Owner'S Manual: KMII-G-2000

V-101946-0018A-0119
12/10/2020
OWNER'S MANUAL
KMII-G-2000 TAG 2122-HT-226
JU-001-06-0018A-2122-00-30-0004 Rev. 0
English 01570794060090-0.ORD 12.1.2018
- - Peru -
VDDR: 11.01
Original instructions 015707940600903001-0 PS09456 12.1.2018
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 2018 © 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 Usage of the Product ................................................................................................................ 10
2.4 Operating Environment ........................................................................................................................... 11
2.5 Safety during Installation ......................................................................................................................... 12
2.6 Safety during Usage................................................................................................................................ 13
2.7 Safety during Maintenance ...................................................................................................................... 13
3 IDENTIFICATION ............................................................................................................................. 15
3.1 Identification Data ................................................................................................................................... 15
3.2 Standards and Directives ........................................................................................................................ 15
4 CONSTRUCTION ............................................................................................................................ 16
4.1 Identifying the Key Parts of the Product ................................................................................................... 16
5 INSTRUCTIONS FOR THE OPERATOR ......................................................................................... 17
5.1 Operator’s Responsibilities...................................................................................................................... 17
5.1.1 Checks to Be Done Before Every Work Shift .................................................................................... 18
5.1.2 Load Handling .................................................................................................................................. 19
5.2 Operating the Product ............................................................................................................................. 23
6 INSTALLATION AND COMMISSIONING ......................................................................................... 24
6.1 Installing the Device ................................................................................................................................ 24
7 MAINTENANCE ............................................................................................................................... 25
7.1 Why You Must Care About Maintenance ................................................................................................. 25
7.2 Service Personnel ................................................................................................................................... 26
7.3 Inspections ............................................................................................................................................. 26
7.3.1 Routine Inspections .......................................................................................................................... 26
7.4 Installing Parts on the Hoist ..................................................................................................................... 27
7.5 Spare Parts and Wear Parts.................................................................................................................... 29
7.6 Lubrication .............................................................................................................................................. 29
7.6.1 General Lubrication Instructions ....................................................................................................... 29
7.7 Disposal of Waste Material ...................................................................................................................... 30
APPENDIX: INSPECTING CHAIN WEAR .............................................................................................. 31
APPENDIX: INSPECTING THE HOOK OPENING ................................................................................. 32
APPENDIX: TRANSPORTING AND STORING THE PRODUCT ........................................................... 33
APPENDIX: TECHNICAL DATA............................................................................................................. 34
APPENDIX: CERTIFICATES.................................................................................................................. 37
This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 2/38
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.
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.
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
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
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.
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.
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.
Do not allow the hook, whether it is loaded or not, to pass over the heads of people below.
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.
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.
2.3 Intended Usage of the Product

The hand chain block is an entity which has been designed to perform common lifting and lowering operations,
within the limits specified in this document. The hoisting machinery for general use must not be modified or used for
any other purpose without the written approval of the manufacturer.
The hoisting 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.
The use of the equipment for horizontal moving is only allowed when the top hook, hoist body, load chain, hook
bottle/load hook are directly inline with the direction of loading. But it must be ensured that the force exerted on the
hoist, at any time, not be greater than the rated capacity marked on the unit.
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.
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.
OWNER'S MANUAL
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
Modifying the equipment without the manufacturer or manufacturer’s representative

NOTICE
modifications.
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) an d +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.
OWNER'S MANUAL
2.5 Safety during Installation
Ensure the competence of installation personnel

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

2 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.
Documentation
3 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.
Ensure availability of tools and equipment

4 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.
Allow sufficient time
5 Owners must ensure that sufficient time has been reserved for installation and testing.
Prevent unauthorized access to the site

6 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.
Minimize the risks of moving machinery
7 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.
Ensure that the support structure is prepared for the product
8 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.
Safety devices must be restored to operational status

9 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.
Check the environmental and space requirements

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

11 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.
OWNER'S MANUAL
Ensure that there are no hazards from loose items

12 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 Usage

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

Before and during 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:
Choose a safe working location

1 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 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.
OWNER'S MANUAL
Inform that equipment will be undergoing maintenance

3 Before starting maintenance, people must be properly informed that the equipment is being
removed from operation.
Ensure that there is no load on the lifting device

4 Before starting maintenance there should be no load on the hook or lifting device.
Use hand lines for lifting and lowering tools

8 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 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.

