TMMast.01en - C ECH FLT - Mast

TECHNICAL MANUAL
MAST
ORIGINAL INSTRUCTIONS
X176322en / C / 13 Apr 2016
TM Mast.02en
This document and the information contained herein, is the exclusive property of Konecranes Lifttrucks and represents a non-public, confidential and proprietary trade secret that may not be
reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Lifttrucks. © 2016 Konecranes Lifttrucks. All rights
reserved. ‘Konecranes’, ‘Lifting Businesses’ and C are either registered trademarks or trademarks of Konecranes Lifttrucks.
TABLE OF CONTENTS TECHNICAL MANUAL
TABLE OF CONTENTS
1 INTRODUCTION....................................................................................................... 5
2 TECHNICAL DATA................................................................................................... 7
2.1 Consumables and special tools.............................................................................. 7
3 TYPES OF MAST...................................................................................................... 8
3.1 Standard duplex mast.............................................................................................. 8
3.2 Free lift duplex mast................................................................................................ 8
3.3 Free lift triplex mast................................................................................................. 9
4 MAST......................................................................................................................... 10
4.1 Removing the forks.................................................................................................. 10
4.2 Removing the standard mast.................................................................................. 10
4.3 Removing the inner mast........................................................................................ 12
4.4 Removing the complete mast.................................................................................. 12
4.5 Installing the standard mast.................................................................................... 15
4.6 Removing the ECC attachment............................................................................... 16
4.7 Installing the ECC attachment................................................................................. 17
4.8 Removing the ECC mast.......................................................................................... 19
4.9 Installing the ECC mast........................................................................................... 22
5 MAST WHEEL........................................................................................................... 24
5.1 Removing the mast wheel (SMV10-16)................................................................... 24
5.2 Installing the mast wheel (SMV10-16)..................................................................... 24
5.3 Removing the mast wheel (SMV18-16)................................................................... 25
5.4 Installing the mast wheel (SMV18-16)..................................................................... 25
5.5 Rewelding the axle journal to the mast wheel....................................................... 26
6 SIDE SUPPORT REEL.............................................................................................. 27

6.1 Removing the side support reel.............................................................................. 27
6.2 Installing the side support reel............................................................................... 27
6.3 Shimming and measuring the mast........................................................................ 28
7 TOP SUPPORT REEL............................................................................................... 29

7.1 Removing the top support reel............................................................................... 29
7.2 Installing the top support reel................................................................................. 29
8 SHAFT....................................................................................................................... 31
8.1 Removing the shaft.................................................................................................. 31
8.2 Installing the shaft................................................................................................... 31
9 LIFT CHAINS............................................................................................................. 32
9.1 Removing the chain wheel...................................................................................... 32
9.2 Installing the chain wheel (SMV8-16)...................................................................... 32
9.3 Adjusting the lift chain............................................................................................ 33
9.4 Checking the lift chains........................................................................................... 34
9.5 Maintaining, cleaning, and lubricating the lift chain.............................................. 35
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This document and the information contained herein, is the exclusive property of Konecranes Lifttrucks and represents a non-public, confidential and proprietary trade secret that may
not be reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Lifttrucks. © 2016
Konecranes Lifttrucks. All rights reserved. ‘Konecranes’, ‘Lifting Businesses’ and C are either registered trademarks or trademarks of Konecranes Lifttrucks.
TECHNICAL MANUAL TABLE OF CONTENTS
10 CARRIAGE................................................................................................................ 36
10.1 Removing the carriage............................................................................................ 36
10.2 Marking the forks..................................................................................................... 37
10.3 Checking and measuring the fork........................................................................... 38
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This document and the information contained herein, is the exclusive property of Konecranes Lifttrucks and represents a non-public, confidential and proprietary trade secret that may
not be reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Lifttrucks. © 2016
Konecranes Lifttrucks. All rights reserved. ‘Konecranes’, ‘Lifting Businesses’ and C are either registered trademarks or trademarks of Konecranes Lifttrucks.
1 INTRODUCTION TECHNICAL MANUAL
1 INTRODUCTION
WARNING
WORKPLACE SAFETY HAZARD
Failure to familiarize yourself with all the relevant safety regulations can result in
serious injury or death.
In addition to the checks and safety regulations in this manual, always refer to the
country’s applicable laws regarding safety regulations.
The mast is suspended on two shafts in the chassis and consists of the following components:
• Outer mast
• Inner mast
• Carriage
• Lift cylinders
• Tilt cylinders
• Fork-positioning cylinders and side shift cylinders
• Lift chains for a standard mast
The machine has fork positioning and fork side shifting as standard. The ,achine is also
available with fork leveling, fixed forks, and central leveling as options. The following different
types of mast are available depending on the requirements and area of use:
• Standard duplex mast

