GEROH GmbH & Co.

KG
Mechanische Systeme
Fischergasse 25
D-91344 Waischenfeld
Germany
Tel. +49(0)9202/18-0
Fax +49(0)9202/18-11

ORIGINAL OPERATING MANUAL

Mast Type: 145-8KVL6

Model/Year: 2015

ID: AKAE086

Serial No.: 42351-42365

last revised: 10.06.2015 Crank Mast 145-8KVL6

AKAE086
Hinged mast base BMAK035
Motor Drive 12 V DC BMAA087

Please keep in a safe place for reference

AKAE086_BMAK035_BMAA087_E.doc Page 1 of 25
Contents

1. Safety ............................................................................................................. 3
1.1 Safety notes .................................................................................................... 3
1.2 Authorised use ................................................................................................ 3
1.3 Avoiding accidents .......................................................................................... 4
1.4 Operator ......................................................................................................... 4
1.5 Safety check ................................................................................................... 4

2. Pre-operational measures ............................................................................ 5

2.1 Specifications.................................................................................................. 5
2.2 Functions ........................................................................................................ 5
2.3 Assembly ........................................................................................................ 5
2.5 Safety Note ..................................................................................................... 9

3. Operation ..................................................................................................... 11
3.1 Mast .............................................................................................................. 11
3.2 Transport ...................................................................................................... 12
3.3 Emergency drive ........................................................................................... 12

4. Maintenance/Check up ............................................................................... 13
4.1 Removing mast from shelter mounting device .............................................. 13
4.2 Cleaning and re-lubricating ........................................................................... 13
4.3 Re-tensioning of retraction rope.................................................................... 15
4.4 Safety check ................................................................................................. 16

AKAE086_BMAK035_BMAA087_E.doc Page 2 of 25
1. Safety

1.1 Safety notes

The 145-8KVL6 mast has undergone a safety check in order to ensure the
corresponding safety standards are met. Incorrect mounting or use, however

 may lead to personal injury to or death of the operator

 may damage the mast or other relevant items
 may limit the functionality of the mast

Persons involved in the mounting, putting into operation, operation or

maintenance of the mast should therefore read and understand the following
notes in complete for their own safety.

1.2 Authorised use

The mast is to be used as a telescopic lighting spot or antenna carrier and

should be mounted to a vehicle.
The mast is suitable only for wind speeds up to 108 km/h and top loads up to
20 kg.
The wind area A*cw of the mast top load (antenna, lighting device including
accessories) must not exceed 0.10 m².
The center of gravity of the antenna-windload may not be higher than 0.5 m
above the mast top.
The maximum permissible side angle for the vehicle is 5° when the mast is
fully extended and exposed to maximum wind speed and top load.

Any other use of the mast is not authorised and will therefore lead to a
loss of warranty.

The manufacturer of the compound system must make sure that all relevant
regulations and instructions will be observed when additional components and
accessories (such as antennae, lighting devices, cables, cable guides, electric
or electronic equipment etc.) are added to the system and when the system is
mounted on a vehicle and will take responsibility for any violation of such
regulations and instructions.

Warning!
 Do not expose the mast to wind speeds or top loads exceeding the
maximum specified.
 Before the mast is put into operation, make sure it is fastened correctly
as described in section 2.3, "Assembly".
 Before extending the mast, please check that the mast will be
positioned at a sufficient distance to buildings, bridges, roofs or other
objects.
 Before mounting the mast, please check that the mast will be positioned
at a sufficient distance to electrical installations and high voltage lines.

AKAE086_BMAK035_BMAA087_E.doc Page 3 of 25
  In case of thunder storms, do NOT assemble or dismantle the mast and
keep away from the extended mast.
 Do not move the vehicle unless the mast is fully retracted.
 Do not climb the mast.

For your own safety, any modifications to the mast are not admissible
unless they have been explicitly authorised by the producer of the mast.

For the operation, maintenance and repair of the mast the instructions
supplied in this manual must in any case be followed. Any use of or work at
the mast not in compliance with these instructions is not authorised by the
producer and will rule out warranty.

1.3 Avoiding accidents

 Do not operate the mast when the gear case cover (protection cap) has
been removed.
 The mast is operated through a rope drive. Damaged pull-out ropes can
result in uncontrollable retraction of the mast.
 In order to avoid personal injury, do not touch the moving telescoping
tubes during retraction or extending of the mast.
 The safety winch is fitted with a load pressure brake to keep the mast in
its adjusted position. Do not remove the safety winch, therefore, unless
the mast is fully retracted, as this would result in an uncontrollable
retraction of the mast.

