SERVICE

Retrofits
for
cranes
 Maximize safety Co
and productivity in
ive Mainrrect
ict ance
edten ote g & Retena ive
n em rin tro nc

real time
fit

M Pr
o
nit

& ai

e
Mo R

Cons
Lifecycle Care is our comprehensive and systematic
Lifecycle Services

& Prntenance
e

Services
ctions
Inspeventiv
approach to managing customer assets; connecting
and Sustainable

ultation
data, machines and people to deliver a digitally-
enabled customer experience in real time. Lifecycle Lifting Solutions

e
i
Care is designed to maximize the productivity of

Ma
uptime and minimize the cost of downtime, thereby
achieving the highest lifecycle value for our customers’
equipment.

Mo
S
ts e
ar n er rvic

d
P e
A consultative approach to help guide decision
re niz es
& Spa uipm atio
making
q n
New E

Our consultative approach can help guide your

decision making. We share our findings and provide
recommendations based on our industry-leading
expertise.

Cost-effective retrofits that deliver value

Improve safety and productivity by There is no need to invest in a new crane technology to enjoy the latest features and
advancements. Simple budget-friendly upgrades can make a big difference in enhancing your
safety, productivity, and cost-effectiveness of your current crane- even if it is decades old.

applying the latest crane technology

Retrofits are an efficient option to replace • Upgrade older equipment for a fraction of the cost
components or add current technology to your of complete replacement.
existing overhead crane. Common retrofits include • Can improve crane safety and ease-of-use with
components, electrics and/or controls, the addition improved control interface options and safety
of new features, and/or technology upgrades and components.
updates. Retrofits typically require minimal downtime, • Helps improve availability and ease of installation of
engineering and pre-planning. replacement components and parts.

LED lighting Collision avoidance 2-Step and hook

Benefits of a retrofit operated limit switches
Safety advantage: Because light Safety advantage: These systems
• Can bring aged equipment up to date to match distribution in LED lights is more are designed to help prevent Safety advantage: These effective
current or changing production demands. focused, the crane operator is less collisions between cranes or their warning signaling and protective
• Can be an alternative to repairing an aged or worn likely to get blinded by the light loads by either slowing down or devices enable safe operation of
out component. when looking at the load. Plus, the stopping crane movements when the lifiting equipment and can help
• Swapping out components can reduce light is directed where it is needed: the crane or its load comes within prevent accidents.
maintenance spending. on the load and on the workstation a pre-determined distance of
• A relatively easy and economical way to add Learn more about or facility. another moving or fixed object.
current features and technologies to a crane. Konecranes Retrofits

2 RETROFITS FOR CRANES RETROFITS FOR CRANES 3

Retrofits to improve safety and productivity
At Konecranes, safety is our highest priority. We offer different retrofit packages Retrofits can also help improve your productivity. New technologies and improved
designed to help improve the safety of your crane and your operations. ergonomics can help make significant improvements in the efficiency and productivity
of your operations.

Side pull prevention

Overhead cranes are designed Konecranes Side Pull Prevention
to lift objects vertically. A side has been designed to stop hoisting
pull occurs when the hoist lifts motion when side pulling is detected.
something that has not been It uses an inclinometer to measure
placed directly beneath it. rope angle during load lifting. If the
angle goes over four degrees, the
Side pull can cause hazardous load system stops hoisting, sounds a horn
swing and in the worst case – load and gives a light signal. When the
Safety lights drops. Side pull can also cause rope angle is back to less than four Variable frequency drives Load display Radio control
damage to the drum, rope and rope degrees, hoisting continues normally.
Equipping your crane with guides and is a common cause of Replacing outdated motor controls Safety advantage: A load display Safety advantage: A radio control
Konecranes Safety Lights are breakdowns. with a new Konecranes variable provides visual confirmation of the offers operators a safer working
more than just illumination –they frequency drive (VFD) allows you load to help prevent overloads. environment, reducing the risk of
significantly improve safety in to take advantage of technology Lifting loads beyond the rated injury as they have the ability to
your facility. By clearly marking the that is designed to address capacity can cause damage to the walk around and view the load from
trolley’s location, they reduce risk requirements for safety in lifting. crane or hoist components which various angles.
of accidents and ensure a safer increased the risk of accidents.
working environment for operators. Equipping your crane with the Production advantage: Improved
latest technology helps it run more Production advantage: Having user ergonomics reduces strain for
Safety LED lights can transform smoothly, endure stress and last a load display can give quick the operator helping to increase
your facility space. They are ideal longer. VFDs not only improve indication that you are lifting what productivity in your process. Radio
for mounting at heights of up to 15 operator safety, maximize crane you intended to lift. For example, controls can also save the operator
meters, these lights not just offer reliability and saves energy costs, lifting a mold from a press, if the time eliminating the need to walk
improved safety but also offer a but they also minimize mechanical load is heavier than expected it from a pendant to the load to rig
top-notch performance. stress on components. VFD can indicate that the mold didn’t countless times in a shift.
control offers smoother travelling release from the press.
Make your crane better with motion which means better load Modern transmitter-receiver
Safety Lights control compared to contactor packages available as
• Strong and durable LED lights controls. VFDs also give you smooth replacements for outdated radio
with low energy consumption. programmable acceleration and models that are not longer in use.
• Ensures focused and effective deceleration rates resulting in easier
illumination. load positioning.
• Control voltage transformer or
a more extensive setup using The precise and infinitely variable
multiple lights. speed selection reduces jerking and Address safety and productivity issues and capitalize on
load swing for enhanced operator improvement opportunities by making timely repairs, replacing
efficiency and productivity.
Side Pull Prevention stops hoisting motion and gives horn and light signals
components and/or adding new technology to your crane
when it detects side pull.