• Free lift duplex mast
• Free lift triplex mast
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X176322en / C / 13 Apr 2016 Copyright © (2016) Konecranes Lifttrucks. All rights reserved.
TM Mast.02en
TECHNICAL MANUAL 1 INTRODUCTION
7
4
Figure 1. Mast
1. Fork-positioning and side shift cylinders 5. Inner mast

2. Carriage 6. Lift cylinder
3. Lift chains 7. Tilt cylinder
4. Outer mast 8. Forks
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2 TECHNICAL DATA TECHNICAL MANUAL
2 TECHNICAL DATA
2.1 Consumables and special tools
Table 1. Consumables
Material Part number
Welding rod 2.5 mm² for welding the axle 50550150

journal
Basic electrode 48-type1)
Welding rod 3.25 mm² for welding the axle 50550142

journal
Basic electrode 48-type1)
1) Classification
AWS/SFA A5.1: E 7018
DIN 1913: E 51 53 B 1
ISO 2560: E 51 5B 120 20H
Swedish standard: 3211 H10
AS 1553.1: E 4818
Table 2. Special tool
Tool Part number
Slide hammer 6130.109
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TM Mast.02en
TECHNICAL MANUAL 3 TYPES OF MAST
3 TYPES OF MAST
3.1 Standard duplex mast
Figure 2. Standard duplex mast
The duplex mast consists of:

• Outer mast
• Inner mast
• Carriage
The inner mast is vertically adjustable through the lift cylinders. The inner mast is vertically
guided in the outer mast. The chains are suspended on the machine and are vertically
adjustable.
The chains are secured in the inner mast and it operates above the chain wheel of inner mast.
When the inner mast is raised, the chain pulls the carriage and forks upwards.
Advantages:
• Simple design
• Good visibility
Disadvantage: The overall height of mast increases when the carriage and forks are raised.
3.2 Free lift duplex mast
Figure 3. Free lift duplex mast
The free lift duplex mast consists of:
• Outer mast
• Inner mast
• Carriage
• Hydraulic cylinder
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3 TYPES OF MAST TECHNICAL MANUAL
The difference between duplex standard and duplex free lift is that the hydraulic cylinder raises
the carriage. The mast allows the lifting of the carriage and forks without the raising of the inner
mast.
Advantages:
• The total height of the mast is affected when the forks reach a certain height
• Capacity to raise the forks without affecting the inner mast, resulting in a low total height
despite raised forks
Disadvantages:
• Complicated design
• Poorer visibility
3.3 Free lift triplex mast
Figure 4. Triplex mast, free lift
The free lift triplex mast consists of:
• Outer mast
• Primary inner mast
• Secondary inner mast
• Carriage
• Hydraulic cylinder
The triplex mast has a further inner mast and it is raised and lowered by the chain. The carriage
is raised by the hydraulics. The inner mast does not need to be raised for the carriage to be
raised.
Advantages:
• Low construction height in relation to maximum lifting height
• When achieving a high lifting height, goods can also be raised in areas with low roof heights
• The total height of the mast is affected when the forks reach a certain height
• Capacity to raise the forks without affecting the inner mast, resulting in a low total height
despite raised forks
Disadvantages:
• Complicated design
• Poorer visibility
• More moving parts
• Heavier
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TM Mast.02en
TECHNICAL MANUAL 4 MAST
4 MAST
4.1 Removing the forks
WARNING
PERSONAL INJURY HAZARD
The forks have a high center of gravity.
Secure the forks and lift them out of the machine with caution to prevent the forks from
tipping over.
1. Operate the fork-positioning sideways.

