The KESLA 2009S and 2009ST are timber handling cranes designed for contracting work, including loading timber, scrap, sand, and fertilizer, provided appropriate grapples are used. The cranes are manufactured by Kesla Oyj in Joensuu, Finland.
Function Description:
The KESLA 2009S and 2009ST cranes operate hydraulically, requiring a drive unit, a hydraulic pump, an oil tank, filters, and hydraulic pipes. All movements, such as turning and lifting the boom or compressing the grapple, are achieved by channeling pressurized oil through hydraulic cylinders to the desired control valve. The operator can control multiple functions simultaneously. The crane's control system includes a STOP switch for emergency shutdowns, which can cut off oil supply or electric current to the pilot-operated control valve. Stopping the drive unit from the control position is also considered a STOP operation.
The cranes are equipped with safety devices, including pressure relief valves to prevent excessive pressure in the main system and individual cylinders. Throttle check valves regulate boom travel speed and ensure adequate oil filling. Stabilizer legs feature pressure-controlled check valves (lock valves) to prevent collapse from overload or hose failure. Some cylinders may also have overcenter valves to lock loads and ensure controlled descent in case of hose breaks.
A load indicator, located at the pilot's post, uses a signal light with three colors to indicate the load in use based on lifting pressure:
- Green: Normal load.
- Yellow: Load is 90-100% of maximum capacity; load cannot be significantly increased.
- Red: Overload; load must be immediately decreased.
A height indicator sensor on the lifting beam controls the boom angle and signals if the maximum height is exceeded, turning on a red signal light at the driver's post. This is crucial for transport, especially when the crane is positioned over the load. An outrigger indicator light glows red when the outriggers are spread.
Important Technical Specifications (KESLA 2009S / KESLA 2009ST):
- Lifting moment: 95 kNm / 89 kNm
- Reach: 8050 mm / 9610 mm
- Turning moment, br (p=23MPa): 22.0 kNm
- Turning angle: 415°
- Stroke of boom extension: 1600 mm / 2 x 1600 mm
- Weight with control unit and stabilizers: 1980 kg / 2140 kg
- Height: 2220 mm / 2500 mm
- Transport width: 2500 mm
- Pump recommendation (working pressure): 24 (240) MPa (bar)
- Pump recommendation (flow):
- 1 circuit: 90 l/min
- 2 circuits: 2 x 70 – 80 l/min
- LS: 160 l/min
- Power input:
- 1 circuit: 27 - 35 kW
- 2 circuits: 45 - 60 kW
- Boom volume at lifting accessory's attachment point (Gb): 290 kg (2009S) / 350 kg (2009ST)
Usage Features:
The crane is designed for safe operation by experienced users who have thoroughly read and understood the safety and operating instructions. It is crucial to ensure the basic unit's compatibility with hydraulics and standing stability. The crane must be properly mounted, and all legally required inspections must be carried out.
Key operational guidelines include:
- Stabilization: Always spread stabilizer legs as wide as possible for good standing stability. If not possible, start with small loads. The ground must be strong and steady. Stabilizer legs should be prevented from turning with pin locking.
- Load Handling: Grab loads carefully and close to their center of gravity. Avoid exceeding maximum load. It is recommended to draw loads closer before lifting with maximum telescopic boom reach. Avoid rapid lifting, lowering, and turning movements, especially before the load is airborne.
- Temperature Conditions: At low temperatures (below -25°C), allow oil to circulate to make gaskets flexible and lift smaller loads to prevent damage. At high temperatures (above 75°C), ensure hydraulic oil does not overheat to prevent gasket damage and reduced oil life.
- Safety Zones: A 25m danger zone around the crane must be observed during operation. It is strictly forbidden for people to be in this zone during lifting. Maintain safety distances from live electrical wires (e.g., 5m for >110kV).
- Prohibited Usage: Lifting persons, operating with hooks, towing, and using a grapple as a hammer are strictly prohibited. Using a damaged or defective crane is also forbidden.
- Transport: Before transport, set the crane in the transport position, pull in and lock stabilizer legs, switch off the hydraulic pump, and secure the load. Ensure the vehicle's height does not exceed authorized limits and maintain controllability, considering increased braking distance.
Maintenance Features:
Regular maintenance is essential for safe and trouble-free operation.
- Daily Inspections: Check hydraulic oil and turning device oil levels, lubricate if necessary, visually inspect mounting screws, shaft mounts, hoses for leaks, and the state of the frame and boom structures. Ensure safety equipment functions correctly and the STOP switch is working.
- Periodic Inspections:
- Every 10 hours: Check cylinders and hoses for leakage, fastenings of shafts and fixing screws.
- Every 50 hours: Inspect hose conditions, lubricate turning device bearings, inspect lateral clearings, and lubricate chain joints.
- Every 250 hours: Clean and inspect load-bearing structures, tighten turning device fixing screws, inspect guide components and cylinder shafts, and inspect vertical clearings.
- Every 500 hours: Maintain return filter and breather cartridge, change pressure filter, tighten rotator body and flange bolts, and tighten grapple fixing bolts.
- Every 1000 hours: Change hydraulic oil, change turning device oil, and clean chains.
- Annually: Periodic inspections and test runs according to SFS EN 12999.
- Every four years: Thorough periodic inspection and test run.
- Every 10 years: Thorough periodic inspection, including dismantling safety-relevant parts and non-destructive inspection methods.
- Lubrication: Use molybdenum-rich grease for joint and slide bearings of booms. General grease is suitable for other locations. Shorten lubrication intervals in dusty or heavily loaded conditions. The turning device is oil-flooded (hypoid oil SAE 80W/90); check oil level via the oil eye.
- Hydraulic System: Maintain cleanliness to prevent impurities, which can cause wear and damage. Use clean containers for oil, and ensure the repair area is clean. Biodegradable hydraulic oils (HEE, HEPG) are available, but HETG oils are prohibited in Kesla products. Consult with the oil seller before switching to biodegradable oil.
- Welding: Any repair welding must follow manufacturer instructions, use appropriate methods and consumables, and be performed by professionals. Disconnect hydraulic power, open the main switch, protect sensitive components, and attach grounding cable directly to the component being welded.
- Modifications: Any changes or repairs not listed in the manual or affecting safety and usability require Kesla's approval and a risk analysis. Unauthorized modifications may invalidate the warranty.
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