OWNER'S MANUAL

KPTC-5000-188

English 05610019170030-0.ORD 02.01.2020

100892659,100892660,100892661,100892662 - DS003819/DS003920/DS -

Original instructions 056100191700303001-0 100892659,100892660,100892661,100892662 PS09078 02-01-2020

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL

Table of contents

1 GENERAL INTRODUCTION .............................................................................................................. 3

1.1 Foreword: About this manual ........................................................................................................................ 3
1.2 Symbols used in this manual ........................................................................................................................ 3
1.3 Safety alert symbols and signal words ......................................................................................................... 4
1.4 Questions and comments ............................................................................................................................. 4
1.5 Exclusion of warranty .................................................................................................................................... 4
1.6 Manual use ................................................................................................................................................... 5
1.7 Environmental information ............................................................................................................................ 5
1.7.1 Lifecycle environmental impacts ............................................................................................................... 5
1.8 Terminology .................................................................................................................................................. 6
2 SAFETY FIRST! ................................................................................................................................. 7
2.1 Personal protective equipment (PPE)........................................................................................................... 7
2.1.1 Fall protection............................................................................................................................................ 8
2.2 Owner’s responsibilities ................................................................................................................................ 9
2.2.1 General safety issues ............................................................................................................................... 9
2.3 Intended use of the product ........................................................................................................................11
2.4 Operating environment ...............................................................................................................................13
2.5 Safety during installation .............................................................................................................................14
2.6 Safety during use ........................................................................................................................................15
2.7 Safety during maintenance .........................................................................................................................16
3 IDENTIFICATION............................................................................................................................. 18
3.1 Trolley identification data ............................................................................................................................18
3.2 Standards and directives ............................................................................................................................18
4 CONSTRUCTION ............................................................................................................................ 19
4.1 Identifying key parts of the product .............................................................................................................19
5 INSTRUCTIONS FOR THE OPERATOR ......................................................................................... 20
5.1 Operator’s responsibilities...........................................................................................................................20
5.1.1 Checks to be done before every working shift ........................................................................................21
5.1.2 Load handling .........................................................................................................................................22
5.2 Operating the product .................................................................................................................................22
6 INSTALLATION AND COMMISSIONING ......................................................................................... 23
6.1 Installing the device ....................................................................................................................................23
6.1.1 Adjustment of flanges .............................................................................................................................23
7 MAINTENANCE ............................................................................................................................... 28
7.1 Why you must care about maintenance .....................................................................................................28
7.2 Service personnel .......................................................................................................................................29
7.3 Inspections ..................................................................................................................................................29
7.4 Spare parts and wear parts.........................................................................................................................29
7.5 Lubrication ..................................................................................................................................................31
7.5.1 General lubrication instructions...............................................................................................................31
7.6 Disposal of waste material ..........................................................................................................................32
APPENDIX: TECHNICAL DATA............................................................................................................. 33

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 2/36
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL

1 GENERAL INTRODUCTION

1.1 Foreword: About this manual

This manual offers guidance to enable safe and efficient operation of the equipment.
Taking the time to read this manual will help you to prevent damage to the equipment, and, most importantly,
personnel situated close to it. The equipment is designed to be safe when used correctly. However, there are many
potential hazards associated with incorrect operation and these can be avoided when you know how to recognize
and anticipate them.
This manual will also make you aware of your responsibilities with respect to the equipment and help you to ensure
that it is kept in a safe operating condition throughout its lifetime.
This manual is not intended as a substitute for proper training but provides recommendations and methods for safe
and efficient operation and maintenance. The equipment’s owner must ensure that operators are properly trained
prior to operation and, at all times, comply with all of the applicable and prevailing safety and other standards, rules
and regulations.

1.2 Symbols used in this manual

Readers should familiarize themselves with the following symbols which are used in this manual.

Note: Indicates items which require special attention by the reader. There is no obvious risk of injury
associated with notes.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL

1.3 Safety alert symbols and signal words

The following symbols are used in this manual to indicate potential safety hazards.

Obey all safety messages that follow this symbol to avoid possible injury or
death.

Indicates a potentially hazardous situation, which if not avoided, MAY result in

CAUTION
minor or moderate injury. It may also be used to alert against unsafe practices.

Indicates a potentially hazardous situation, which if not avoided, COULD result

WARNING
in death or serious injury.

INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT

DANGER
AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

Addresses situations not related to personal injury, such as likely or possible damage
NOTICE
to equipment.

Shall Indicates that a rule is mandatory and must be followed.

Should Indicates that a rule is a recommendation, the advisability of which depends on the facts in each situation.

1.4 Questions and comments

Any questions or comments relating to the content of this manual and/or the operation, maintenance and/or service
of manufacturer products should be directed to: www.konecranes.com

1.5 Exclusion of warranty

THE MANUFACTURER MAKES ABSOLUTELY NO WARRANTY WHATSOEVER WITH REGARD TO THE
CONTENTS OF THIS MANUAL, EXPRESS OR IMPLIED, WHETHER ARISING BY OPERATION OF LAW OR
OTHERWISE, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL

1.6 Manual use

Every person exposed to the manufacturer’s equipment must, prior to OPERATING, SERVICING AND/OR
MAINTAINING SUCH PRODUCTS, read and understand the contents of this manual and strictly adhere AND
CONFORM THEIR CONDUCT WITH AND TO THE INFORMATION, RECOMMENDATIONS AND warnings
provided herein.