10 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.
Perform regular inspections and preventive maintenance

11 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.
Returning the equipment to operation after overload or collision

12 After an overload or collision incident, the appropriate inspection and repair operations must be
discussed with the supplier of the equipment.
Pay special attention to all safety-critical components

13 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.
OWNER'S MANUAL
3 IDENTIFICATION
3.1 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 hoist
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.
OWNER'S MANUAL
4 CONSTRUCTION
4.1 Identifying the Key Parts of the Product
Note: The figure above is shown for illustration purposes only and may not exactly match your product.
Key parts of the hoist
1 Hoist frame
2 Rating plate
3 Load chain
4 Hand chain
5 Pulley block / Hook bottle
6 Top hook
7 Load hook
OWNER'S MANUAL
5 INSTRUCTIONS FOR THE OPERATOR
5.1 Operator’s Responsibilities

Hoists 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 hoist has no direct involvement or control over the hoist’s operation and
application, conforming to good safety practices is the responsibility of the owner, and the equipment’s operating
personnel. 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:
Operators SHALL be trained by the owner of the equipment or a qualified designee and be
1 competent for the task.
Operators SHALL learn how to operate the equipment safely before actually starting to work with it.
2
Operators SHALL learn how to control the movements of the hook and load.
3
Operators SHALL be aware of any risk of accident posed by the operating site.
4
Operators SHALL familiarize themselves with the signs and warnings marked on the equipment.
5
Operators SHALL use this manual to familiarize themselves with the equipment and equipment’s
6 controls.
Operators SHALL be familiar with proper rigging procedures.

7
OWNER'S MANUAL
Operators SHALL carry out daily inspections.

8
Always follow the local regulations.

9
Operators SHALL NOT:

Operators SHALL NOT operate the equipment when under the influence of alcohol or drugs.
1 Alcohol and drugs can impair judgment and thereby cause a hazard.
Operators SHALL NOT operate the equipment when under medication which may cause a hazard
2 to the operator or others. If unsure, consult your doctor or pharmacist. Always comply with local
regulations regarding working under the influence of medication.
Operators SHALL NOT operate the equipment while suffering from any illness or injury which might
3 impair their ability to properly use the equipment.
5.1.1 Checks to Be Done Before Every Work 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.
Check the general condition of Visually check the operating

1 the hoist.
2 environment to make sure
that there are no new hazards
which might prevent the safe
use of the product.
Visually check the chains for Inspect the load hook for
3 any deformation, damage, or 4 nicks, gouges, deformation of
twists. Check the chain for the throat opening, wear on
cleanness and correct the saddle or load bearing
lubrication according to the point, and twisting. Also check
instructions given in chapter that the hook rotates freely.
Lubrication. Ensure that the hook safety
latch is on the hook, is in
good condition, and closes
automatically.
OWNER'S MANUAL
Check that the chain has no

5 damages and that it is not
twisted. Check the fixing of the
chain ends.
Check that the chain is
correctly lubricated according
to the instructions given in
chapter.
5.1.2 Load Handling

Note: If a customized or a customer provided grab device is used, follow its manual for the proper working
sequence.
To avoid damaging the hook, lifting devices must only

1 be positioned on the load bearing surface of the hook.
That is, the lowest point of the hook.
Ensure that the hook safety latches are closed. Check

2 that the safety latch is not subjected to any force by
the load.
The weight of the load must be centered on the center

3 line of the hook forging so that the load does not bend
the neck of the hook. Never try to lift anything with the
tip of the hook!
Load hook (if applicable)

4 If the hook is damaged or buckled, it should be
swapped out. The hook should be swapped out if:
Safety latch is broken or not working properly
Hook’s opening becomes wider.
The image shows:
1) Buckled hook
2) Normal hook
3) Hook opening.
OWNER'S MANUAL
Ensure that the load lifted is not greater than the rated
5 capacity marked on the unit. Check that it is balanced
and safely fastened at the lifting points. The load must
not be able to slide, slip, or detach itself when
suspended.
Before operating the hoist ensure that the top hook,

6 hoist body, load chain, hook bottle/ load hook are
directly inline with the direction of loading, no matter if
it is vertical or horizontal. But it must be ensured that
the force exerted on the hoist, at any time, is not
greater than the rated capacity marked on the unit.
Do not side drag the load along the ground while the
7 hook is in a slanting position, relative to the hoist body.
Or the hook and hoist might be damaged.
The operator must ensure that the product or the load

8 does not collide with anything or fall from the lifting
device.
Do not divert attention from the load while operating

9 the lifting device.
Never leave the load hanging on the hook unattended.