2. Secure the fork-positioning cylinders.
3. Remove the screws which hold the cylinders in the forks.
4. Attach the straps to the forks.
5. Lift the forks out of the machine.
4.2 Removing the standard mast
WARNING
HIGH PRESSURE HAZARD
The hydraulic system is pressurized, and can cause severe injury.
Always depressurize the hydraulic system before starting work on the hydraulic
system.
1. To slacken the lift chains and hydraulic hoses, lower the inner mast.
2. Mark up the hydraulic hoses and remove the connections from the machine.
3. Seal the hoses and connections with a plug.
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4 MAST TECHNICAL MANUAL
4. To avoid the hoses rolling around the hose

wheel due to hose tension, secure the
hoses.
5. Open and remove the cotter pin (1).
1
1
2
6. Remove the pin (2) from the chain tensioner.

7. To avoid rolling around the chain wheel, secure the lift chain.
8. To take the load off the rollers, tilt the mast.
9. Lift the inner mast carefully.
10. Check that the lift chains and hydraulic hoses are not trapped.
11. Reverse the machine when the lowest part of the inner mast passed the upper rollers of the
carriage.
12. Lower the inner mast.
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4.3 Removing the inner mast

1. Secure the lift sling on the top yoke of the
inner mast.
2. Secure the lift cylinders.

3. Disconnect the lift cylinders from the inner mast.
4. To release the load from the mast wheels, tilt the mast vertically.
5. To lift the inner mast, use an overhead hoist or crane.
6. Tilt the mast forward.
4.4 Removing the complete mast
WARNING
PERSONNEL INJURY HAZARD
The mast can wobble when the shafts release, causing compression injuries.
Secure against machinery movements and release the shafts with caution.
1. Remove the hose clamps (2).
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2. Mark up and remove the hydraulic hoses (1) from the outer mast.
3. Seal the connections with a plug.
4. Mark up and remove the hydraulic hoses
(1) from the lift cylinder (3).

(1) from the return connection (4).
1

8. Mark up and remove the electrical connections between the machine and mast.
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9. Attach the lift chains to the lifting eyelets of

outer mast.
10. To secure the outer mast, use an overhead hoist.

11. To secure the tilt cylinder, place a wooden
block (5) below the tilt cylinder (6).
8 9
12. Remove the screws (7) that lock the shaft (8) to the upper mounting of the tilt cylinder.
13. To relieve the load from the tilt shafts, tilt the mast forward.
14. To pull the shaft, screw a slide hammer (9) in the threads of the shaft.
15. Repeat the procedure with the other cylinder.
16. Tilt both the cylinders backwards.
17. Fold the tilted cylinders towards the chassis.
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18. Remove the screw (11) from the shaft lock.
11
12
13
19. To release the mast from the shafts, use an overhead hoist.
20. Install the long screws (13) in the threaded holes (12) of the shaft lock.
21. Press the shafts and remove both the shafts.
22. Lift the outer mast.
4.5 Installing the standard mast

1. To raise the outer mast, use an overhead hoist.
Ensure that the lower mounting of the mast is in position with the mounting eyelets of the
machine.
2. Install the shafts to the lower suspension of the mast.
3. Tighten the screw of the shaft lock.
4. Install the tilt cylinders at the mounting of the mast.
6. Check that the tilt cylinders are securely attached to the machine.
7. Remove the lift sling from the outer mast.
8. Secure the lift sling on top yoke of the inner mast.
9. To raise the inner mast in position, use an overhead hoist.
10. Guide in the lift cylinders to the correct position in the top plate of inner mast.
11. Connect the electrical connections between the machine and mast.
12. Connect the return hoses from the lift cylinders to the return connection.
13. Connect the hydraulic hoses to the lift cylinders.
14. Connect the hydraulic hoses from the machine to the mast.
15. Secure the hydraulic hoses with the hose clamps.
16. Raise the inner mast and operate the machine forward to the carriage.
17. Lower the inner mast above the carriage.
18. Pull the hydraulic hoses towards the machine around the hose wheels for hose tension.
19. Connect the hydraulic hoses.
20. Pull the lift chains over the chain wheel.
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21. Install the lift chains in the chain tensioner of the machine.
22. To lock the shaft to the chain tensioner, use cotter pins.
23. To adjust the length of the lift chain, use the chain tensioner. For more information, see
Adjusting the lift chain (page 33).
24. Install the forks in the machine.
25. Screw the plates of the side shifting cylinders into the forks.
4.6 Removing the ECC attachment

1. Position the mast in vertical position.
2. Attach the shackles and lifting slings to the
attachment.
3. Lift the attachment until the lift chains slacken.