Note: Keep these instructions in a safe, accessible location for future reference by personnel operating the
equipment or exposed to the equipment’s operation.

Read and understand the contents of this manual prior to operating, servicing,
and or/maintaining the equipment. Failure to do so can result in serious injury
or death.

Manufacturer shall not be liable for and owner and READER shall release, and hold manufacturer, harmless from
any and all claims, demands, AND damages, regardless of their nature or type losses and expenses , whether
known or unknown, present or future, any and all liability, of and from any and all manner of actions, cause[s] of
actions, all suits in law, in equity, or under statute, State or Federal, of whatever kind or nature, third party actions,
including suits for contribution and/or indemnity on account of or in any way arising out of acts or omissions of the
Owner or READER and relating in any way to this MANUAL or THE PRODUCTS referenced herein, including, but
not limited to the Owner’s or READER’S use thereof or any other cause identified herein or that may be reasonably
inferred HEREFROM.

1.7 Environmental information

Environmental aspects have been taken into account in designing and manufacturing this product. To prevent
environmental risks during use, please follow instructions for safe lubricant handling and disposal of waste material.
Proper use and maintenance improves environmental performance of this product.

1.7.1 Lifecycle environmental impacts

The lifecycle stages are:
 Production of materials
 Components and energy
 Transportation to factory
 Equipment manufacturing and assembly
 Transportation to customer
 Assembly at site
 Use phase including maintenance and modernisation
 End of life dismantling and recycling of the materials

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL

1.8 Terminology
The following terms and definitions may have been used in this manual:

ANSI American National Standards Institute.

ISO International Organization for Standardization.
Authorized personnel Persons who are authorized by the owner and who have the necessary training to carry out
operation or service actions.
CE marking The symbol indicates that the hoist complies with the appropriate CE regulations.
Check A visual and functional assessment (not a test) of the hoist without dismantling.
Crane operator Person operating the hoist for the purpose of handling loads.
Experienced service man authorized by A person with service experience who is authorized by the hoist manufacturer to perform service
the manufacturer of the crane actions.
Expert A person with extensive knowledge about the current subject matter.
Hoist The complete mechanism for lifting and lowering the load.
Inspection Looking at the hoist for defects and checking the operation of the controls, limiting and indicating
devices without loading the hoist. This is much more than a check but does not normally require
any part of the unit to be dismantled other than for removal or opening of covers or housings.
Lifting Capacity Load that the hoist is designed to lift for a given operating condition (e.g. configuration, position of
the load).
Owner’s manual Principal means by which the manufacturer provides information or instructions concerning the
hoist which are relevant to the product owner.
Qualified personnel One with necessary qualification, based on theoretical and practical knowledge of hoists or/and
cranes, for required activities as listed in operating instructions. The person must be in a position to
assess the safety of the installation in conjunction with the application. Persons with the authority to
undertake certain maintenance work on products of manufacturers include manufacturers’ service
engineers and trained fitters with corresponding certification.
Trolley The trolley moves along the bridge (main girder).
Pulley A pulley, also called a sheave or a drum, is a mechanism composed of a wheel on an axle or shaft
that may have a groove between two flanges around its circumference. A rope, cable, belt, or chain
usually runs over the wheel and inside the groove, if present
Sling A sling is used to attach the hook to the load when the load cannot be lifted directly by the hook

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL

2 SAFETY FIRST!
Safety requirements must be understood and followed.

2.1 Personal protective equipment (PPE)

Note: This chapter proposes personal protective equipment to ensure operator’s full safety. Local regulations
and requirements of the working environment shall be followed.

For safety, the operator or others in close proximity to the product may be required to wear Personal Protective
Equipment (PPE). Various types of PPE are available and must be selected according to the requirements of the
working environment. Some examples of different types of PPE are:

Typical PPE
A. Hard hat
B. Hearing
protection
C. Gloves
D. Safety shoes
E. Safety goggles
F. Face mask
G. Flashlight for
use in case of
power failure
H. Overalls

Appropriate clothing must be selected for each task. For example:

 Fire-resistant clothing must be worn when welding, flame cutting or using an angle grinder.
 Tear-resistant clothing must resist damage from sharp edges in the steel structure.
 Anti-static clothing must be worn when working on electrical circuits so that components do not get damaged by
a discharge of static electricity.
 When working with lubricants, clothing must prevent direct skin contact with the lubricant.
 Clothing should be chosen with consideration to the temperature at the working site.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL

2.1.1 Fall protection

While personnel are performing inspection or maintenance work at heights, they must follow fall protection
procedures as required by local regulations. Fall prevention practices and fall protection equipment aim to protect
personnel working on or around the equipment from exposure to falls.
If the equipment does not have a service platform or handrail, personnel must use a properly fitted safety harness
that is attached to the dedicated fixing points on the building or equipment in order to prevent falls.
If the product does not have dedicated fixing points for fall protection, it is the owner’s responsibility to make sure
that there are suitable fixing points in the building structure.
If ladders must be used, personnel must practice setting and securing the ladders before using them for actual
work.
A typical fall protection program may include:
 Documented and established site policies and procedures.
 Conducting site assessments for fall hazards
 Selection of the proper fall protection system and equipment
 Training on fall protection procedures and the proper use of fall protection systems
 Inspection and proper maintenance of fall protection equipment
 Measures to prevent falling objects
 Rescue plans
If necessary, contact your supplier or service organization for assistance with designing your fall protection
program.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL

2.2 Owner’s responsibilities

2.2.1 General safety issues

No modifications or additions to the product structures or performance values

CAUTION are permitted unless they are first discussed with and approved by the
manufacturer or manufacturer’s representative of the product.

