from vehicle s manual M Rear axle weight without payload Information from vehicle s manual Rear front axle weight without payload vehicle with 4 axles Information from vehicle s manual n Stability coefficient a Angle between centre line of vehicle and tipping line to be calculated from the measured information Different crane vehicle units with their calculation formulas are given on the next pages 29 KESLA FITTING AND COMMISSIONING INSTRUCTIONS FOR DETERMINATION OF STABILITY CALCULATION LOADER CRANES 1 A vehicle with 2 or 3 axles with the crane mounted behind the cab the stability coefficient shall according to SFS 4677 be 14 the stability coefficient is calculated with formula M M C If the result is gt 1 4 crane 15 considered
37. ng the loader mounted on a removable console from rear end of the truck onto its stabiliser legs Pin locking is usually not needed during work Note that the greatest part of the increasing load is taken by the stabiliser legs because the springs of the truck are compensated by the stabiliser legs Therefore we recommend to relieve the stabiliser legs when about half way trough the loading thus shifting the weight to the truck wheels Avoid loading on an inclined ground If not possible observe extreme caution and lift only smaller loads When loading from the uphill side of the vehicle remember that the relief valve of the slewing cylinders can be overloaded causing the load to run away in the downhill direction and leading to a dangerous situation he stability of the machine unit is at its weakest when the load area is empty Lower the load immediately to the ground if the unit starts to tip over Do not drop the load by opening the grapple Ensure that the work area of the loader is clear of persons and that you have an unobstructed view over the whole area Never lift a load above people ake 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 load table Do not lift the load with the maximum reach of the telescopic boom Instead pull the load closer with extension boom and then lift 40 OPERATION KESLA OYJ OPERATING AND SAFETY INSTRUCTIO
38. nual 4 Hyaraulicoiltank returnfiller CS 5 Pressure filter s 6 Quick connectors pressure and return hoses Soo o 7 o 8 Function of control levers Returning to neutralposition o Too 9 j Controvalves o j 10 Safetyvalveforstabilieercontrol X f rf f 72 Conditionofhydrauichoses 73 Conditionofhydraulictubes xC r r r f o o 14 Fittingofloader fitingbolts Csi 15 Condition of the slewing device f 16 Conditionoftheboomassembly x o 17 Condition of the stabiliser legs f r r r 18 Pinsandtheirlocking 000 19 Grapple rotator and link o 20 Worklighs 21 Crackimgs o o Testing according to SFS 4261 1 Checking the workingpressure Ci f o 2 Loadtest with maximum allowed load CT o 3 Checking all of the movementstothelimis CT o o 4 Checking the function of reliefvaves CT o o Checking the function of stabiliser safety valves anti cavitation valves hose burst valves 6 Condition of main structuresaftertesting S o o 7 Tightness of the hydraulic system _ o NOTES Next inspection to be done latest on Inspected by Date an KESLA OYJ CERTIFICATE OF WARRANTY SERVICE Sold Fitted Fitting date Warranty Service must be carried out within 30 days from fitting and commissioning of the loader Failure to comple
39. of extensions if needed i grease gun 50 SAE 10W50 Greasing oil 50 SAE 10W50 48 SERVICE as KESLA OYJ LUBRICATION POINTS 1 SLEW MECHANISM A couple of presses with the grease gun will do Lubricate the upper 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 bushings at the top end of the stabilizer leg have 2 grease nipples and the pendulum beam has one 2 LIFT BOOM Lubricate the bushing by squeezing in so much grease that some oozes out bushing at the upper end of the pillar has one grease nipple The bushing in the link between the lift and outer boom has 2 grease nipples Lubricate the bushing in the lift boom links from the grease nipple located at the lower side of the boom he linkage bar has 3 grease nipples Lubricate the spherical bearings 4 pcs of the lift and outer cylinder regularly 3 OUTEH BOOMS Lubricate the rear glide pads of the extension from the grease nipple on top of the outer boom Keep the extensions retracted All of the grease nipples of the loader can be lubricated at one time by folding the outer boom with the extension retracted under the lift boom in an angle In this position the inner surfaces of the extensions and the inner chain are oiled through the
40. of the side glide pad Turn the glide pad clamp 2 clockwise equally much on each side of the boom until there is no clearance If this does not eliminate the clearance the glide pad 3 is worn and must be replaced Turn the glide pad clamp 2 back for the locking screw 1 to fit in Secure with lock nut 4 Glide pad amp Lack 7 Shim Fixing screw gt A 6Glide pad holder ADJUSTING THE VERTICAL CLEARANCE Open the fixing screws 5 If needed add shims 7 between the glide pad holder 6 and the top surface of the boom shim thickness 1 or 2 mm here is no adjustment left when the glide pads 8 of the bottom side are worn to almost the same level as the lock plates 9 If so change the glide pads 8 NOTE If the glide pads are adjusted too tight they will wear sooner or the extension may not move at all 51 as KESLA DYJ SERVICE REPLACING THE BUSHINGS Refer to Safety instructions while servicing The booms are fitted with exchangeable thin shell bushings with grease pockets which are long lasting when correctly lubricated When the bearing is so worn that there is a distinct clearance in the link remove the pin and the old bushings by opening them at the seam with e g a wedge Use a matching assembly core when installing a new bushing to prevent damaging the end of the bushing Also check that possible greasing holes align Before fitting the pin check its condition a