4. Remove the cotter pins (1) and pull out the
pin (2) from the lift chain.
1
1
2
5. To prevent the chains from falling, secure the chains.

Tighten the chains with a rope and have an assistant hold them until the attachment is
loose. Then pull the chains down again.
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TM Mast.02en

(3) from the attachment and plug the ends.
7. Disconnect and remove the electrical

cables (4) from the attachment.
8. To prevent the hoses and electrical cables from falling over the hose wheels, secure the
hoses and the electrical cables.
Tighten the hoses and electrical cables with a rope and have an assistant hold them until
the attachment is loose. Then pull the hoses and electrical cables down again.
9. Raise the inner mast carefully while monitoring the chains and hoses.
10. When lowest part of the inner mast has passed the attachment, reverse the machine and
then lower the inner mast.
4.7 Installing the ECC attachment
WARNING
The mast can wobble when the shafts release, causing compression injuries.
Secure against machinery movements and release the shafts with caution.
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2. Attach the shackles and lifting slings to the

attachment.
3. Lift the attachment and raise the inner mast.

4. When the lowest part of the inner mast has passed the attachment, carefully position the
attachment in the mast.
5. Carefully lower the inner mast.
6. Install the pin (2) and fit the cotter pins (1)
to the lift chains.
1
1
2
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7. Connect the hydraulic hoses (3) to the

attachment.
8. Connect all the electrical cables (4) to the

attachment.
9. Lower the inner mast carefully to its lowest position.
4.8 Removing the ECC mast
WARNING
Releasing the mast from the shafts can cause the mast to wobble. Risk of compression
injuries.
Use an overhead hoist and secure the mast with caution to prevent wobbling.
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2. Mark up and remove the hydraulic

hoses(3) from the mast and plug the
connections.

(3) from the lift cylinder (4).
3 4

(1) from the return connection (4)
1
7. Mark up and remove the electrical connections between the machine and mast.
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8. Install the lift chains in the lifting eyelets of

the mast.
9. To secure the mast, use an overhead hoist.

10. To secure the tilt cylinder (6), place a
support (5) below the tilt cylinder.
6 5
11. Remove the screw (7) that lock the shaft

(8) to the upper mounting of the tilt
cylinders. 8
9
7
10
12. Tilt the mast forward to relieve the load from the tilt shafts.
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13. Screw a slide hammer (9) in the threads of the shaft and then pull out the shaft.
14. Repeat the same procedure on the other tilt cylinder.
15. Tilt both the cylinders backwards.
16. Remove the screw (11) from the shaft lock.
11
12
13
17. To release the mast from the shafts, use an overhead hoist.
18. Install the long screws (13) in the threaded holes (12) of the shaft lock and press out the
shaft.
19. Remove both the shafts.
20. Lift the outer mast.
4.9 Installing the ECC mast

1. To raise the mast in position, use an overhead hoist.
Ensure that the lower mounting of the mast is in position with the mounting eyelets of the
machine.
2. Install the shafts to the lower mountings of the mast.
4. Install the tilt cylinders at the mounting of the mast.
6. Check that the tilt cylinders are securely attached to the machine.
7. Remove the lift sling from the outer mast.
8. Connect the return hoses from the lift cylinders to the return connection.
9. Connect the hydraulic hoses to the lift cylinders.
10. Connect the hydraulic hoses from the machine to the mast.
11. Secure the hydraulic hoses with the hose clamps.
12. Connect the electrical cables between the machine and mast.
13. Pull the hydraulic hoses around the hose wheel for hose tension.
14. Connect the hydraulic hoses.
15. Pull the lift chains over the chain wheel.
16. Install the lift chains in the chain tensioner.
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17. To adjust the length of the lift chain, use the chain tensioner. For more information, see
Adjusting the lift chain (page 33).
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TECHNICAL MANUAL 5 MAST WHEEL
5 MAST WHEEL
5.1 Removing the mast wheel (SMV10-16)
1. Remove the inner snap ring (1).
7
6
5
4
3
2
2. Remove the inner spacer (2).