10
OWNER'S MANUAL
The product is designed for lifting and transporting

11 material only.
Never use the equipment for lifting or transporting people. Lifting or

WARNING
transporting people could cause serious injury or death.
CAUTION Never use the safety devices as a means of measuring loaded weight.
CAUTION Never use the load chain as a sling.
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.
Balancing the load

The hook, slings, and harnesses must be positioned so that the pulling force of the product lies on the load’s centre
of gravity so that the load is balanced. When the operators begin to move the load, they must check that it is
properly balanced before lifting it high off the ground. If the load is not balanced, lower it down and adjust the lifting
point.
Lifting centrally balanced loads

1 The centre of gravity is usually in line with the centre of the load.
If the contents of the container cannot move around, the balance of the load stays the
same.
Lifting off-centre balanced loads

2 The centre of gravity of an off-centre balanced load is usually towards the heavier end
of the load.
If the contents of the container cannot move around, the balance of the load stays the
same.
OWNER'S MANUAL
Never try to balance an unbalanced load with your hands. Lower the load and
WARNING adjust the lifting point. Trying to balance an unbalanced load with your hands
could cause death or serious injury.
WARNING Make sure to raise or lower loads smoothly!
Stop lifting or lowering the load if the effort required on the hand chain is
CAUTION greater than normal because the equipment may be overloaded. The unit must
always be operated by hand power only.
Shock loading
The product and accessories are designed to take up the weight of loads gradually and steadily. They are not
designed to withstand sudden increases or decreases in the apparent weight of the load. Shock loading can occur
in any situation where the load on the product suddenly increases or decreases. Some examples of how shock
loading can occur are shown below.
Change of load balance

1 A change in load balance can suddenly pull on the hoisting chain.
Unstable load
2 If the load is unstable, it can exert sudden force on the hoisting chain.
The contents of packing cases should be securely fastened so that they cannot move
around during lifting.
Rapid load reduction

3 A sudden loss of the load can cause the trolley or hoist to jump.
Avoid shock loading the product. Shock loading the product could damage the product
NOTICE
or the load.
After a shock load, equipment must not be used before authorized service
personnel or an experienced service technician authorized by the manufacturer
CAUTION or manufacturer’s representative has determined that the equipment is safe to
use. The usage of a defective product can result in serious damage, injury, or
death.
OWNER'S MANUAL
5.2 Operating the Product

The hoist lifts and lowers the rated load in a controlled manner when a manual force is applied to the hand chain.
The hoist is equipped with an integrated load pressure brake, which keeps the load securely in position when the
hand chain is released. The brake controls the rated load when the hoist is being operated in either direction.
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.
If the chain hoist is attached to a trolley, refer to the trolleys own manual.
6.1 Installing the Device

Attach the suspension hook to the supporting structure or trolley.
Check if the hook is properly suspended.
Check if load chain and hand chain are hanging down freely and that they are not bent or twisted.
Pull once the whole length of the hand chain without load.
Perform multiple lifting and lowering motions, using the entire length of the load chain, without load.
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 can only be
made after they have been approved by the product’s manufacturer.

NOTICE
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 your spare
part manuals for further information.
Before maintenance the owner must see the instructions in chapter “Safety
first”.
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 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 shall carry out regular inspections to ensure the safe operation. The product’s
owner shall 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.
7.3.1 Routine Inspections

The operator of the device must inspect it on a daily basis to keep the operator and other people in the operating
radius of the device safe. Operator must inspect the device for visible damage and wear, and list any unusual
noises that the device makes when in use.
to be revised.
OWNER'S MANUAL
The following to be checked on routine basis:
Interval Type of check Inspection / Maintenance

Check the external condition of the unit
Check the condition of mechanism
Check the condition of the load chain and the attachments
Check the condition of the hooks
Check the condition of the hook safety latch
1 month Visual examination
Check the condition of accessories
Clean the dust from the equipment
Check the greasing:
Lubricate the load chain with a brush or rag
Use an oil can to grease the hooks at the top and bottom, and the hoist (blocks and pulleys)
Check the operation of the brake
Check the condition of the load wheel
6 months In-depth examination
Inspect the load chain for wear or distortion
Inspect the hooks for wear or distortion
12 months Maintenance Open the gear cover and grease the gears
7.4 Installing Parts on the Hoist

Load Chain Installation
Place the end of the load chain on the load wheel, opposite side of the slack chain fixing point.
Check that the chain is not twisted and that it runs smoothly on the chain wheel, while rotating the chain wheel by
pulling on the hand chain.
Fasten the slack end of the chain to the chain fixing point.
Install the fall stop assembly. Fall stop assembly must be place at least 150 mm [6”] from the free end of the load
chain.
For easier installation, it is recommended, to take a flexible wire of about 50 cm (20 in) in length and insert the wire
between the load wheel and the chain guide until it comes out on the other side.
Hook the chain onto the end of the wire on the load side.
Pull the wire to bring the chain in contact with the load wheel while ensuring that the chain is not twisted.
Continue with step 2 from above. Installing the load hook

Insert the free end of the chain in to the hook block.
Insert load pin
Tighten the nut on the load pin, check that the chain in securely fastened to the hook.
Dissasembling the load limiter (optional)