1.4 Operator

The company operating the mast and its agents and representatives must
provide the instructions to the operator of the mast. They must make sure the
operator has completely read and understood the instructions, before the mast
is put into operation.

1.5 Safety check

As set forth in the German regulations for the prevention of accidents

concerning winches, pulling and lifting devices (BGV D8 – formerly VBG 8),
winches, lifting and pulling devices must be checked by a qualified engineer
prior to the initial operation and at least once a year. These regulations apply
to this mast both in Germany and, as a part of the terms and conditions for the
purchase of the mast, in all other countries.
For more information on the extent and the procedures to be used in this
check up, please see the printed checklist attached.

AKAE086_BMAK035_BMAA087_E.doc Page 4 of 25
2. Pre-operational measures

2.1 Specifications

Crank mast, type 145-8KVL6

AKAE086

Length of mast, extended approx. 8.0 metres

Length of mast, retracted approx. 1.76 metres
No. of mast stages 6
Base tube, cross section 145 mm x 145 mm
Weight approx. 37 kg

Permissible top load: 20 kg max.

Permissible wind area of top load: 0.10 m2 max.

Permissible wind speed: 108 km/h max.

Permissible side angle at max. wind load

and max. top load 5° max.

Motor drive:
Rated voltage 12 V DC
Rated current 35 A
Protective system IP 54
Operating mode (IEC60034-1) S2 – 5 min

2.2 Functions

The gear case at the base stage of the mast holds a winch drum to be
operated through a motor drive. The pull-out and retraction ropes are routed
from the winch drum via guide rollers to the individual telescoping stages and
thus control the extension and retraction of the mast.

2.3 Assembly

The vehicle should comply with the licensing and traffic regulations after the
mast and the accessories have been mounted to the vehicle. In case you are
not sure if the vehicle complies to these regulations, please contact the
competent vehicle licensing office.

AKAE086_BMAK035_BMAA087_E.doc Page 5 of 25
 Warning!
Incorrect mounting of the mast may lead to hazardous situations and personal
injury. Please check that the mounting complies with the mounting instructions
to make sure the mast is securely fastened.

a) Mount clamp (fig. 1/pos. 1) to the vehicle roof and install hinged mast
bottom (fig. 1/pos. 2) to the vehicle mounting device as follows:
 In order to mount the top clamp, the vehicle roof should be
equipped with customised roof adapters
 Make sure that the mast is mounted square to the vehicle.
 Check that the vehicle mounting areas are solid enough to support
the mast. If necessary, reinforce the mounting areas using
additional metal plates or other reinforcement pieces. The mounting
areas should resist horizontal forces of 6200 N in each direction.
 Use property class 8.8 screws and secure the screws to avoid
uncontrolled loosening.

b) Insert mast into the mast carrier.

To this end the mast must be fully retracted. Coil lifting belt below the
head frame around the tube of the mast base stage.
 Open clamp (fig. 1/pos. 1).
 To open the clamp, remove spring bolt (fig. 1/pos. 4) and loosen
star handle nut (fig. 1/pos. 3).
 Insert mast into the mast bottom and fasten mast using the two
screws (fig. 1/pos. 6).
 Re-close clamp (fig. 1/pos. 1), fasten star handle nut (fig. 1/pos. 3)
and secure star handle nut using the spring bolt (fig. 1/pos. 4).

Caution:
Having closed and secured the clamp using the spring bolt, the clamp
should not open when turning the star handle to the hilt.
If necessary, insert additional washers between the star handle nut and
the clamp.

c) Install locking clamp:

Fasten clamp (fig. 1/pos. 9) to the rectangular tube of the mast base
stage using the two hexagon screws. Adjust height of the clamp to
ensure that the bolt (fig. 1/pos. 8) securely engages into the locking
clamp latch and that the bolt sticks out about 2 to 5 mm over the latch
(see figure 1).
When raising the mast, it must securely snap into the spring bolt
mechanism.

AKAE086_BMAK035_BMAA087_E.doc Page 6 of 25
Mounting scheme:

figure 1

AKAE086_BMAK035_BMAA087_E.doc Page 7 of 25
2.4 Motor Drive

The subsequent description for mounting the motor drive and the adjustment
of the limit switches has to be followed in case of an afterwards or new
mounting after repair or emergency drive.
In case of mounting carried out by the producer items subsequent mentioned
concerning the electrical connections have to be observed.