3. Pull out the mast wheel (6) from the axle journal (7).
4. Remove the outer snap ring (3).
5. Remove the outer spacer (4).
6. Press the roller bearing (5) from the mast wheel (6).
7. Check for any damage to the bearings and axle journal.
5.2 Installing the mast wheel (SMV10-16)

1. Install the roller bearings (5) inside the
mast wheel (6).
7
6
5
4
3
2
2. Install the outer spacer (4).

3. Install the outer snap ring (3).
4. Install the mast wheel (6) to the axle journal (7).
5. Install the inner spacer (2).
6. Install the inner snap ring (1).
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5 MAST WHEEL TECHNICAL MANUAL
5.3 Removing the mast wheel (SMV18-16)

1. Knock out the cylindrical lock pin (1) from
the inside of the mast.
7
6
5
4
3
2
1
2. Remove the nut (2).

3. Remove the seal (3).
4. Remove both roller bearings (5) and snap rings (4) from the mast wheel (6).
5. Check for any damage to the bearings and the axle journal (7).
5.4 Installing the mast wheel (SMV18-16)

1. Apply the grease on the roller bearings.
2. Insert the roller bearings (5) and snap ring (4) in the mast wheel (6).
3. Install the mast wheel (6) to the axle
journal (7)
7
6
5
4
3
2
1
4. Insert the seal (3).

5. Install the nut (2).
Ensure that the thread is clean and lubricated.
6. To give tension to the bearings, tighten the nut (2) to a torque of 250 Nm.
7. Turn around the mast wheel and at the same time knock it using a copper mallet.
8. Post tightening, tighten it until it cannot be tightened further.
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TECHNICAL MANUAL 5 MAST WHEEL
9. Tighten the nut further to match one of the holes with opposite locking hole in the axle
journal.
10. Lock the nut with the cylindrical lock pin.
5.5 Rewelding the axle journal to the mast wheel

The axle journal must be replaced if it has become worn due to seizure.
1. Cut, chisel or grind off the welds (2) and (3)

for the axle journal.
Do not cut the material from the guide hole
(1) of the member.
2
1
1) Check the a-dimension before
grinding off the axle journal. The a-
dimension varies with mast size. WB
Comparison steel standard:
Sweden, SS 2142-01 4
3
EU, SS-EN 10 025-3-S355N WB
1)
USA, ASTM A 572 aX
WB
2. Grind and clean the mating surfaces.

3. Install the new axle journal (4).
4. Check that the contact to the mast is good and that the axle journal is at the correct angle.
5. Increase the temperature of the axle journal to approximately 150ºC.
6. Weld the axle journal with metal arc weld.
Use basic electrodes. For more information, see Consumables and special tools (page 7)
6.1 Start with internal welds (3).
6.2 Continue with external welds (2).
6.3 To prevent shrinkage cracks, do the welding without long gaps.
6.4 Allow the material to cool slowly.
7. Grind the inside smooth surface.
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6 SIDE SUPPORT REEL TECHNICAL MANUAL
6 SIDE SUPPORT REEL

6.1 Removing the side support reel
1. Remove the four screws (5).
1 2
5
2. Pull off the axle supports (4) with the shims (1) and (2) from the axle.
3. Remove the bushings and axle.
4. Check that the axle, side support reel (3), and bushings are not damaged.
5. Clean the contact surface of side support reel.
6.2 Installing the side support reel

1. Check the dimensions of the outer mast and shim of the support reels. For more
information, see Shimming and measuring the mast (page 28).
2. Install the axle (7), bushings (6), and side
support reel (3).
7
6
3
4
5
2
1
3. Attach the axle support (4).