Modifying the product without the manufacturer or manufacturer’s representative

approval can invalidate the guarantee. Furthermore, the manufacturer does not
NOTICE
accept responsibility for accidents which happen as a consequence of unauthorized
modifications.

Maintain safe conditions under the load

1 Owners SHALL make it clear to all parties (including operator, service personnel and visitors), that
no-one must ever venture underneath the load for any reason. This rule must be respected at all
times.

Maintain the lighting

2 Owners SHALL ensure that there is adequate lighting, in good working order, at the operating site
so that the product can be operated safely and efficiently at all times.

Maintain operating and safety requirements

3 Owners SHALL ensure that the product meets the applicable (local and global) safety and
operating requirements.

Maintenance
4 Owners SHALL ensure that maintenance is carried out at the recommended intervals as
determined by the manufacturer.

Maintain the operating conditions

5 Owners SHALL ensure that conditions at the product operating site correspond to the operating
conditions for which the product is designed.

Do not allow the product to be used unless it is in proper condition. In case of

doubt, contact a service agent authorized by the manufacturer or
WARNING
manufacturer’s representative! The use of defective equipment can result in
serious damage, injury or death.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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OWNER'S MANUAL

Keep the product in a safe condition

6 Owners SHALL ensure that the product is kept in a safe condition.
For example, all warning devices must be kept in good working order.

Fire safety
7 Owners SHALL ensure that personnel are prepared in case of fire and that the correct fire-fighting
equipment is available and maintained.

First aid
8 Owners SHALL ensure that, in accordance with local regulations, personnel are prepared in case of
accidents and that a suitable first-aid kit is available and maintained.

Ensure that signs are maintained in good condition

9 Owners SHALL ensure that signs and warnings are present on the product and are in good
condition.

Keep the working site clean

10 The working site should be kept free of clutter and dirt. Oil spills must be cleaned up immediately to
reduce the risk of slipping.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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OWNER'S MANUAL

2.3 Intended use of the product

The cross shaft of the push trolley and the hand-geared trolley is suited for the top hook of manual chain hoists or
manual lever pullers. In addition, electric chain hoists can be adapted to the push trolley, either with a top hook or a
lug. The top hook, equipped with a safety latch, simply hooks over the cross shaft. The shaft is specially shaped to
keep the top hook or the lug centered in place.
Most manual trolley models have two beam flange width ranges to cover a wide range of beam flange widths. In
these cases, the trolley has two cross shaft lengths, one for each range. The trolley wheels are single flange and
crown tread type suitable for Wide Flange beams or tapered flange beams.
Wheel bearings are permanently lubricated and do not require greasing. Trolleys have safety drop lugs and rubber
bumpers are standard.
Make sure that this instruction manual is available for any employee tasked with installing and maintaining this
device, particularly those responsible for operating the device.
Only use this device in accordance with the operating instructions contained in this manual. Comply with all safety
instructions and regulations proscribed by accident prevention legislation.
If this device develops a fault, or you have any questions about how to operate or handle the device, please
contact your authorized product dealer.
The machinery for general use is suitable for use in general manufacturing only; it is not suitable for use in harsh
environments. Please contact the manufacturer or manufacturer’s representative in case of doubt.
The equipment must be positioned directly above (perpendicular to) the load so that there are no side-pulling
forces.

Never allow the equipment to be used to pull or drag a load sideways. Side
pulling accelerates hoisting machinery wear and can damage the equipment.
CAUTION
The load must always be lifted clear of the ground before performing travelling
movements.

DO NOT ALLOW THE EQUIPMENT TO BE USED FOR LIFTING PERSONNEL

DANGER UNLESS THE MANUFACTURER OR MANUFACTURER’S REPRESENTATIVE
HAS DECLARED IN WRITING THAT IT MAY BE USED FOR THIS PURPOSE.

Modifying the equipment without the permission of the manufacturer or manufacturer’s representative can be
dangerous and can invalidate the equipment guarantee. Any fundamental modifications to the equipment must be
authorised in writing by the manufacturer. Examples of such modifications include:
 Welding or otherwise attaching new items to the equipment.
 Attaching devices for special material handling such as turning the load.
 Alterations to load-bearing components.
 Alterations to drives and speeds.

No modifications or additions to the equipment structures or performance

CAUTION values are permitted unless they are first discussed with, and approved by, the
supplier of the equipment.