Load limiter, 3 screws Load limiter center nut
1. Remove the hand chain wheel cover. 1. Remove the hand chain wheel cover.
2. Remove the hand chain from the hand chain wheel. 2. Remove the hand chain from the hand chain wheel.
3. Remove each M5 screw (4). 3. Bend the safety clip open (5).
4. Remove the connection plate (3). 4. Remove the center nut (4).
5. Pull off the hand chain wheel (1). 5. Pull off the hand chain wheel (1).
OWNER'S MANUAL
Load limiter, 3 screws Load limiter, center nut
1 Hand chain wheel Hand chain wheel
2 Brake disc Brake disc
3 Connection plate Belleville washer
4 Screw M5 X15 Nut
5 Disk spring set Safety clip
6 - Load limiter lining
Installing the hand chain wheel

Load limiter, 3 screws Load limiter center nut
1. Place the hand chain on the chain wheel (1). 1. Place the hand chain on the chain wheel (1).
2. Add the connection plate. 2. Insert the Belleville washer.
3. Insert each M5 screw (4) making sure the stack up of 3. Tighten the center nut (4).
the disc springs is correct.
4. Set the overload limiter (see below). 4. Set the overload limiter (see below).
5. Bend the safety clip back (5).
Setting the overload limiter

The overload limiter can be adjusted by turning the three screws or the center nut clockwise for increasing the
capacity. For lowering the lifting capacity loosen the screws or center nut counterclockwise.
1. Make sure that the friction surfaces are clean, free from any rust, dirt, dust, oil and so on.
2. When using a hoist with a three-screw load limiter tighten each M5 screw (4) evenly until tight. When using
a hoist with a center nut load limiter, tighten the center nut.
3. Set it at a level that the hoist can lift 125% of the nominal load but cannot be damaged. Use a test load that
is equal to 125% of the nominal load.
4. Loosen each M5 screw an equal number of turns, or loosen the center nut. Until the hand wheel slides and
the test load can no longer be lifted.
OWNER'S MANUAL
5. Test with load at capacity. Check that the safety clip is bent back.
6. Reinstall the hand chain wheel cover.
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, by twisting it 90°.
3. Adjust the length of the hand chain by removing extra chain links. Make sure the open chain does not get
twisted.
4. Ones the chain is at a suitable height, properly close the previously opened link.
5. Check that the link is not deformed and that there are no sharp edges.
6. To check the function of the hoist, pull the entire length of the hand chain trough the chain block.
7.5 Spare Parts and Wear Parts

CAUTION Only use genuine spare parts and wear parts approved by the manufacturer.
For a spare part lis, contact your local dealer.
7.6 Lubrication
7.6.1 General Lubrication Instructions

Lubrication has a considerable influence on the service life of the load chain. Therefore chains must be lubricated
before commissioning and during operation with a penetrating gear lubricant oil.
The chains must be lubricated in an unloaded condition, so that the lubricant can penetrate into the chain links.
Always keep the chain clean and free of debris. Clean as necessary with paraffin or diesel, drain, and reoil. Do not
clean the chain with thinners or degreasing agents under any circumstances.
The following table provides advice on the lubrication procedures which should be followed.
Chain
1 Lubricate the chain carefully before the first run (commissioning). Grease the chain with a
substantial amount of lubricant and make sure that the chain is lubricated all over its surface and
links, especially on all contact areas between the chain links.
To extend chain lifetime, continue to lubricate the chain within regular intervals.
The lubrication interval varies from a minimum of one week to one year, depending on the usage.
Lubricate before there are any signs of corrosion or dryness.
Using the chain without proper and sufficient lubrication results in a strong increase of chain wear
and can cause chain breakage.
Lubricate the chain with a suitable lubricant. The lubricant for the chain must be water resistant,
non-adhesive oil or grease which is able to penetrate.
Excessive lubrication may cause dribbling.
Handle lubricants carefully. Prevent leakages.

2
OWNER'S MANUAL
Keep lubricants away from heat and open fires. Do not smoke when handling lubricants.
3
Avoid contact with skin. Wear protection gloves and safety goggles when handling lubricants. Wash
4 hands thoroughly after lubrication.
Keep away from food and drink. Do not inhale any fumes or swallow lubricants.
5
Used lubricant must be handled as hazardous waste following local legal requirements.
6 Store used lubricant in containers indicated for the purpose and dispose by a licensed company.
The specified lubrication periods apply in favorable conditions and normal use. More frequent
7 lubrication is recommended in more demanding conditions and in heavy use, particularly of the
slide bearings.
7.7 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.
Metals should be recycled.