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TECHNICAL MANUAL 6 SIDE SUPPORT REEL
4. Attach the shims (1) and (2).

5. Put the four screws (5) on the axle support and tighten them.
6.3 Shimming and measuring the mast

1. Carefully measure the distance between
the inner walls (a) of outer mast.
2. Measure along the entire inner walls and record the shortest distance.
3. Transfer the distance to the side support reels.
The gap between the side support reels and inner walls of outer mast must be 0.0–0.5 mm.
4. To achieve the correct clearance, align the shims in pairs between the holders of the side
support reels and the mast.
Two different thicknesses of shims are available:
• 1.0 mm
• 2.0 mm
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7 TOP SUPPORT REEL TECHNICAL MANUAL
7 TOP SUPPORT REEL

7.1 Removing the top support reel
1. Remove the four screws (5) and washers
(4) from the holder (6) which hold the top
1
support reel.
2
3
5
4
6
7
9 8
2. Remove the cotter pin (9), shims (7) and (8).

3. Pull out the axle (1) and remove the bushings (3).
4. Check the axle and bushings for any damage.
5. Clean and check the top support reel (2).
6. Check the outer contact surfaces and clearance between axle (1) and the bushings (3).
7.2 Installing the top support reel

1. Carefully measure the distance between the outer walls of inner mast.
2. Measure along the entire outer walls and record the greatest distance.
3. Transfer the distance to the top support reels.
The total clearance between the top support reels and the outer walls of inner mast must be
0.0 ... 1.0 mm.
4. To achieve the correct tolerance, align the shims in pairs between the holders of the top
support reels.
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TECHNICAL MANUAL 7 TOP SUPPORT REEL
5. Attach the holder (6).

1
2
3
5
4
6
7
9 8
6. Install the axle (1), bushings (3) and top support reel (2).
7. Install the cotter pin (9)
8. Attach the shims (7) and (8).
9. Put the washer (4).
10. Put the four screws (5) and tighten them.
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8 SHAFT TECHNICAL MANUAL
8 SHAFT
8.1 Removing the shaft
The lower suspension of the mast is secured in the frame by the two shafts. The mast is also
secured in the frame by the two tilt cylinders that hold the mast in the correct position.
The two shafts secure the mounting between the tilt cylinders and mast.
Secure the mast in an overhead crane and disconnect the tilt cylinders before removing
NOTE the shafts.
1. Remove the locking screw (10), washer

(11), and spacer (12) which hold the lock of
the shaft (14).
12
11
10
14
13
2. To remove the shaft (14), screw in the two screws at the holes (13).
3. Check for any damage to the shaft and bushings.
8.2 Installing the shaft

1. Install the shaft (14).
12
11
10
14
13
2. Install the spacer (12), washer (11), and the lock screw (10)
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TECHNICAL MANUAL 9 LIFT CHAINS
9 LIFT CHAINS
9.1 Removing the chain wheel
There are two versions of chain wheel. Machine sizes SMV10-16 are equipped with bushings
and SMV18-60 have double roller bearings.
1. Remove the lift chains. For more information, see Removing the standard mast (page 10).
2. Remove the lock screw (1) from the shaft
(3).
3. To remove the shaft (3), screw into the threaded hole (2).
4. Remove the chain wheel (4) and bushing or roller bearing that is inside the chain wheel.
5. Clean the chain wheel, bushing, and shaft.
6. Check the components for any wear or damage.
9.2 Installing the chain wheel (SMV8-16)

1. Install the chain wheel (9) with the roller
bearings (8) in the lateral support (7).
8
9
7
8
7
5 6
2. Install the shaft (6) with lock plug.

3. Put the lock screw (5) and tighten it.
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9 LIFT CHAINS TECHNICAL MANUAL
9.3 Adjusting the lift chain

1. Adjust the lift chains using the adjusting
nuts (1) so that the distance between the
base plate and the carriage is 10 mm when
the mast is in the lowest position.
Both the lift chains must be adjusted with 1
the same procedure.
2. To adjust:
2.1 Raise the carriage to 50 mm.
2.2 Place a spacer 10 mm on both sides below the carriage (1).
2.3 Lower the carriage so that it rests on the spacer.
2.4 Adjust so that both the lift chains have the same tension using the nuts (4).
3. Lock the lower adjusting nut (5) of the lift
chain.
4. Raise the carriage with load.