CAUTION Never use the hoist as an earth reference for welding

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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OWNER'S MANUAL

Modifying the equipment without the manufacturer or manufacturer’s representative

approval can invalidate the guarantee. Furthermore, the manufacturer does not
NOTICE
accept responsibility for accidents which happen as a consequence of unauthorized
modifications.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL

2.4 Operating environment

USING THE EQUIPMENT IN AN ENVIRONMENT FOR WHICH IT IS NOT

DANGER DESIGNED CAN BE DANGEROUS. IT WILL ALSO REDUCE THE EQUIPMENT’S
LIFETIME AND INCREASE THE MAINTENANCE REQUIREMENTS.

If the operating environment deviates from the environment specified when the equipment was ordered, contact the
manufacturer or manufacturer’s representative. Solutions are available to enable the equipment to work in a wide
range of operating environments. If the equipment for general use will be used in exceptional ambient
conditions/temperatures or to handle dangerous materials, consult the manufacturer or manufacturer’s
representative. Examples of exceptional ambient conditions include windy areas, earthquake zones and corrosive
atmospheres. Molten metal is considered to be a dangerous material.

The equipment for general use may be used in a normal default industrial environment only, with the following
limitations:
Indoor products must be situated indoors, protected from outdoor weather conditions.
Ambient temperature is specified in the order confirmation. Typically it is between -20 °C (-4 °F) and +50 °C
(122 °F).
Air quality meets the requirements of the EN standard 14611-1 1999.
Product is not exposed to any corrosive chemicals or an explosive atmosphere.
If the product is used in an area prone to earthquakes, special hazards may appear in case of an earthquake.
 The air relative humidity must not exceed 90 %.

Note: There can be extra optional features in your equipment which can allow operation in special environments
such as outdoors, explosive. In case of doubt please contact your manufacturer or manufacturer’s
representative.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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OWNER'S MANUAL

2.5 Safety during installation

1 Ensure the competence of installation personnel

Owners SHALL ensure that installation personnel are professionally competent, professionally
qualified and are provided with adequate instructions for carrying out the work.

2 Ensure proper commissioning and handover

Owners SHALL ensure that the test loading, test drive and commissioning inspection have
been properly executed and that the handover log has been properly completed.
Owners SHALL ensure that components and steel structures of the product have been
inspected and certified as defect-free.

3 Documentation
At handover, check with your supplier that you have received all of the documents that you are
supposed to have and that they correspond to the equipment.
Owners SHALL ensure that all equipment documentation is available and is in the agreed
language.

4 Ensure availability of tools and equipment

The owner must ensure that tools and equipment are available for installation, in accordance
with the sales contract.
Lifting equipment, man lifters and test loads may be required.
Hand lines, securely attached to the building structure, should be used for lifting or lowering
materials and tools. Use proper safety equipment to prevent objects from falling when working
in high places.

5 Allow sufficient time

Owners must ensure that sufficient time has been reserved for installation and testing.

6 Prevent unauthorized access to the site

Owners must prevent unauthorized persons and bystanders from walking on or below the work
site.
Ensure that the secured area is spacious enough to prevent injuries which could occur as a
result of falling components or tools.

7 Minimize the risks of moving machinery

Make sure that there is no possibility for personnel or body parts to be struck, crushed or
compressed by moving machinery.
Owners must secure the area so that installation personnel are not at risk from the movements
of machines, automatic doors or adjacent cranes at the installation site.
Ensure that machinery and equipment cannot move during installation and servicing. Maintain
sufficient space in the working area to reduce the risks. Moving parts should be properly
shielded with guards to prevent entrapment. Safety devices must never be overridden.
Be prepared in case equipment moves in the wrong direction during testing.

8 Ensure that the support structure is prepared for the product

Owners must ensure that the support structure which the product is attached to is designed for
the load of the product and meets the specific requirements and tolerances.

9 Safety devices must be restored to operational status

Ensure that any safety devices which have been bypassed for testing purposes have been
restored to full operational status before allowing the equipment to be used for normal
operation. Never bypass a safety device for normal operation.

10 Check the environmental and space requirements

Ensure that the operating environment and space reserved for the equipment in the operating
location is suitable for all functions of the product.

11 Check for dimensional conformance

Immediately following installation and prior to commissioning, check that the supplied parts
conform to the drawings, instructions, parts lists and structural measurements. Discuss any
non-conformance with the supplier immediately.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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OWNER'S MANUAL

12 Ensure that there are no hazards from loose items

Items which are not properly secured to the equipment, such as tools or detached components,
could move or fall accidentally, with potentially serious consequences.
When dismantling the equipment, lower components to the ground at the earliest practical
opportunity.

2.6 Safety during use

This chapter only presents the owner’s responsibilities towards the operator with regard to equipment usage. See
instructions for the operator for detailed safety information concerning actual usage of the equipment.

1 Operator training
Owners SHALL ensure that operators are properly trained. Operators must know how to operate
the equipment safely before starting to work with the equipment.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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OWNER'S MANUAL

2.7 Safety during maintenance

Before and during the equipment maintenance, the owner must take the following precautions:

NOTICE Safe access to the equipment is the owner’s responsibility.

Use experienced service personnel, authorized by the manufacturer or

manufacturer’s representative, for servicing the equipment. The person
CAUTION
servicing the equipment must be competent for the task and must be familiar
with the servicing and inspection instructions.