Warning!
Electrical cable connections must be set up by qualified engineering staff.
The motor drive is to be protected appropriately by fuse when installed.

a) With the motor drive dismounted, extend the mast using the winch
handle, to position the smallest telescopic stage at a distance of at least
150 mm to the head frame of the mast base stage (see fig. 2).

b) Connect motor drive to 12 volts DC. Make sure you do not mix up the
cables when connecting the motor drive to the power supply.
Connect touch button of the motor drive as shown in the diagram
attached, and move drive to the lowest position. The "mast retracted"
position limit switch "S7" should have operated before the motor drive is
mounted to the mast.

c) Place motor drive on the wrist pin at the mast gear and fasten it using
four hexagon head cap screws (fig. 1/pos. 10).
After mounting, the motor drive's fastening flange should be attached
evenly to the mast gear base plate.

d) Use motor drive to cautiously extend the mast to an extension length of

6335 mm measured from the mast top to the upper edge of the base
stage head frame (see fig. 3).
The "mast extended" position limit switch "S6" should have operated
now.

In case the limit switch has not operated, readjust the switch as follows:

Remove case cover from motor drive (see fig. 4/pos. 2) and adjust final
switch "S6" through the adjusting hole using a screwdriver:

 turn to the left to decrease switching distance

Or, in case the limit switch "S6" has operated before having reached the
correct switching position:

 turn to the right to increase switching distance

After adjusting the drive, extend and retract the mast several times to control
the switching distances (see fig. 2 and 3.)

AKAE086_BMAK035_BMAA087_E.doc Page 8 of 25
 Caution:
Do not mount or dismount motor unless the mast has been retracted and limit
switch "S6" is activated to ensure that the assignment of the limit switches to
the respective mast extension lengths will be retained. The distances should
be checked after mounting and readjusted if necessary.

Make sure to follow the motor manufacturers' operating instructions for the
motor you will find attached to this manual.

2.5 Safety Note

Before the mast is put into operation, make sure you have read and
completely understood the operation and safety instructions. For your own
safety, always follow the instructions.

Figure 2

AKAE086_BMAK035_BMAA087_E.doc Page 9 of 25
 Figure 3

Figure 4

AKAE086_BMAK035_BMAA087_E.doc Page 10 of 25
3. Operation

Make sure the safety notes in chapter 1 are adhered to!

Otherwise the mast should not be operated.

3.1 Mast

Caution:

The moving telescoping tubes might cause personal injury when touched! Do
not touch the telescoping tubes during the retracting and the extension
processes.
The safety winch is fitted with an automatic load pressure brake to keep the
mast in its adjusted position. Do not remove the safety winch if the mast is not
fully retracted as this would result in uncontrollable retraction of the mast.

a) Installing the antenna:

Remove spring bolt (fig. 1/pos. 4), loosen star handle nut (fig. 1/pos. 3),
and open clamp.
Support the mast with one hand to keep it from dropping, pull spring
bolt (fig. 1/pos. 8) and carefully lower the mast.
Having secured the antenna to the mast head, insert mast head into the
mast top stage and fasten mast head using the two star handle screws
(fig. 1/pos. 5).
Then raise the mast again, close clamp, fasten star handle nut and
secure the fastening assembly using the spring bolt.

b) Extending the mast:

Press the extension button to extend the mast. You can stop the
extension of the mast at any length. The extension will stop
automatically, when the mast has reached maximum length.

c) Retracting the mast:

Caution!
Depending on the equipment used and the way the mast is mounted on
the vehicle, it might not be possible to retract the mast after
readjustment of the antennas if the antennas collides with the body of
the vehicle. In order to allow retraction of the mast, the antennas must
be rotated into their original positions first.

Press the retraction button to retract the mast. You can also stop the
retraction of the mast at any length.

AKAE086_BMAK035_BMAA087_E.doc Page 11 of 25
 d) Retracting the mast when formations of ice have built up on its
surface:

Warning!
When retracting the mast in icy condition, particles of dropping from the
telescoping tubes might cause personal injury. Always wear protection
gloves and a helmet when retracting the mast in icy condition.

e) Pivot the mast:

In order to install the antenna, the mast can be pivoted downwards after
opening the clamp (fig. 1/pos. 1). For this purpose, follow the
instructions under step 3.1 a).
While pivoting the mast, secure the mast against dropping.
After removing or installing the antenna, raise mast again, close clamp,
fasten star handle nut (fig. 1/pos. 3) and secure the fastening assembly
using the spring bolt (fig. 1/pos. 4).