5. Tighten the nut (3) and lock with the nut (2).
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TECHNICAL MANUAL 9 LIFT CHAINS
9.4 Checking the lift chains
WARNING
FALLING LOAD HAZARD
If a chain breaks, the load may fall uncontrollably and cause personal injury or damage
to the machine.
If in doubt, replace the chain. Always replace the full chain. Do not splice or rerivet lift
chains.
Before inspection, clean the chains in their entire length. Always check the chains when without
a load.
Figure 5. Lift chains
For inspection intervals, see section "Regular service" in the maintenance manual.
1. Check that the length of the chain has not increased by more than 3% compared to its
original length.
Measure the 25 links that are lifted first and that most often break on the chain wheel. The
25 links are the part of the chain where the extension is the greatest.
2. Compare with the value for the given chain sizes in the table below.
3. If the 3% limit is exceeded, replace the chain.
Local regulations may require that the chain must be replaced when the length
NOTE increases by 2%. The same applies if safety depends on a single chain.
Table 3. Length of 25 links of chain
Parting (p) Length of 25 links for Length of 25 links at 2% Length of 25 links at 3%

new chain extension extension
38.1 mm (1.5 in) 952.5 mm (37.5 in) 971 mm (38.2 in) 981 mm (38.6 in)
50.8 mm (2 in) 1270 mm (50 in) 1295 mm (51 in) 1308 mm (51.5 in)
63.5 mm (2.5 in) 1587.5 mm (62.5 in) 1619 mm (63.7 in) 1635 mm (64.37 in)
76.2 mm (3 in) 1905 mm (75 in) 1943 mm (76.5 in) 1962 mm (77.2 in)
4. Check the state of the lift chains. Make sure that there are:
• No loose pins in the outside washers
• No visible cracks in any washer (link section)
• No visible mechanical damage
34/38
TM Mast.02en
9 LIFT CHAINS TECHNICAL MANUAL
• No jarring noise when the chain moves

• No corrosion in the chain
• No resistance when the chain bends over the chain wheel
5. Lubricate the chains after inspection using a thin oil or lubrication spray.
9.5 Maintaining, cleaning, and lubricating the lift chain

Service life depends on maintaining the chain. Maintenance intervals depend on the
NOTE environment. In normal conditions the interval is approximately 2,000 hours.
1. Lower the machine to the bottom position.

2. Remove the lift chains from the mast. For more information, see Removing the standard
mast (page 10)
3. Clean the entire length of the lift chains properly.
4. Lubricate the lift chains with thin oil or lubrication spray.
5. Install the chain upside down, inside out.
35/38
TM Mast.02en
TECHNICAL MANUAL 10 CARRIAGE
10 CARRIAGE
10.1 Removing the carriage
1. Place the forks in the fork compartments or
in some form of load to secure them.
2. Lower the inner mast until the lift chains slacken.

3. Pull out the pins from the lift chains.
4. To prevent the chains from falling, secure them.
Tighten the chains with a rope and have an assistant hold them until the attachment is
loose. Then pull the chains down again.
5. Remove the hydraulic hoses from the machine and plug the ends.
6. To prevent the hoses from falling over the hose wheel, secure them.
Tighten the hoses and electrical cables with a rope and have an assistant hold them until
the attachment is loose. Then pull the hoses and electrical cables down again.
7. To take the load off the rollers, tilt the mast.
8. Raise the inner mast carefully while
monitoring the chains and hoses.
36/38
TM Mast.02en
10 CARRIAGE TECHNICAL MANUAL
9. When lowest part of the inner mast has

passed the reels, the machine reverses
and the inner mast is lowered.
10.2 Marking the forks

Each fork is stamped (1) with information about thickness and the capacity of the fork. The
marking is on the side of the shaft.
Example:
6000/6350x600x60
• 6000 = The capacity of fork with a safety factor of 3 with the indicated center of gravity
distance.
• 6350 = The capacity of fork with a safety factor of 2.834 with the indicated center of gravity
distance.
• 600 = Center of gravity distance (TP).
• 60 = Original thickness of the fork blade.
Figure 6. Marking of forks
1. Stamp, fork thickness