After a collision or overload situation, inspection and repair operations to be

CAUTION
carried out on the equipment must be discussed with the supplier.

CAUTION Only use genuine spare parts approved by the manufacturer.

Before and during equipment maintenance, the equipment’s owner must be aware that the following precautions
should be taken by maintenance personnel:

1 Choose a safe working location

The equipment should be moved to a location where it will cause the least disturbance and where it
can be accessed easily.

2 Prevent unauthorized access to the site

Prevent unauthorized persons and bystanders from walking on or below the work site. For
example, you can lock doors, install barriers and display notices.
Ensure that the secured area is spacious enough to prevent injuries which could occur as a result
of falling components or tools.

3 Inform that equipment will be undergoing maintenance

Before starting maintenance, people must be properly informed that the equipment is being
removed from operation.

4 Ensure that there is no load on the lifting device

Before starting maintenance there should be no load on the hook or lifting device.

8 Use hand lines for lifting and lowering tools

Hand lines, securely attached to the building structure, should be used for lifting or lowering
materials and tools. Use proper safety equipment to prevent objects from falling when working in
high places.

9 Safety devices must be restored to operational status

Ensure that any safety devices which have been bypassed for testing purposes have been restored
to full operational status before allowing the equipment to be used for normal operation.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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OWNER'S MANUAL

10 Minimize the risks of moving machinery

Secure the area so that personnel are not at risk from the movements of machines, automatic
doors or adjacent cranes at the meintenanse site.
Ensure that machinery and equipment cannot move during installation and servicing.
Be prepared in case equipment moves in the wrong direction during testing.

11 Perform regular inspections and preventive maintenance

To ensure ongoing safe and efficient operation of the equipment, carry out regular inspections and
preventive maintenance in compliance with the instructions. Keep a record of all inspections and
servicing. If in doubt, contact the supplier of the equipment.

12 Returning the equipment to operation after overload or collision

After an overload or collision incident, the appropriate inspection and repair operations must be
discussed with the supplier of the equipment.

13 Pay special attention to all safety-critical components

Hooks, pulley blocks, load chain, brake, end stops, overload limiting device are all safety-critical
items which must always be kept in good order.
Ensure that safety devices (overload protector) work properly so that they provide protection
against human error.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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OWNER'S MANUAL

3 IDENTIFICATION

3.1 Trolley identification data

1 Brand Brand logo of the manufacturing company

2 Type Type of product.

3 Year Manufacturing year of product.

4 Maximum load Maximum load which can be lifted with the product

5 Serial number Serial number of product

6 Chain type The chain type used on the trolley

7 Address Address of the manufacturing company

Note: The example data in the above figure is shown for illustration purposes only and does not necessarily
match the data on your product.

3.2 Standards and directives

This state of the art product has been designed and manufactured to conform to European and international
standards and directives.

 Safety Standard ASME B30.16

 EN 13157
 EC Machine directive.

Owners should also make sure that the appropriate employees are suitably trained in how to operate this device in
accordance with applicable legislation, particularly accident prevention regulation BGV D6 / BGV D8.

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OWNER'S MANUAL

4 CONSTRUCTION

4.1 Identifying key parts of the product

1 Nut

2 Buffer

3 Suspension axle

4 Flanges

5 Travel wheel

6 Chain wheel (only geared model)

7 Spacers / Sleeves

8 Washers

9 Pin

10 No rock adjuster (only geared model)

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OWNER'S MANUAL

5 INSTRUCTIONS FOR THE OPERATOR

5.1 Operator’s responsibilities

Hoists and trolleys are used for various purposes, they handle different types of loads and are operated differently
by many operators. Many workers, as part of their regular job responsibilities, normally operate hoists as non-
dedicated operators.
Because the manufacturer of the trolley and hoist has no direct involvement or control over the products operation
and application, conforming to good safety practices is the responsibility of the owner, and the operating personnel
of the equipment. Only those Authorized Personnel and Qualified Personnel who can demonstrate that they have
read and understood this manual and that they understand the proper operation and maintenance of the product
should be permitted to work with it.

Failure to adhere to the instructions and warnings provided in this manual can
result in serious injury or death.

Operators SHALL:
1 Operators SHALL be trained by the owner of the equipment or a qualified designee and be
competent for the task.

2 Operators SHALL learn how to operate the equipment safely before actually starting to work with it.

3 Operators SHALL learn how to control the movements of the hook and load.

4 Operators SHALL be aware of any risk of accident posed by the operating site.

5 Operators SHALL familiarize themselves with the signs and warnings marked on the equipment.

6 Operators SHALL use this manual to familiarize themselves with the equipment and equipment’s
controls.

7 Operators SHALL be familiar with proper rigging procedures.

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OWNER'S MANUAL

8 Operators SHALL carry out daily inspections.

9 Always follow the local regulations.

Operators SHALL NOT:

1 Operators SHALL NOT operate the equipment when under the influence of alcohol or drugs.
Alcohol and drugs can impair judgment and thereby cause a hazard.

2 Operators SHALL NOT operate the equipment when under medication which may cause a hazard
to the operator or others. If unsure, consult your doctor or pharmacist. Always comply with local
regulations regarding working under the influence of medication.

3 Operators SHALL NOT operate the equipment while suffering from any illness or injury which might
impair their ability to properly use the equipment.