3.2 Transport

Always check the following conditions before transportation:

 The mast must be fully retracted.
 The antennae and all additional equipment (depending on the mounting
and the equipment supplied by the manufacturer of the vehicle) must be
removed from the mast or secured.
 The clamp (fig. 1/pos. 1) must be safely closed and secured using the
spring bolt.
 Check that the mast is properly and securely installed in the mast base
stage.

3.3 Emergency drive

To use emergency drive, attach safety winch to the right end of the drive shaft.
Make sure that the gearwheel safely locks into the catch. Use locking ring
included to secure hand winch.

Remove the four fastening screws and dismount motor drive (fig. 1/pos. 10).
When re-mounting motor, the limit switches will have to be readjusted as
described in paragraph 2.4.

Warning!
When operating the mast with motor drive, the hand crank has to be removed!

AKAE086_BMAK035_BMAA087_E.doc Page 12 of 25
 4. Maintenance/Check up

The mast does not require extensive maintenance, as polymethyleneoxide

guides are used with the telescoping tubes. The gear shafts and the rope
drums in the tube heads and inside the mast are equipped with self-lubricating
bearings.

Action Time interval Description

Cleaning and re-lubricating every 12 months 4.2

Checking the retraction rope every 12 months * 4.3 a)
Re-tensioning the retraction rope as required 4.3 b)
Safety check-up every 12 months 4.4/1.5

* for a new mast see 4.3

4.1 Removing mast from shelter mounting device

Various maintenance tasks require the mast to be removed from the vehicle.
To do this, follow the steps explained in 2.3 in reverse order.

Warning!

 Hazardous situations and personal injury might be caused by faulty

mounting of the mast.

 Electrical cable connections must be set up by qualified engineering staff!

When mounting the mast, follow the description in 2.3.

4.2 Cleaning and re-lubricating

Depending on the site and environmental circumstances, the mast should be

cleaned in regular intervals. The life of the mast is affected by dirt, dust and
gumming oil.

In normal operational conditions it is recommended to clean the mast every

twelve months. Operating the mast in particular environmental circumstances,
however, might necessitate more frequent cleaning.

a) For removing the mast from the vehicle/ shelter, see 4.1

b) Bring the mast in its horizontal position and push the extension button
to release it. The top of the mast must be positioned beneath the
bottom to avoid draining of the cleaning liquid into the mast. Slightly
support the top of the mast when cranking. Support the released mast
at the top end, in the centre and at the bottom end.

AKAE086_BMAK035_BMAA087_E.doc Page 13 of 25
 c) Clean the telescoping tubes using petroleum ether. Thoroughly clean
the telescoping tubes from dirt and gumming oil using a cloth or a soft
brush.

Warning!
When working with petroleum ether, make sure the appropriate
regulations for the prevention of accidents are adhered to.

d) Re-lubricating

Caution!
When operating the mast while the cover of the gear is open, the gear
should not be touched, as this might cause personal injury!

Remove the cover (fig. 1/ pos. 7) of the gear.

Re-lubricating the gear and the telescoping tubes:

Lubricated item(s) Fig.5/Pos.: Lubricant

Rope sheaves 1 IOAA010
Nova PTFE OIL

Rope on the rope drum * 2 IFAA001

Molykote BR 2

Tubes in extended condition - IOAA001

TECHLON Sprühöl
UN 3295 3 (II)

* in released as well as re-loaded condition

Re-attach the gear cover.

e) Lubricate the star handle screws (fig. 1/pos.3, 5) of the mast using
machine oil.

f) Lubricate the hinge of the mast bottom (fig. 1/pos. 2) and the locking
bolt (fig. 1/pos. 8) using machine oil.

f) When fitting the mast to the vehicle/shelter, please observe the

warnings in 4.1.

AKAE086_BMAK035_BMAA087_E.doc Page 14 of 25
4.3 Re-tensioning of retraction rope

Due to the persistent tension - even if the mast is not stressed - the ropes
inside the mast stretch differently. Therefore the tension of the retraction ropes
in the gear must be checked regularly.
When using a new mast, it is recommended to carry out the first check of the
retraction rope's tension after approximately 100 rope operations or 8 weeks,
respectively.

Caution!