41. out moving bolster gt a3 spindle valve for stabilizer leg control 6 THREE WAY GLOBE VALVE DECAL Colour combination yellow and black The decal is located by the top seat on the fixing plate of the right hand control valve The pressurised oil is guided with the three way valve either to the control valve or to the stabilizer leg valve 9 as KESLA GENERAL If the oil is guided to the control valve the stabilizer leg control valve does function 10 GENERAL as KESLA STANDARD MODELS AND ACCESSORIES Standard loader 1 1 1 S 1 E y 7 1 aw The controls can be installed directly behind the pillar or by using wedges slightly to the right or left so that the boom will not obstruct the 8 view The control valves are delivered with either 2 or 4 levers plus 2 pedals customer s option The valve for stabilizer leg control is delivered depending on the functions needed with 3 5 spindles e g moving bolster detachable fitting console etc It can be either electrically or mechanically controlled from the top seat Outer boom alternatives single or double extension Hydraulic system alternatives for single pump or for twin 2 pumps The system can be also made for a variable displacement pump Loader with a cab 4 e er he crane cab is fitted to guide posts on the left hand
42. ove 70 C in the summertime winter oil can be used all year around First filling oil ESSO UNIVIS N 32 Foremost follow the recommendations of the vehicle manufacturer or the supplier of the hydraulic system when choosing hydraulic oil Because the oil volume depending on loader size is about 50 l a lot of oil will remain when changing the oil Therefore pay special attention to the compatibility of the refilling oil and the first filling oil 43 as KESLA DYJ SERVICE TENSIONING TORQUES Description Part number Screw Thread Nm kpm Loader mounting 9001 3950 M 30 1200 122 Slew mechanism 9001 3836 M 30 mounting Piston 302 0026 M24 nyloc 700 71 Piston 302 0049 M39x3 nyloc 900 92 Piston 302 0049 M39x3 nyloc 900 92 Boom extension cyl single extension bush 2824 6202 M64x2 Piston 302 0009 M20 nyloc 400 41 Stabilizer leg cylinder Piston 302 0119 M55x2 KM11 200 20 Outrigger cylinder bush 2833 7202 M55x2 700 Piston 302 0026 M24 nyloc 700 0 0 Mounting of controls M12 6 6 Control valve F 130 CF segments pipes When opened remove and replace with a new nyloc nut Screw down and secure with locking screw Secure with bonding fluid e g LOCTITE 242 or corresponding 44 SERVICE KESLA OYJ MAINTENANCE PROCEDURES 1 GENERAL Service the loader regularly to ensure its safe and troublefree function All the tools needed for ma
43. parts will be supplied Copy the information on the machine plate onto the picture below 2 GENERAL as KESLA x KESLA oY FIN 80101 Joensuu Finland 013 682 841 Tvvnppni Paina Tvne Weight Serial Na Year Nosturil Kranklass T oader class 7 Valm No Valm V O 3280201 3 as KESLA GENERAL CRANE PRESENTATION FIELD OF APPLICATION The Foresteri truck loader is designed for professional loading of A cut to length timber Do not ever use the crane for lifting persons une 111111 IN sss 3 OPERATING PRINCIPLE To be in working order the loader needs a power unit with attached hydraulic pump and necessary hydraulic equipment among others oil reservoir filter hydraulic pipes All working motions hydraulic Separate functions slewing of booms boom lifting grapple closing etc are achieved by leading pressurised oil with the control valve to the desired hydraulic cylinders If needed the operator can drive several functions simultaneously 4 KESLA GENERAL MAIN LOADER COMPONENTS 9100029 4 40010 SS UDISU X3 Wong Jang wood 1411 A Sr Nf Japun A3 uoisuaJx3 Japura J3jnp sun juauidinba Da Jazi iquis 481013 BulMa s JapurA2 4417 482114115410 8 lel usunuaau 51 DA TOA 104410 1
44. pport looses its contact from the ground during the test If more than one point of support looses its contact put a load of 25 of the max permissible load in the load area and repeat the test In this case the halved lifting values and the text Vehicle empty or with a lt 25 load are to be added on the load plate Stability determined by the installation firm 38 FITTING AND COMMISSIONING KESLA Installation firm Date Signature 39 as KESLA OPERATION AND SAFETY INSTRUCTIONS Do not ever run the loader unless the operator is familiar with the operation and safety instructions Always have the parking brakes engaged when loading If needed place parking blocks in front of the wheels Check the safety chain when mounting the rear installation console The oil is guided by the three way globe valve to the loader s control valve or to the stabiliser leg valve The stabiliser legs are controlled with the valve fixed on the base or with remote control from the top seat Spread out the stabiliser legs as wide as possible to achieve good stability If not possible start loading with smaller loads Ensure stabiliser legs are on a firm ground Use extra plates if needed The pilot pressure operated check valves hold the stabiliser legs up even in case of overload or hose burst If need be the stabiliser legs can be locked with a pin to prevent them from folding E g when detachi