5.1.1 Checks to be done before every working shift

Before every working shift, the operator SHALL make the following checks to ensure that the product is in a safe
operating condition. By carrying out these simple checks, the operator can identify potential problems at any early
stage, thereby enhancing safety and minimizing downtime.

1 Check the general condition of

the trolley. 2 Visually check the operating
environment to make sure
that there are no new hazards
which might prevent the safe
use of the product.

3 Check that the chain has no

damages and that it is not
twisted. Check the fixing of the
chain ends.

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OWNER'S MANUAL

5.1.2 Load handling

See the lifting units own manual for safely lifting loads.

Note: If a customized or a customer provided grab device is used, follow its manual for the proper working
sequence.

Never use the equipment for lifting or transporting people. Lifting or

WARNING
transporting people could cause serious injury or death.

Never attempt to move a load greater than the capacity indicated on the
CAUTION
equipment.

Do not use the equipment for a purpose or in a situation for which it is not
CAUTION
designed.

Always observe the load while it is in motion to ensure that it does not collide with
NOTICE
anything or fall from the lifting device.

5.2 Operating the product

The trolley moves the lifted load from one place to another. Depending on the model, the trolley can either be
pushed or driven by chain. The trolley may not be dragged.

The trolley moves the rated load in a controlled manner when a manual force is applied to the hand chain, the
trolley can be moved in both directions.

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OWNER'S MANUAL

6 INSTALLATION AND COMMISSIONING

Before starting to install the device, visually check that the package in which the product has been delivered to you
is intact. Also check that the content of the delivery matches your order. If not, contact your supplier.
Carefully follow the installation instructions provided in the equipment's instruction manual.
The chain must be fitted in accordance with the instructions and oiled before any load is applied.
Verify that all safety items are in good working order (brake, end stop, and so on) in accordance with the instruction
manual.
Make sure that trolley stops are installed at the limits of trolley travel. Do not user trolley stops as a primary means
of stopping the trolley.

6.1 Installing the device

Make sure
 that the profile is secured.
 that the dimensions are compatible with the trolley that is going to be installed.

6.1.1 Adjustment of flanges

The trolley can be adjusted according to the different track widths.

Note: To make the measuring easier, check that the beam is at one end at the point where the
rounding starts.

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Procedure
Check the width B of the track.
The distance between the wheel flanges can be adjusted using the spacers and washers.
Make sure that the suspension axle is centered underneath the track. Depending on the tolerances of the washers
and spacers, the stacking can be different on the left side and on the right side. The distance between the flanges
and the center of the suspension axle must be equal.
In any case, provide at least one washer outside the flange, under the nut.
After adjustment, tighten the nuts. First tighten the nuts by hand. Lock the nuts by using a wrench. Tighten the nut
until the groove in the nut matches with the first bore in the shaft. Insert the pin.
When adjusting the dimension between the travel wheels, ensure that the measurement X is correct. The X
measurement is the total space between where the travel wheel begins its rounding, and the end of the beam.
For trolleys up to 2,000 kg: X = up to 3 mm
For trolleys over 2,000 kg: X = 3 – 5 mm
The above values are for guidance only. The clearance depends on the tolerance and the quality of the track.

Without assembling the trolley on the track

Place the trolley onto the track through either end of the hoist track.
Check the measurement X.
Remove the trolley from the track.
Adjust to the right width using the provided spacers and washers. Unused washers and spacers should be placed
on the outside of the flanges.
Place the trolley back on the track.
Check the measurement X.
If X is correct, fit the travel limit stops (not provided) at the end of the runway. Then tightened the nuts. First tighten
the nuts by hand. Lock the nuts by using a wrench. Tighten the nut until the groove in the nut matches the first bore
in the shaft. Insert the pin. IF NOT, go back to step 3.

Make sure that the suspension axle is centered on the track.

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OWNER'S MANUAL

Assembling the trolley on the track

See pictures on the next page.
If it is not possible to place the trolley onto the track through either end of the hoist track – for example, if the
mechanical stops are already in place – the trolley can also be installed by removing one of the flanges.
In this case:
1. Remove the nuts on one side of the trolley and move the flanges apart.
2. When one side of the trolley is secured onto the beam, move the other side into place.
3. Make sure that dimension X is correct.
4. Adjust to the right width using the provided spacers and washers. Unused washers and spacers should be
placed on the outside of the flanges.
5. Then tightened the nuts. First tighten the nuts by hand. Lock the nuts by using a wrench, tighten the nut
until the groove in the nut matches with the first bore in the shaft, insert the pin.

Note: Make sure that the suspension axle is centered on the track.

On the curved profiles, the driving wheels should be positioned on the outside of the curve.
Check these points after a repair, a maintenance operation, or a long stop.

Curve radius:
20,000
250 kg 500 kg 1,000 kg 2,000 kg 3,000 kg 5,000 kg 7,500 kg 10,000 kg 12,500 kg 16,000 kg
kg
1.0 m 1.0 m 1.5 m 2.0 m 2.0 m 2.0 m 3.0 m 3.0 m 3.0 m 3.5 m 3.5 m

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OWNER'S MANUAL

Assembly of a 250 – 2000 kg trolley

Assembly of a 3000 – 20000 kg trolley

Note: The remaining washers (not used to adjust the beam width) should be placed outside this plate as shown
on the above picture.

