Technical Handbook: 049354en / Revision A / 2014-05-08 Original Instructions

TECHNICAL HANDBOOK
BOOM
ORIGINAL INSTRUCTIONS
049354en / Revision A / 2014-05-08
This document and the information contained herein, is the exclusive property of Konecranes Plc 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 Plc. © 2014 Konecranes Plc. All rights reserved. ‘Konecranes’,
‘Lifting Businesses’ and C are either registered trademarks or trademarks of Konecranes Plc.Copyright © (2014) Konecranes Plc. All rights reserved.
TABLE OF CONTENTS TECHNICAL HANDBOOK
TABLE OF CONTENTS
1 INTRODUCTION........................................................................................................... 5
2 TECHNICAL DATA....................................................................................................... 6
2.1 Consumables and weights.......................................................................................... 6
3 BOOM............................................................................................................................ 7
3.1 Removing the boom..................................................................................................... 7
3.2 Assembling the inner and outer boom....................................................................... 8
3.3 Installing the wear pads in the rear end of the inner boom...................................... 10
3.4 Installing the wear pads on the side of the inner boom............................................ 10
3.5 Installing the cable chain............................................................................................. 11
3.6 Installing the hoses and cables.................................................................................. 12
3.7 Installing the length sensor......................................................................................... 13
3.8 Installing the boom...................................................................................................... 14
3.9 Checking the tolerances in the boom suspension.................................................... 17
4 ATTACHMENT.............................................................................................................. 19
4.1 Removing the attachment........................................................................................... 19
4.2 Installing the attachment............................................................................................. 20
3/20
This document and the information contained herein, is the exclusive property of Konecranes Plc 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 Plc. © 2014 Konecranes Plc. All rights reserved. ‘Konecranes’,
‘Lifting Businesses’ and C are either registered trademarks or trademarks of Konecranes Plc.
TECHNICAL HANDBOOK TABLE OF CONTENTS
4/20
This document and the information contained herein, is the exclusive property of Konecranes Plc 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 Plc. © 2014 Konecranes Plc. All rights reserved. ‘Konecranes’,
‘Lifting Businesses’ and C are either registered trademarks or trademarks of Konecranes Plc.
1 INTRODUCTION TECHNICAL HANDBOOK
1 INTRODUCTION
The boom consists of an outer and inner boom. The inner boom moves through the extension
cylinder and slides on wear pads. The extension cylinder is located inside the boom.
Two lift cylinders enable lifting. The attachment, which is suspended on the pendulum axle,
shifts sideways and spreads for contact with 20-foot or 40-foot containers.
There are two types of attachment:
• Top lift attachment with only twistlock

• Combination attachment with twistlock and bottom lift leg
1 2
7
3
4
6
Figure 1. Boom Lift
1. Inner boom 5. Attachment

2. Outer boom 6. Pendulum axle
3. Lift cylinder 7. Damp cylinder
4. Boom suspension
5/20
049354en / Revision A / 2014-05-08 Copyright © (2014) Konecranes Plc. All rights reserved.
TECHNICAL HANDBOOK 2 TECHNICAL DATA
2 TECHNICAL DATA
2.1 Consumables and weights
Table 1. Consumables
Material Part Number
Locking fluid for cylindrical installation 6180.012
Table 2. Weights
Equipment Weight (approximately)
Boom (without attachment) 14–17 t
Top lift attachment 9t
Combination attachment 13 t
6/20
3 BOOM TECHNICAL HANDBOOK
3 BOOM
3.1 Removing the boom

1. Retract and lower the boom.
2. Check that the hydraulic system is depressurized.
3. Remove the attachment. For more information, see Removing the attachment (page 19)
4. Disconnect all the hydraulic hoses from the boom and the extension cylinder.
5. Disconnect all the electrical wiring from the boom.
6. Install the lifting device on the boom.
7. Relieve the lift cylinder by raising the boom with the lifting device.
8. To hold up the cylinders, raise each cylinder with lifting device.
9. To pull out the shafts of the lift cylinder, use
extraction screws (1).
10. Lower the lift cylinder until it rests on its mounting.

11. Relieve the rear mounting of the boom.
THE BOOM CAN SWING OUT WHEN THE SHAFTS ARE
WARNING REMOVED.
Personal injury hazard.
7/20
TECHNICAL HANDBOOK 3 BOOM
12. Loosen the screws which hold the shafts

(2).
2
1
13. To pull out the shafts, use the extraction screws (1).
14. Lower the boom and place it on a suitable surface.
3.2 Assembling the inner and outer boom