45. r See also Dismantling the slew mechanism The start up inspection shall be carried out at this stage 23 KESLA FITTING AND COMMISSIONING 24 FITTING AND COMMISSIONING as KESLA 3 CONNECTING THE EMERGENCY STOP BUTTON hyaraulic system of the truck must be fitted with an electrical valve between the pressure and return lines Please note that the valve must be strong enough to work at 250 bar pressure and wide enough to pass a flow of 70 l min for each pump circuit The alternative method of connecting the emergency stop is to use the electric engine stop circuit The truck supplier can provide the additional components needed INSPECTIONS 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 Record files Record forms for start up and periodical inspections are supplied with the user manual During every inspection such a form must be filled out and stored with the loader Please refer to the national regulations 1 STAHT UP INSPECTION inspection shall be carried out immediately after installation before taking the loader in use The procedure is given in the record of start up inspection enclosure 1 consisting of the determination of stability of the machine unit according to Finnish standard SFS 4
46. s valid for new products only for the above stated time while in the possession of the first owner The warranty will cover any defects the machine its accessories 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 5 The warranty shall not apply to hydraulic hoses and their hydraulic oil seals For purchased components Kesla Oyj 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 Kesla will not assume any liability for any economical losses which the purchaser 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 manufacturer s sole representative The warranty shall be invalidated also if the preset pressure settings have been altered i 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
47. s with e g spray Check the oil quantity of the slew mechanism and add if necessary Drain some oil from the draining plug to let out any condensed water Brush paint on the points where it is cracked or worn By repairing all faults and defects now the loader will be ready for work when taken into use again Store the loader with the slew mechanism in upright position and support it properly to prevent it from tipping over Store the loader away from sunlight preferably under roof Reuse after storing Clean the piston rods check the slew mechanism oil the fixing screws of the loader and function of the safety equipment K DISCARDING THE LOADER Tae When the loader has come to the end of its service life and can no longer be repaired it Shall be discarded in a way which will cause no needless harm to the environment 1 Deliver the machine to a scrap metal treatment plant where it will be unassembled according to regulations 2 If unassembled 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 scrap metal dealer 54 SERVICE as KESLA OYJ KESLA OYJ gives a manufacturer s warranty Foresteri truck loaders as stated below Twelwe 12 months from the date of delivery to the end user The warranty i
48. stable FIGURE 1 FIGURE 2 30 FITTING AND COMMISSIONING KESLA INSTRUCTIONS FOR _DETERMINATION STABILITY CALCULATION LOADER CRANES 1 CRANE MOUNTED BEHIND THE CAB pict 1 and 2 Vehicle information needed for calculation M front axle weight less load kg rear axle weight less load kg X wheel base Y distance from rear axle to crane stabiliser legs mm Z distance between centre of rear wheels track gauge Manufacturer s information on Foresteri cranes N crane weight less booms weight of booms Kg G load with max reach L max reach from slewing centre Lpp distance between centre of gravity of booms and slewing centre Lz support width of stabiliser legs from slewing centre mm K slewing centre distance from stabiliser legs The angle a the angle between the centre line of the vehicle and the tipping over verge and the coefficients A B C D and E of the calculation formula are calculated on the basis of the above data A scientific calculator is needed for the calculation arc tan Lrj Z 20 Y Ke sina cosa 2 B L A C Ze cos o 2 D sina Ze cosa kg 31 KESLA FITTING AND COMMISSIONING 2 L PP A mm Place the resulted numerical values into the formula D A Moe Cz The crane is considered stable if the result is gt 1 4 32
49. te the Warranty Service will end the Warranty Period of the loader at 30 days from assignment to the customer This certificate must be filled by the Service Centre and copies must be given 1st to the customer 2nd to the Distributor of the Loader and remains with the Service Centre To e inspected before testing the loader Checked 3 Service training for the operator 4 User s Service Manual is with the loader Testing 1 Driving all of the movements to the limits withload X 2 Checking the working pressure the back pressure 3 Theboomsstayup nointernalleakage 2124 4 Pressure relief valves operate correctly 0 Inspections after testing No hydraulic oil leakage Temperature of hydraulic oil stays normal REMARKS ajajajaja N OQ ICO N Place Fitted by Signature of the Fitter Date Accepted by Signature of the Customer