Note: Make sure that the suspension axle is centered on the track.

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OWNER'S MANUAL

Setting of axle "no rock"

Only for the chain travel trolley, 2000 kg or less

Adjust this when the trolley is put in its place.

The dimension "H" between the lower face of the beam and the upper line of the axle is 1 mm. This value can be
adjusted to get the best operation.

Adjusting the hand chain

It is recommended that you adjust the hand chain to a suitable height. To do this:
1. Locate the open chain link.
2. Open the chain link.
3. Adjust the length of the hand chain by removing extra chain links.
4. Ones the chain is at a suitable height, close the previously opened link.
5. Check that the link is not deformed.
6. Pull the entire length of the hand chain trough the chain block.

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trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
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OWNER'S MANUAL

7 MAINTENANCE

7.1 Why you must care about maintenance

 It is the product owner’s responsibility to organize proper regular inspections maintenance to ensure long-
term safety, reliability, durability, operability and warranty for the product. Keep this manual in a safe,
accessible location during the whole lifetime of the product.
 Owner must keep a record (log book) of all maintenance activities and usage relating to the product.
 Different maintenance actions must be carried out at different intervals and by different persons, all of whom
must be qualified and authorized to perform the checks which relate to them.
 Operators must carry out daily checks and minor lubrication. These checks are very important in catching small
faults before they become major faults.
 Maintenance actions, excluding the daily actions performed by operators, must be done by service personnel
who are authorized by the manufacturer or manufacturer’s representative.
 Owner must ensure that replacement parts and materials meet the specifications defined by the product
manufacturer.

Do not modify the product without the manufacturer’s permission. Any

WARNING modifications to the product structures or performance values must only be
made after they have been approved by the product’s manufacturer.

Modifying the product without the manufacturer or manufacturer’s representative

approval can invalidate the guarantee. Furthermore, the manufacturer does not
NOTICE
accept responsibility for accidents which happen as a consequence of unauthorized
modifications.

Failure to regularly and properly maintain the product can result in death,
WARNING
injury, or damage.

Do not allow the product to be used if it is not in proper condition. Contact a

service agent authorized by the manufacturer or manufacturer’s representative
WARNING
immediately in case of doubts! The usage of a defective product can result in
serious damage, injury, or death.

Only use genuine spare parts, materials, and lubricants approved by the
CAUTION product’s manufacturer or manufacturer’s representative. Consult the spare
part manuals for further information.

Before maintenance the owner must see the instructions in chapter “Safety
first”.

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OWNER'S MANUAL

7.2 Service personnel

Only authorized service personnel or an experienced service technician authorized by the manufacturer or
manufacturer’s representative may perform the detailed examinations necessary for scheduled maintenance. Such
examinations must be performed in accordance with the inspection and maintenance plan provided by the
product’s manufacturer. The original manufacturer or manufacturer’s representative has approved authorized
service personnel to maintain its products.
The owner or operator of the product must perform the daily checks and, if necessary, daily lubrication. Service
personnel authorized by the owner may also lubricate the product at the necessary intervals.

Note: Mechanical and electrical maintenance work requires special skills and tools to ensure safe and reliable
operation of the product. Maintenance work shall be carried out only by authorized service personnel or an
experienced service technician authorized by the product’s manufacturer or manufacturer’s representative.

7.3 Inspections
The operator or owner of a product must carry out regular inspections to ensure the safe operation. The product’s
owner must also keep record of the inspections and findings.
Periodic inspections must be carried out by authorized service personnel or experienced service technician
authorized by the product’s manufacturer or manufacturer’s representative. Inspections must be carried out
according to manufacturer’s instructions.

Note: If the working environment or product usage changes, the inspection and maintenance intervals may need
to be revised.

Note: Products used under harsh conditions may require shorter service intervals. Consult with the manufacturer
or manufacturer’s representative for a tailored service agreement.

Note: Periodic inspections SHALL be carried out in accordance with local regulations.

Any defects or abnormalities which are detected during the inspections must be
CAUTION investigated and corrected in accordance with the instructions relevant to
component in question.

Check Interval Qualification of personnel

For loose screws and signs of deformation or corrosion Annually Qualified mechanic
Condition of the drive pinion Annually Operator
Measurement of the wheel groove diameter Annually Operator
Lubrication of open gear monthly Operator

7.4 Spare parts and wear parts

Only use genuine spare parts and wear parts approved by the manufacturer.
CAUTION For detail information of spare part and wear part list, refer to the spare part
manual.

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OWNER'S MANUAL

For a list of spare parts, contact your local dealer.

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OWNER'S MANUAL

7.5 Lubrication

7.5.1 General lubrication instructions

The following table provides advice on the lubrication procedures which should be followed.

1 Handle lubricants carefully. Prevent leakages.

2 Keep lubricants away from heat and open fires. Do not smoke when handling lubricants.

3 Avoid contact with skin. Wear safety gloves and safety goggles when handling lubricants. Wash
hands thoroughly after lubrication.