1. Prepare the extension cylinder as follows:
1.1 Tighten the four screws of the valve 3
block (3).
2 x4
1.2 Place the pressure hose (2) between
the valve block and connecting pipe of
the cylinder.
1.3 Tighten the three screws of the 1
buckling support (1).
x3
2. Grind and clean the paint from the shaft

holes for the boom (8), lift cylinder (5), and
4 5 6
attachment (12).
8 7
9
10 11
14 13 12
3. Grind and clean the internal mountings of

the extension cylinder.
8/20
4. Grind and clean the paint from the holes of the damp cylinders (11).
5. Check that the shafts to the extension cylinder and lift cylinders fit inside the bearings easily.
6. Apply the grease on the outer (4) and inner (10) boom of the sliding surfaces.
7. Install the rear, lower wear pad (13) without shims on the inner boom.
The guide pads (6 and 14) are securely screwed after the inner boom is in place.
8. Insert the extension cylinder in the inner
boom and assemble the cylinder in the
front cylinder suspension ear with the shaft. 16
8.1 Install a snap ring on the shaft.
8.2 Insert the shaft (15) through the hole in 15
the outer boom.
8.3 Insert the shaft in the front cylinder
suspension ear (16) and the cylinder.
8.4 Install a snap ring on the other side of
the shaft.
9. Insert the inner boom in the outer boom until 1 m remains.

10. Screw the wear pad retainer onto the front
edge and underside of the outer boom.
11. Insert the inner boom.

The guide pads are securely screwed after the inner boom is in place.
9/20
3.3 Installing the wear pads in the rear end of the inner boom
1. Install the retainer with the rear upper wear
pad on top of the inner boom.
1
2. Assemble the extension cylinder in its rear suspension.

3. Align the inner boom with the outer boom.
4. To press the inner boom towards the roof of the outer boom, use a jack.
5. Remove the cover from the lower wear pads (2).
6. Add shims to level with the cover.
7. Install the covers and screw into place. Use Nordlock washer.
8. Remove the jack.
3.4 Installing the wear pads on the side of the inner boom
1. Align the inner boom in the outer boom.
2. Place the round guide pad (1) in the side
holes on the inner boom.
1
3. Add shims to level with the covers.

4. Install the covers and screw into place. Use Nordlock washer.
5. Repeat the same procedure with the round guide pads on the front edge of the outer boom.
10/20
3.5 Installing the cable chain

1. Screw the cable chain into place.
x4
x4
11/20
3.6 Installing the hoses and cables
Figure 2. Hoses and cables
1. Pull the hydraulic hoses and electrical wiring from the back forwards, through the cable
chain, through the cable duct and until the attachment.
2. To secure the cables and hoses along with the boom, use hose clamps.
12/20
3. Screw the valve block (1) on the front edge

of the inner boom.
4. Connect the hydraulic hoses to the valve block.
3.7 Installing the length sensor

1. Screw the length sensor (2) into the outer
boom.
2. Pull out the wire (1) from the length sensor (2) and connect it to the inner boom.
13/20
3.8 Installing the boom

1. Align and install both the bushings (3) in
the rear boom suspension ear.
2. Lock the bushings with locking fluid for cylindrical installation. For more information, see
Consumables and weights (page 6).
3. Align and install both bushings (4) in the
mountings of the attachment.
4
4
4. Lock the bushings with locking fluid for cylindrical installation. For more information, see
Consumables and weights (page 6).
14/20
5. Install the lift cylinder (5) in the chassis (7):

5.1 Place a spacer (6) on the outside of
the mounting. 5
5.2 Install the shaft (8) and screw them
with the two screws (9). 6
5.3 Lower the lift cylinders to rest on the 7
mountings.
8
6. Install the lifting device on the boom.
7. Raise the boom on the chassis.

8. Check that the rear mounting (17) on the
boom is in line with the rear mounting (18)
13
on the chassis. 12
11
14
10
15
x2 x2
17 16
18
9. Install both the shafts (15) and screw them into place using two screws.
15/20
10. Install the spacers (11) and keep them in place while the boom is lowered fully towards the
lift cylinder (10).
The spacers must be on the inside of the lift cylinder.
RISK OF ENTRAPMENT WHEN HOLDING THE SPACERS
WARNING IN PLACE.
11. To locate the upper suspension ear (12) of the lift cylinder correctly, raise the lift cylinder
(10) and lower the boom.
A spacer (11) must be on the inside of the upper suspension ear of the lift cylinder.
12. Install both the shafts (13) and screw them into place using two screws.
13. Install the hydraulic hoses of the extension
cylinder.
14. Install the ground wire (19) between the

rear edge of the boom and the chassis.
19
20
21
15. Install the hydraulic hoses (20) of the attachment in the rear edge of the boom.
16. Install the electrical wiring (21) of the attachment in the rear edge of the boom.
16/20
17. Install the angle sensor (25) between the

boom and chassis.
22
25
23
24
x4 x4
18. Screw the mounting bracket (23) into the chassis.

19. Mount the angle sensor (25) in the mounting.
20. Install the link arm (22).
21. Connect the cable (24).
22. Install the damp cylinders (26) in the upper
mountings of the boom with the shaft (27).
27
26
23. Secure the shaft (27) with snap rings.