50. tersection of the tipping lines Centre points of the stabiliser legs centre of wheels centre of wheel pairs centre of front axle on a vehicle mounted loader mounted behind the chassis Weights and dimensions for deterring the stability by calculation depend on the male and model of the vehicle Therefore the determination of the stability must be done case by case depending on the make and model of the vehicle the way of loader installation and the loader model based on real measured or calculated dimensions and weights For weight and dimensions which cannot be found in the vehicle s service manual registration documents please contact the nearest 2 KESLA FITTING AND COMMISSIONING dealer or importer of the vehicle The same for the loader can be obtained from the nearest Foresteri dealer 28 FITTING AND COMMISSIONING KESLA INSTRUCTIONS FOR DETERHMINATION _ STABILITY CALCULATION LOADER CRANES Calculation formula standard formula for all mounting alternatives D C C 2n Ge B P Formula keys A Distance from slewing centre of loader to tipping by measuring or calculation B Distance from suspended load tip of the boom to tipping line by measuring or calculation C Distance from rear axle centre to tipping line by measuring or calculation measure information from vehicle Distance from rear front axle centre with 4 axles to tipping li
51. use Do not operate the loader without having read and understood the manual and safety instructions Follow all instructions and warnings on the loader to avoid unnecessary damage Ensure the stability of the vehicle in all circumstances see Instructions for determination of stability by calculation loader cranes Make sure that the loader is fitted properly see later in this chapter Do not start the vehicle unless the hydraulic pressure to the loader is disconnected Use extreme caution while engaging or disengaging the loader from the back of the truck if a detachable mounting console is used the ground must be firm and level use a locking pin to prevent the stabilizer legs from folding danger of tipping over remember the safety chain Always connect the return hose before pressure hoses Make sure that the hose is properly connected or the control valve may be damaged When connected to the hydraulic system for the first time there might be air in the hydraulic lines which can cause sudden and uncontrolled movements Vent the system carefully by driving all the cylinders to their limits 4 5 times Before connecting the pressure to the loader check that all the control levers of the loader are in middle position and also return to middle position when released 17 KESLA TECHNICAL SPECIFICATIONS Note the location of EMERGENCY STOP button before operating the loader
52. 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 55 as KESLA DYJ SERVICE reference number of invoice or Bill of Material of the exhanged spare parts as KESLA OY INSPECTION CERTIFICATE OF FITTING Customer Loader model Serial number Year Sold by Fitted by Fitting Inspection must be carried out immediately after fitting prior to taking the loader in use This certificate must be filled at the assignment of the loader to the customer The fitter that has the authorisation from the manufacturer confirms with the signing of this certificate that the loader has been inspected at the time of assignment and meets the Code of Practice for the Safe Application and Operation of Truck Loaders To be inspected before testing the loader Accepted To be Fixing fixed accepte d Correct User s and Service Manual supplied with the loader Stability has been verified through calculation or testing Safe working load table Safety decals Fixing of the loader to the vehicle Movement of control valve spools return to neutral position The fitting of the hydraulic pump PTO shaft Hydraulic system fitted to the truck fit for the loader Pressure and return filters fitted Quick connectors are good and properly connected Amount and quality of h
53. ydraulic oil slewing gear oil 0 s The work and testing Lubricating the joints bearings and bushings and cables 111 Air removal by driving all movements to their limits 4 to 5 times without load Test according to SFS 4261 21 11 Control lever movements and loader movements correct 11 All of loader movements reach their limits Pressure relief valves operate correctly 11 0 1 The booms stay up no internal leakage N Inspections after testing No leakage Temperature of hydraulic oil stays normal Installation has been done according to CE directives and standards and the installers CE plate has been affixed to the vehicle The operator is instructed to safe operation of the loader and he has familiarised himself in the User s Manual NOTES Place Fitted by Signature of the Fitter Accepted by Signature of the Customer D D 9 KESLA OYJ CERTIFICATE OF ANNUAL SERVICE AND INSPECTION OF TRUCK LOADER Customer address and telephone Inspected by Fitting method oTractor oRoof mounted oBack of truck fixed oTruck oBehind the cab oBack of truck detachable oTrailer oFront oCentre To be inspected before testing the loader Accepted To be Fixing fixed accepte d 1 made o o o 2 Serial number tag Safe working load plate Safety decals O o o 1 3 User s manual Service ma

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