1
Electronics and electromechanical components should be collected separately and recycled.
2 Some electrical parts may be treated as hazardous waste, for example, standard fluorescent lamps
contain mercury.
Batteries and other energy storage components may contain hazardous substances. These items
3 should be collected separately and recycled according to local regulations.
Plastics should be either recycled as material or used for energy recovery or landfilled. PVC plastic
4 should be recycled according to local regulations.
Chemicals, such as oil, grease and other liquids must never be spilled onto the ground, soil, or
5 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.
Packing materials, like plastics, wood and cardboard, should be reused or recycled as material or
6 to energy.
OWNER'S MANUAL
APPENDIX: INSPECTING CHAIN WEAR
Measuring wear on the chain
Note: The chain should be inspected regularly for wear, rust, and corrosion.
VISUAL CHECKS
Examine visually for gouges, nicks, weld splatter, corrosion, or distorted links and slacken chain.
A chain with excessively pitted, corroded, nicked, gouged, twisted, or worn links should be replaced
with a factory approved chain.
MEASURE LINK THICKNESS (d)
Measure the dimension (d) at several points of the chain and calculate the dimension (dm).
dm = (d1 + d2) /2 ≤ 0.9 * dn
dn = Nominal
MEASURE ELONGATION (P)
Link wear must not exceed 3% of the specified diameter of the load chain. This dimension P
depends on chain type (new chain).
Measure the load chain over 11 links as shown. Compare the measurement with the appropriate
value of the Dimension over 11 links for a new load chain. Replace the unit if the link wear exceeds
3%.
Load Chain ∅ x pitch P = Dimension over 11 links Number of falls

[kg] [mm] [mm]
250 4*12 132 (+0.4, -0.2) 1
500 5*15 165 (+0.5,-0.3) 1
1000 6*18 198 (+0.6,-0.4) 1
1500 7*21 231 (+0.7,-0.4) 1
2000 8*24 264 (+0.8,-0.5) 1
3000 10*28 308 (+1,0,-0.6) 1
5000 9*27 297 (+0.9,-0.5) 2
7500 9*27 297 (+0.9,-0.5) 3
10000 9*27 297 (+0.9,-0.5) 4
12500 9*27 297 (+0.9,-0.5) 5
16000 9*27 297 (+0.9,-0.5) 6
20000 9*27 297 (+0.9,-0.5) 8
Do not assume that a load chain is safe because it measures below replacement
points that are given here. Other factors, such as those mentioned in visual
CAUTION
checks above, may render the chain unsafe or ready for replacement long
before elongation replacement is necessary.
OWNER'S MANUAL
APPENDIX: INSPECTING THE HOOK OPENING
Measuring wear on the hook

Wear on the suspension and lifting hooks should be checked regularly. Damaged safety catches should be
replaced immediately.
Visual checks
Hook surface should be free of significant rust, weld splatter, deep nicks, or gouges.
Check for damage from chemicals, deformation, or cracks or allowing the hook latch to bypass
hook tip.
Any hook that is twisted or has excessive throat opening indicates abuse or
WARNING overloading of the hoist. Other load bearing components of the hoist should be
inspected for damage.
Measure hook opening (a2)
Hooks must be replaced if it has cracks or if the maximum dimension (a2) on the lifting hook is
greater than the initial dimension by more than 10%.
Note: Due to many types and sizes of hooks that can be furnished and specifically requested, it is recommended
that you measure the actual throat opening of the hook as originally furnished and record it on the above sketch
and retain for a permanent record. This record can then be used for determining when the hook must be
replaced due to deformation or excessive throat opening.
OWNER'S MANUAL
APPENDIX: TRANSPORTING AND STORING THE PRODUCT

Transportation Instructions
Products must be loaded and transported with caution and using appropriate methods, making proper
preparations and taking appropriate caution.
Loading or transporting products is prohibited if your alertness or working ability is impaired, for example by
medication, illness or injury.
Load must be securely fastened during transportation.
During loading and transportation, the product package must be orientated in the same way as when it was
received from the manufacturer. Inverting the product could cause lubricants to leak.
Storage Instructions
Product should be stored at room temperature.
Product shall be protected from dust and humidity.
Product shall be stored the same way up as it would be during normal operation.
Product shall be protected from adverse weather conditions, if stored outdoors.
Defects or faults which are due to improper transportation or storage are not covered
NOTICE
by the product’s warranty.
NOTICE Essential parts of the product can become damaged if stored improperly.
OWNER'S MANUAL
APPENDIX: TECHNICAL DATA
With galvanized load chain