4 RETROFITS FOR CRANES RETROFITS FOR CRANES 5

 TRUCONNECT
Brake Monitoring
TRUCONNECT Brake Monitoring uses a condition monitoring
device to collect the status of brake air gap, mechanical
and electrical faults from the electromagnetic disc brakes.
The service provides visibility into current brake condition,
estimates remaining service life and indicates brake faults. Brake
Monitoring information is used in predictive maintenance and
can also be used for brake maintenance planning.

TRUCONNECT
Wire Rope Monitoring
TRUCONNECT Wire Rope Monitoring is designed to provide
real-time insight into the condition of a wire rope. It reveals
both visible exterior defects as well as internal defects that
are not detectable with a visual inspection. Specialized and
patented sensors continuously monitor the wire rope while the
crane is in normal operation and alerts via text or email occur
when rope condition deteriorates below set limits. Wire rope
condition information helps you plan for maintenance and
repair, or wire rope replacement.

Control unit TRUCONNECT modem Cranes not manufactured Demag cranes

by Konecranes

Retrofits to enable The Control Unit allows for A TRUCONNECT modem can A TRUCONNECT Retrofit Kit is The TRUCONNECT Retrofit for
the addition of features be installed on cranes with available to equip a crane not Demag Cranes allows Demag
such as overload protection ControlPro or PLC controls to manufactured by Konecranes SafeControl controlled cranes

predictive maintenance
and TRUCONNECT Remote provide connection capability with the hardware required to be equipped with the
Monitoring. This package is for TRUCONNECT Remote for TRUCONNECT Remote necessary hardware needed
available as a retrofit for most Monitoring. Monitoring. for TRUCONNECT Remote
cranes, regardless of type, Monitoring.
brand or age.

Konecranes offers a variety of retrofit packages to loads, motor starts, work cycles and emergency
enable the latest technology for remotely monitoring stops.
your crane. Konecranes TRUCONNECT Remote
Monitoring will also give you access to our digital TRUCONNECT Remote Monitoring with alerts based
customer portal yourKONECRANES.com. on the equipment/application is required in order yourKONECRANES.com
to effectively implement predictive maintenance.
Upgrading your crane with TRUCONNECT Remote Remote Monitoring data combined with inspection TRUCONNECT data is viewable at any time on our cloud-
Monitoring provides condition, usage and alerts and maintenance data provided by the maintenance based customer portal – yourKONECRANES.com.
that can be used in maintenance planning and in program gives a comprehensive view of equipment
predicting possible component or equipment maintenance needs and performance. TRUCONNECT data is presented in easy-to-read graphs
failure. It also provides alerts of certain anomalies and with thorough explanations including common or likely
enables predictive maintenance.
causes, what you should be concerned about and
Collected data varies depending on asset make and recommended actions.
model but typically covers condition and expected
service life of critical components, running time, lifted

6 RETROFITS FOR CRANES RETROFITS FOR CRANES 7

Konecranes is a global leader in
material handling solutions, serving
a broad range of customers across
multiple industries. We consistently
set the industry benchmark, from
everyday improvements to the
breakthroughs at moments that
matter most, because we know we can
always find a safer, more productive
and sustainable way. That’s why, with
around 16,600 professionals in over
50 countries, Konecranes is trusted
every day to lift, handle and move what
the world needs. In 2022, Group sales
totalled EUR 3.4 billion. Konecranes
shares are listed on Nasdaq Helsinki
(symbol: KCR).

© 2024 Konecranes. All rights reserved. ‘Konecranes,’

‘Moves what matters’ and are either registered trademarks
or trademarks of Konecranes.

This publication is for general informational purposes only.

Konecranes reserves the right at any time, without notice,
to alter or discontinue the products and/or specifications
referenced herein. This publication creates no warranty on
the part of Konecranes, express or implied, including but not
limited to any implied warranty or merchantability or fitness
for a particular purpose.