24. Connect the hydraulic hoses to the damp cylinders.
3.9 Checking the tolerances in the boom suspension

1. Retract and lower the boom fully.
2. Measure the vertical distance 'X' between the top of the plate and top of the radius on the
frame. To measure, use vernier with at least ±0.1 mm accuracy.
17/20
3. Measure on both left and right-hand side

and record the measurements.
'X' left-hand side:______mm
X
'X' right-hand side:______mm
4. Lift the front end of the boom with an

overhead crane or any other equipment
until the lift cylinder pistons extend slightly.
'A': Lift cylinders extended
approximately 1–2 mm
5. Again measure the distance 'X' while the lifting boom is relieved and record the
measurements.
'X' left-hand side:______mm
'X' right-hand side:______mm
Difference between the two measurements on left-hand or right-hand side must not exceed
1.0 mm.
6. If, the difference exceeds 1.0 mm on any
side, remove the shafts and check where
the play is located.
1
6.1 Play up to 1.0 mm is allowed between
the shaft (1) and bushing (2).
B
2
If the play exceeds 1.0 mm on any
side, replace bushing (2) on both side
A
and if necessary the shafts (1).

6.2 There must be no play between ear (3)
and bushing (2). Bushing (2) should be 3
firmly fitted and should not rotate.
4
6.3 There must be no play between
chassis ear (4) and shaft (1).
7. If there is play in accordance with (6.2) and (6.3), contact to a Konecranes Lifttrucks Dealer.
18/20
4 ATTACHMENT TECHNICAL HANDBOOK
4 ATTACHMENT
4.1 Removing the attachment

1. Check that the attachment is:
1.1. Slide in to a position of 20 feet (6 m)
1.2. Centered
1.3. Turned 90° in relation to the boom
2. Secure the lifting device in the attachment.
3. Disconnect the electrical wiring from the attachment.

4. Disconnect the hydraulic hoses from the attachment.
5. Seal the hydraulic hoses and connections with a plug.
6. Remove the snap rings from the shafts (1)
of the damp cylinders and then tap out the
shafts. 2
1
7. To prevent damage to the piston, secure the damp cylinders.

8. To release the mounting from the attachment, use lifting device.
9. Remove the screws which hold the shafts to the attachment.
10. To relieve the shafts, lift up the attachment.
19/20
TECHNICAL HANDBOOK 4 ATTACHMENT
THE ATTACHMENT CAN SWING OUT WHEN THE

WARNING SHAFTS ARE REMOVED.
Personal injury hazard.
11. Use extraction screws (3) to pull out the shafts (2).
12. Lower the attachment and place it on a suitable surface.
4.2 Installing the attachment

1. Secure the lifting device in the attachment.
2. To prevent damage to the piston rods, push the damp cylinders on the boom to one side.
3. Lift up the attachment in position.
4. Install both the shafts (3) of the attachment.
Screw the shafts into place using two
screws (2). 1 2
5. Position the lower mountings on the damp cylinders.

6. Install the shafts (1) of the damp cylinders.
7. Secure the shafts with the snap rings.
8. Connect the electrical wiring and hydraulic hoses to the attachment.
20/20
www.konecranes.com
Corporate HQ
Region EMEA HQ
Hyvinkää, Finland
Region Americas HQ
Springﬁ eld, Ohio Region AP AC HQ
Shanghai, China
Main production sites

Sales and service locations
This document and the information contained herein, is the exclusive property of Konecranes Plc 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 Plc. © 2014 Konecranes Plc. All rights reserved. ‘Konecranes’,
‘Lifting Businesses’ and C are either registered trademarks or trademarks of Konecranes Plc.Copyright
© (2014) Konecranes Plc. All rights reserved.

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TECHNICAL HANDBOOK

There are two types of attachment:

• Top lift attachment with only twistlock

Figure 1. Boom Lift

1. Inner boom 5. Attachment

2.1 Consumables and weights

Material Part Number

Locking fluid for cylindrical installation 6180.012

Equipment Weight (approximately)

Boom (without attachment) 14–17 t

Top lift attachment 9t

3.1 Removing the boom

10. Lower the lift cylinder until it rests on its mounting.

12. Loosen the screws which hold the shafts

3.2 Assembling the inner and outer boom

2. Grind and clean the paint from the shaft

3. Grind and clean the internal mountings of

9. Insert the inner boom in the outer boom until 1 m remains.

11. Insert the inner boom.

2. Assemble the extension cylinder in its rear suspension.

3. Add shims to level with the covers.

3.5 Installing the cable chain

3.6 Installing the hoses and cables

Figure 2. Hoses and cables

3. Screw the valve block (1) on the front edge

4. Connect the hydraulic hoses to the valve block.

3.7 Installing the length sensor

3.8 Installing the boom

5. Install the lift cylinder (5) in the chassis (7):

6. Install the lifting device on the boom.

7. Raise the boom on the chassis.

14. Install the ground wire (19) between the

17. Install the angle sensor (25) between the

18. Screw the mounting bracket (23) into the chassis.

23. Secure the shaft (27) with snap rings.

3.9 Checking the tolerances in the boom suspension

3. Measure on both left and right-hand side

4. Lift the front end of the boom with an

and if necessary the shafts (1).

4.1 Removing the attachment

3. Disconnect the electrical wiring from the attachment.

7. To prevent damage to the piston, secure the damp cylinders.

THE ATTACHMENT CAN SWING OUT WHEN THE

4.2 Installing the attachment

5. Position the lower mountings on the damp cylinders.

Main production sites

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