Extra [m] of
Weight Effort to hand
Load weight
Capacity Body A B C D E Ø a1 a2 for 3-m raise chain
Falls chain per m
[kg] size [mm] [mm] [mm] [mm] [mm] [mm] [mm] lift SWL needed
size lift
[kg] [N] to lift 1
[kg] m
250 250 1 4x12 121 115 280 70 69 31 21 6.5 0.4 235 17.7
500 500 1 5x15 148 132 345 85 83 35 22 9.3 0.6 240 32.5
1000 1000 1 6x18 172 151 376 95 88 40 26 12.2 0.8 250 53.9
1500 1500 1 7x21 196 173 442 115 93 45 31 16.5 1.1 265 78.9
2000 2000 1 8x24 210 175 470 120 94 49 35 19.5 1.4 335 92.8
3000 3000 1 10x28 255 205 548 160 104 55 39 32 2.2 372 105.6
5000 5000 2 9x27 280 189 710 180 100 65 45 41.3 3.6 360 395
7500 7500 3 9x27 433 189 690 274 110 75 54 62 5.4 380 590
10000 10000 4 9x27 433 189 765 275 110 80 54 78.5 7.2 380 790
12500 12500 5 9x27 430 220 835 290 130 80 54 110 9.0 380 1180
16000 16000 6 9x27 718 200 900 359 110 95 71 135 10.8 380 2 x 590
20000 20000 8 9x27 840 200 950 420 110 106 75 192 14.4 380 2 x 790
Lower and upper hooks have same dimensions, galvanized chain is grade 80 T-Class.
HCB 250 - 3,000 kg
OWNER'S MANUAL
HCB 5,000 kg HCB 7,500 kg
HCB 10,000 kg , 12,500 kg HCB 16,000 kg , 20,000 kg
OWNER'S MANUAL
Capacity with stainless steel load chain

Same hook size as with galvanized load chain.
Effort to raise SWL

Capacity [kg] Body size Falls Load chain size
[N]
4x12
250 250 1 235
450 500 1 5x15 216

6x18
700 1000 1 175
950 1500 1 7x21 167

8x24
1250 2000 1 210
10x28
1950 3000 1 241
9x27
3000 5000 2 216
9x27
4500 7500 3 228
9x27
6000 10000 4 228
Stainless steel chain is grade 50
Capacity with stainless steel load chain & stainless steel lower hook
Same hook size for top hook as with galvanized load chain
Lower hook type Effort to raise

Load C Ø a1 a2
Capacity [kg] Body size Falls DIN15401-M SWL
chain size [mm] [mm] [mm]
EN1.4404 / 316L [N]
250 250 1 4x12 300 30 21 RSN012 235

450 500 1 5x15 360 36 22 RSN025 216
700 1000 1 6x18 385 40 26 RSN04 175
950 1500 1 7x21 460 48 33 RSN08 167
1250 2000 1 8x24 480 48 33 RSN08 210
1950 3000 1 10x28 570 55 41 RSN1.6 241
3000 5000 2 9x27 810 63 41 RSN2.5 216
Stainless steel chain is grade 50
OWNER'S MANUAL
APPENDIX: CERTIFICATES
Hook Certificate
Breaking W
Load Test load Material Marking X Y H
load (min) Hook width
[kg] [kg] [kg] [mm] [mm] [mm] [mm]
250 500 1000 20Cr 0.25 25.0 34.6 16.2 13.5 (0;+1)
500 1000 2000 20Cr 0.5 29.4 42.0 19.3 15.5 (-0.5;+1)
1000 2000 4000 20Cr 1 34.0 45.0 25.1 20.5 (-0.5;+1)
1500 3000 6000 20Cr 1.5 38.0 52.0 28.8 24 (-0.5;+1)
2000 4000 8000 20Cr 2 43.0 60.0 33.4 27 (-0.8;+1.6)
3000 6000 12000 20Cr 3 47.5 67.0 38.6 32 (-0.8;+1.6)
5000 10000 20000 20Cr 5 53.5 75.0 44.5 42 (-0.9;+1.8)
7500 15000 30000 20Cr 7.5 61.7 93.0 52.1 39 (-1;+1)
10000 20000 40000 35CrMo 10 69.0 102.0 62.3 47 (-1;+2)
12500 25000 50000 35CrMo - 69.0 102.0 62.3 47 (-1;+2)
16000 32000 64000 20Cr - 84.0 - 88.0 66 (-1.1;+2.2)
20000 40000 80000 20Cr 20 84.0 - 88.0 66 (-1.1;+2.2)
Chain certificate
Load Chain ∅ x pitch A = Dimension over 11 links Number of falls
[kg] [mm] [mm]
250 4*12 132 (+0.4, -0.2) 1
500 5*15 165 (+0.5,-0.3) 1
1000 6*18 198 (+0.6,-0.4) 1
1500 7*21 231 (+0.7,-0.4) 1
2000 8*24 264 (+0.8,-0.5) 1
3000 10*28 308 (+1,0,-0.6) 1
5000 9*27 297 (+0.9,-0.5) 2
7500 9*27 297 (+0.9,-0.5) 3
10000 9*27 297 (+0.9,-0.5) 4
12500 9*27 297 (+0.9,-0.5) 5
16000 9*27 297 (+0.9,-0.5) 6
20000 9*27 297 (+0.9,-0.5) 8
OWNER'S MANUAL
CHAIN CERTIFICATE
_________________________________________________________________________
Manufacturer No. 157079406/90
Customer's reference PO00006611
Batch Number 0000163244
Serial number of the hoist 100137138
Chain Type COROLIM
Length 3.700 M
Size (diameter x pitch) 8 X 24 MM
Class T
Grade G80
Maximum working load, 1 fall, M5/M3 2000 KG
Break load (kN) 80
Total breaking elongation 10 %
We do hereby certify that the particulars above are correct.
Konecranes Inc. Date