4 Keep away from food and drink. Do not inhale any fumes or swallow lubricants.

5 Handle used lubricant as hazardous waste following local legal requirements.

Store used lubricant in containers indicated for the purpose and dispose by a licensed company.

6 The specified lubrication periods apply in favorable conditions and normal use. More frequent
lubrication is recommended in more demanding conditions and in heavy use, particularly of the
slide bearings.

Note: Do not use excessive lubricant. Excessive grease may cause bearing to overheat and reduces the lifetime
of the bearings.

Lubrication point Specifications Quantity

KP 0-K grease (DIN 51502)

Soap-based lithium + MoS 2
Wheel drive pinion Approx. melting point + 180°C As necessary
Worked penetration 355°C…385°C
Operating temperature

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OWNER'S MANUAL

7.6 Disposal of waste material

Waste material from installation, maintenance, or dismantling must be handled and disposed of according to local
regulations. From the sustainability point of view, the preferred waste handling methods are reuse, recycle as
material, recycle to energy, and as a final resort, safe disposal.
As waste regulations and types of recovery and disposal methods vary so much regionally, no general detailed
guidance can be given. The chart below gives example of manufacturer’s proposals for adequate waste handling
methods.

NOTICE Use always licensed recycling companies.

1 Metals should be recycled.

2 Electronics and electromechanical components should be collected separately and recycled.

Some electrical parts may be treated as hazardous waste, for example, standard fluorescent lamps
contain mercury.

3 Batteries and other energy storage components may contain hazardous substances. These items
should be collected separately and recycled according to local regulations.

4 Plastics should be either recycled as material or used for energy recovery or landfilled. PVC plastic
should be recycled according to local regulations.

5 Chemicals, such as oil, grease and other liquids must never be spilled onto the ground, soil, or
sewage. Waste oil and grease must be stored in containers indicated for the purpose. More
detailed information of chemical handling as waste can be found in the chemical’s Safety Data
Sheet that is available from manufacturer of the chemical.

6 Packing materials, like plastics, wood and cardboard, should be reused or recycled as material or
to energy.

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OWNER'S MANUAL

APPENDIX: TECHNICAL DATA

Manual trolley normal headroom
500 kg – 2000 kg

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OWNER'S MANUAL

Manual trolley normal headroom

Capacity
500 kg 1000 kg 2000 kg
250 kg
50–202 65–202 88–202
Range 1 50–202-
[mm] 188–310 188–310 188–310
Range 2

Range 1 303 316 340

D 278
Range 2 411 424 448
B 32 32 39 42
B0 18 24 28 36
B1 48 52 57 61
B2 16 20 25 28
C 60 62 81 96
E 12.5 17 20 22
F 173 186 225 272
G 80 84 101 124
H 190 210 242 296
J 15 20 24 30
K 50 55 62 76
L 62 67 76 92
N 30 34 38 38
P 99 106 135 159
Q (1) - - 146 146
S (1) - 4.3 5.7 3.4

U 19 19 24 27

Minimum radius of track curve [m] 1.0 1.0 1.5 2.0

Push travel Range 1 3.5 8 12 20

Weight (kg) Range 2 - 10 14 22
Geared travel Range 1 - - 14 22
Weight (kg) Range 2 - - 16 24
Effort on hand chain to
- - 36 60
move trolley (N)

Distance for 1 m of hand chain - - 0.275 0.285

(1) Dimensions only applicable for geared travel trolley.

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OWNER'S MANUAL

Manual trolley normal headroom

3,000 kg - 20,000 kg

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OWNER'S MANUAL

Manual trolley normal headroom

Capacity 3000 kg 5000 kg 7500 kg 10000 kg 12500 kg 16000 kg 20000 kg

Range 1 100–202 114–202 124–202 124–202 124–202 136–202 136–202
[mm]
Range 2 188–310 188–310 188–310 188–310 188–310 188–310 188–310

Range 1
D
356 325 394 400 358 416 449
Range 2
464 434 502 508 464 522 551
B 49 60 68 70 70 92 88
B0 44 48 50 50 50 50 50
B1 70 73 78 76 76 91 93.5
B2 30 39 49 53 53 75 75
C 140 161 176 187 187 283 278
E 25 33 38 39 39 51 51
F 322 360 410 434 442 555 555
G 144 158 185 200 200 272 272
H 346 384 434 458 466 579 579
J 28 35 43 50 50 64 68
K 96 108 130 132 134 168 175
L 114 126 150 155 155 197 217
N 42 42 45 46 45 64 60
P 192 226 247 265 265 390 390
Q (1) 38 58 68 67 64 78 78
S (1) 6.5 10.8 22 35 35 7 3.5

U 32 36 45 49 50 77 77

Minimum radius of track

2.0 2.0 3.0 3.0 3.0 3.5 3.5
curve (m)
Push travel Range 1 38 59 100 116
- - -
Weight (kg) Range 2 40 61 103 119
Geared travel Range 1 42 63 104 120 125 215 220
Weight (kg) Range 2 44 65 107 123 130 220 228
Effort on hand
chain to move 55 83 96 123 154 81 102
trolley (N)
Distance for 1
m of hand [m] 0.216 0.221 0.205 0.204 0.204 0.105 0.110
chain

(1) Dimensions only applicable for geared travel trolley.

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