The safety winch is fitted with an automatic load pressure brake to keep the
mast in its adjusted position. Do not remove the safety winch if the mast is not
fully retracted as this would result in uncontrollable retraction of the mast.

a) Checking the tension of the retraction rope

Remove the gear cover.

Caution!
 When cranking while the cover of the gear (protection cap) is
open, the gear should not be touched, as this might cause
personal injury!

 Check the tension of the retraction rope only when extending the
mast. Gradually extend the retracted mast by cranking the handle
and check the tension of the retraction rope continuously. The
retraction rope must rest on the left rope pulley slightly tensioned
(fig. 5/pos. 2). The ropes must rest tightly side by side in the rope
grooves of the winch drum and must not form slack loops.
Otherwise the retraction rope must be re-tensioned.

b) Re-tensioning the retraction rope

The tension screw for re-tensioning of the retraction rope is located
inside the final mast stage at the top (hexagonal socket screw SW 5,
see fig. 5/pos. 3).

 Rotate the tension screw one or two turns to the right (clockwise)
using a hexagonal socket key SW5 with 250 mm extension.

 Release and reload the mast by cranking the handle

approximately three times and check the rope in the mast gear, as
described in 4.3 a). If necessary, re-tension by one more turn of
the screw and check again.

 Re-attach the gear cover.

 When fitting the mast to the vehicle/shelter, please observe the warnings in
4.1.

AKAE086_BMAK035_BMAA087_E.doc Page 15 of 25
4.4 Safety check

As set forth in the German regulations for the prevention of accidents (BGV D8
– formerly VBG 8), winches, lifting and pulling devices must be checked by a
qualified engineer prior to the initial operation and at least every half a year.
These regulations apply to this mast both in Germany and, as a part of the
terms and conditions for the purchase of the mast, in all other countries.

For more information on the extent and the procedures to be used in these
check-ups, please see the printed checklist attached.

AKAE086_BMAK035_BMAA087_E.doc Page 16 of 25
 figure 5

AKAE086_BMAK035_BMAA087_E.doc Page 17 of 25
 Ersatzteilliste / Spare part list AKAE086
Kurbelmast / Crank mast type 145-
8KVL6

Revision:10.2014 Blatt/ sheet 1/8

AKAE086_BMAK035_BMAA087_E.doc Page 18 of 25
 Ersatzteilliste / Spare part list AKAE086
Kurbelmast / Crank mast type 145-
8KVL6
Getriebe / Gear box

Revision:10.2014 Blatt/ sheet 2/8

AKAE086_BMAK035_BMAA087_E.doc Page 19 of 25
 Ersatzteilliste / Spare part list AKAE086
Kurbelmast / Crank mast type 145- BSAA033
8KVL6
Seiltrommel / Rope drum

Revision:10.2014 Blatt/ sheet 3/8

AKAE086_BMAK035_BMAA087_E.doc Page 20 of 25
 Ersatzteilliste / Spare part list AKAE086
Kurbelmast / Crank mast type 145-
8KVL6
Vierkantrohr / Square tube 145

Revision:10.2014 Blatt/ sheet 4/8

AKAE086_BMAK035_BMAA087_E.doc Page 21 of 25
 Ersatzteilliste / Spare part list AKAE086
Kurbelmast / Crank mast type 145-
8KVL6
Vierkantrohr / Square tube 120

Revision:10.2014 Blatt/ sheet 5/8

AKAE086_BMAK035_BMAA087_E.doc Page 22 of 25
 Ersatzteilliste / Spare part list AKAE086
Kurbelmast / Crank mast type 145-
8KVL6
Vierkantrohr / Square tube 100/80

Achtung!
Beim Austausch der Führungen auf die Kennzeichnung achten.
Revision:10.2014 Blatt/ sheet 6/8

AKAE086_BMAK035_BMAA087_E.doc Page 23 of 25
 Ersatzteilliste / Spare part list AKAE086
Kurbelmast / Crank mast type 145-
8KVL6
Vierkantrohr / Square tube 60/40

Achtung!
Beim Austausch der Führungen auf die Kennzeichnung achten.

Revision:10.2014 Blatt/ sheet 7/8

AKAE086_BMAK035_BMAA087_E.doc Page 24 of 25
 Seillaufplan / Wire rope diagram
Kurbelmast / Crank mast type 145-
KVL6

Revision:10.2014 Blatt/ sheet 8/8

AKAE086_BMAK035_BMAA087_E.doc Page 25 of 25