4505 Gateway Boulevard 08-05-2019
45502 SPRINGFIELD, OH
USA
EC DECLARATION OF CONFORMITY
(Machinery Directive 2006/42/EC, Annex II, sub. A)
_________________________________________________________________________
Manufacturer: Konecranes France SA

2 Boulevard de I'Industrie
28500 Vernouillet
FRANCE
Name and address of the person authorised to compile the technical file:
Loïc Bernard
2 Boulevard de l'Industrie
28500 Vernouillet
FRANCE
The manufacturer declares that the:

Product description: Manual Chain Hoist
Serial number: 100137138
Model: KMII-G-2000
Customer's reference: PO00006611
- is in conformity with the relevant provisions of the Machinery Directive 2006/42/EC
- is manufactured according to the following harmonized standard: EN 13157.
Date and place of issue: 08-05-2019 Vernouillet, FRANCE

Issued by:
Guillaume Arnal
Factory Director
HOIST TEST CERTIFICATE
_________________________________________________________________________
References
Manufacturer No. 157079406/90 Customer's reference PO00006611
Hoist
Serial number 100137138 Load chain type G Galvanized
Product type KMII-G-2000 Reeving system 01 1 x 1 falls, normal reeving
Height of lift 3.5 m Chain batch number 0000163244
Load 2,000 kg Chain length 3.700 m
Trolley
Serial number - Trolley type -
Trolley travel type - Flange width -
Factory tests
Dynamic overload test with 125% load
Overload set at 110% load
Konecranes Inc.
Date
4505 Gateway Boulevard
08-05-2019
45502 SPRINGFIELD, OH
USA
OWNER'S MANUAL
KPT-2000-88-202
English 01570794060250-0.ORD 12.1.2018
- - Peru -
Original instructions 015707940602503001-0 PS09078 12.1.2018
This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary
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
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.
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.
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
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
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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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.
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.

NOTICE
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.
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.
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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Modifying the equipment without the manufacturer or manufacturer’s representative

NOTICE
modifications.
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.
OWNER'S MANUAL
2.5 Safety during installation

Ensure the competence of installation personnel
1 Owners SHALL ensure that installation personnel are professionally competent, professionally
qualified and are provided with adequate instructions for carrying out the work.
Ensure proper commissioning and handover

2 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.
Documentation
3 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.
Ensure availability of tools and equipment

4 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.
Allow sufficient time
5 Owners must ensure that sufficient time has been reserved for installation and testing.

6 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 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.
Ensure that the support structure is prepared for the product
8 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 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.
Check the environmental and space requirements

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

11 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.
OWNER'S MANUAL
Ensure that there are no hazards from loose items

12 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.
Operator training
1 Owners SHALL ensure that operators are properly trained. Operators must know how to operate
the equipment safely before starting to work with the equipment.
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:
Choose a safe working location

1 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 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.
Inform that equipment will be undergoing maintenance
3 Before starting maintenance, people must be properly informed that the equipment is being
removed from operation.
Ensure that there is no load on the lifting device

4 Before starting maintenance there should be no load on the hook or lifting device.
Use hand lines for lifting and lowering tools

8 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 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.
OWNER'S MANUAL

10 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.
Perform regular inspections and preventive maintenance

11 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.
Returning the equipment to operation after overload or collision

12 After an overload or collision incident, the appropriate inspection and repair operations must be
discussed with the supplier of the equipment.
Pay special attention to all safety-critical components

13 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.
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.
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)
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:
Operators SHALL be trained by the owner of the equipment or a qualified designee and be
1 competent for the task.
Operators SHALL learn how to operate the equipment safely before actually starting to work with it.
2
Operators SHALL learn how to control the movements of the hook and load.
3
Operators SHALL be aware of any risk of accident posed by the operating site.
4
Operators SHALL familiarize themselves with the signs and warnings marked on the equipment.
5
Operators SHALL use this manual to familiarize themselves with the equipment and equipment’s
6 controls.
Operators SHALL be familiar with proper rigging procedures.