2. Shaft
3. The thickness of the blade must not be less than 90% of the stamped thickness
4. Fork taper
37/38
TM Mast.02en
TECHNICAL MANUAL 10 CARRIAGE
10.3 Checking and measuring the fork

1. Check that the angle between blade and
shaft is 90°.
90°
2. Check the fork blade deflection.

3. Check for crack formation at the points that are exposed to the most stress.
4. Check welds (5) and fork base (6).
5. Carry out checks regularly according to local regulations, or every 2,000 hours.
38/38
TM Mast.02en
www.konecranes.com
Corporate HQ
Region EMEA HQ
Hyvinkää, Finland
Region Americas HQ
Springﬁeld, Ohio Region APAC HQ
Shanghai, China
Main production sites

Sales and service locations
This document and the information contained herein, is the exclusive property of Konecranes
Lifttrucks and represents a non-public, confidential and proprietary trade secret that may not be
reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever
without the express written consent of Konecranes Lifttrucks. © 2016 Konecranes Lifttrucks. All rights
reserved. ‘Konecranes’, ‘Lifting Businesses’ and C are either registered trademarks or trademarks of
Konecranes Lifttrucks.Copyright © (2016) Konecranes Lifttrucks. All rights reserved.

TMMast.01en - C ECH FLT - Mast

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TECHNICAL MANUAL

6 SIDE SUPPORT REEL.............................................................................................. 27

7 TOP SUPPORT REEL............................................................................................... 29

• Standard duplex mast

1. Fork-positioning and side shift cylinders 5. Inner mast

Material Part number

Welding rod 2.5 mm² for welding the axle 50550150

Welding rod 3.25 mm² for welding the axle 50550142

AWS/SFA A5.1: E 7018

ISO 2560: E 51 5B 120 20H

Swedish standard: 3211 H10

Table 2. Special tool

Tool Part number

Slide hammer 6130.109

Figure 2. Standard duplex mast

The duplex mast consists of:

3.2 Free lift duplex mast

Figure 3. Free lift duplex mast

The free lift duplex mast consists of:

3.3 Free lift triplex mast

Figure 4. Triplex mast, free lift

The free lift triplex mast consists of:

1. Operate the fork-positioning sideways.

4.2 Removing the standard mast

4. To avoid the hoses rolling around the hose

5. Open and remove the cotter pin (1).

6. Remove the pin (2) from the chain tensioner.

4.3 Removing the inner mast

2. Secure the lift cylinders.

4.4 Removing the complete mast

1. Remove the hose clamps (2).

5. Seal the connections with a plug.

7. Seal the connections with a plug.

9. Attach the lift chains to the lifting eyelets of

10. To secure the outer mast, use an overhead hoist.

18. Remove the screw (11) from the shaft lock.

4.5 Installing the standard mast

4.6 Removing the ECC attachment

3. Lift the attachment until the lift chains slacken.

5. To prevent the chains from falling, secure the chains.

6. Mark up and remove the hydraulic hoses

7. Disconnect and remove the electrical

4.7 Installing the ECC attachment

1. Position the mast in vertical position.

2. Attach the shackles and lifting slings to the

3. Lift the attachment and raise the inner mast.

7. Connect the hydraulic hoses (3) to the

8. Connect all the electrical cables (4) to the

9. Lower the inner mast carefully to its lowest position.

4.8 Removing the ECC mast

1. Position the mast in vertical position.

2. Mark up and remove the hydraulic

3. Seal the connections with a plug.

5. Seal the connections with a plug.

8. Install the lift chains in the lifting eyelets of

9. To secure the mast, use an overhead hoist.

11. Remove the screw (7) that lock the shaft

4.9 Installing the ECC mast

2. Remove the inner spacer (2).

5.2 Installing the mast wheel (SMV10-16)

2. Install the outer spacer (4).

5.3 Removing the mast wheel (SMV18-16)

2. Remove the nut (2).