7
OWNER'S MANUAL
Operators SHALL carry out daily inspections.

8
Always follow the local regulations.

9
Operators SHALL NOT:

Operators SHALL NOT operate the equipment when under the influence of alcohol or drugs.
1 Alcohol and drugs can impair judgment and thereby cause a hazard.
Operators SHALL NOT operate the equipment when under medication which may cause a hazard
2 to the operator or others. If unsure, consult your doctor or pharmacist. Always comply with local
regulations regarding working under the influence of medication.
Operators SHALL NOT operate the equipment while suffering from any illness or injury which might
3 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.
Check the general condition of Visually check the operating

1 the trolley. 2 environment to make sure
that there are no new hazards
which might prevent the safe
use of the product.
Check that the chain has no

3 damages and that it is not
twisted. Check the fixing of the
chain ends.
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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.
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.
OWNER'S MANUAL
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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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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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.
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.
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.

NOTICE
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”.
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.
to be revised.
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.
OWNER'S MANUAL
For a list of spare parts, contact your local dealer.
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.
Handle lubricants carefully. Prevent leakages.

1
Keep lubricants away from heat and open fires. Do not smoke when handling lubricants.
2
Avoid contact with skin. Wear safety gloves and safety goggles when handling lubricants. Wash
3 hands thoroughly after lubrication.
Keep away from food and drink. Do not inhale any fumes or swallow lubricants.
4
Handle used lubricant as hazardous waste following local legal requirements.

5 Store used lubricant in containers indicated for the purpose and dispose by a licensed company.
The specified lubrication periods apply in favorable conditions and normal use. More frequent
6 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
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.
Metals should be recycled.

1
Electronics and electromechanical components should be collected separately and recycled.
2 Some electrical parts may be treated as hazardous waste, for example, standard fluorescent lamps
contain mercury.
Batteries and other energy storage components may contain hazardous substances. These items
3 should be collected separately and recycled according to local regulations.
Plastics should be either recycled as material or used for energy recovery or landfilled. PVC plastic
4 should be recycled according to local regulations.
Chemicals, such as oil, grease and other liquids must never be spilled onto the ground, soil, or
5 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.
Packing materials, like plastics, wood and cardboard, should be reused or recycled as material or
6 to energy.
OWNER'S MANUAL
APPENDIX: TECHNICAL DATA

Manual trolley normal headroom
500 kg – 2000 kg
OWNER'S MANUAL
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.
OWNER'S MANUAL

3,000 kg - 20,000 kg
OWNER'S MANUAL
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.

Owner'S Manual: KMII-G-2000

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V-101946-0018A-0119

Original instructions 015707940600903001-0 PS09456 12.1.2018

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

1.1 Foreword: About this manual

1.2 Symbols used in this manual

1.3 Safety alert symbols and signal words

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

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

INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT

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

1.4 Questions and comments

1.5 Exclusion of warranty

1.6 Manual use

1.7 Environmental information

1.7.1 Lifecycle environmental impacts

ANSI American National Standards Institute.

2.1 Personal Protective Equipment (PPE)

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

2.1.1 Fall Protection

2.2 Owner’s Responsibilities

2.2.1 General Safety Issues

No modifications or additions to the product structures or performance values

Modifying the product without the manufacturer or manufacturer’s representative

Maintain safe conditions under the load

Maintain the lighting

Maintain operating and safety requirements

Maintain the operating conditions

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

Keep the product in a safe condition

Ensure that signs are maintained in good condition

Keep the working site clean

2.3 Intended Usage of the Product

DO NOT ALLOW THE EQUIPMENT TO BE USED FOR LIFTING PERSONNEL

No modifications or additions to the equipment structures or performance

CAUTION Never use the hoist as an earth reference for welding

Modifying the equipment without the manufacturer or manufacturer’s representative

2.4 Operating Environment

USING THE EQUIPMENT IN AN ENVIRONMENT FOR WHICH IT IS NOT

2.5 Safety during Installation

Ensure the competence of installation personnel

Ensure proper commissioning and handover

Ensure availability of tools and equipment

Prevent unauthorized access to the site

Safety devices must be restored to operational status

Check the environmental and space requirements

Check for dimensional conformance

Ensure that there are no hazards from loose items

2.6 Safety during Usage

2.7 Safety during Maintenance

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

Use experienced service personnel, authorized by the manufacturer or

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

CAUTION Only use genuine spare parts approved by the manufacturer.

Choose a safe working location

Prevent unauthorized access to the site

Inform that equipment will be undergoing maintenance

Ensure that there is no load on the lifting device

Use hand lines for lifting and lowering tools

Safety devices must be restored to operational status

Minimize the risks of moving machinery

Perform regular inspections and preventive maintenance

Returning the equipment to operation after overload or collision

Pay special attention to all safety-critical components