The document discusses why modernizing cranes is beneficial, including prolonging their economic life, addressing increased production demands, and reducing maintenance costs. It describes how a Crane Reliability Study evaluates a crane's condition and remaining useful life. Common crane modernizations include replacing hoists, trolleys, controls and adding technologies to increase capacity, speed and safety. Upgrades to braking, motors, cabins and automation can further improve crane performance and productivity.

1. MODERNIZATIONS

2. WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT
WHY
MODERNIZE?
• Prolong the economic service life of
your crane
• Critical components are reaching the
end of their economic service life
• Your production demands are increasing
• Your application has changed
• Statutory requirements have changed
• Costs and time spent maintaining your
aged crane are rising
• You are considering replacing your crane

3. ARE YOUR
CRANES FIT FOR
THE FUTURE?
If you’re considering whether a
modernization is a valid option, you need a
tool to help make decisions about the
future use of your cranes. A Crane
Reliability Study is an engineering
assessment that evaluates the current
condition of your crane and provides a
theoretical estimate of its remaining design
life and recommendations for next steps.
ALL CRANES HAVE A FINITE SERVICE LIFE
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

4. ALL CRANES
HAVE A FINITE
SERVICE LIFE
You may choose to perform a Crane
Reliability Study when you're not sure if
your cranes are capable of meeting growing
production demands, or if you’re using your
crane for purposes other than how they were
originally classified. If you have safety
issues or aren’t sure if it’s time to
modernize, a CRS can give you the
information you need.
CRS PROCESS
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

5. CRS PROCESS
• A team of Konecranes specialists observes the
production and operating environment of your crane
• The overall condition of your crane structures and
components is evaluated in detail with a focus on
safety, productivity, reliability, usability and
remaining design life
• Operators and maintenance personnel are
interviewed and all pertinent documentation
is reviewed
• The team provides a detailed report and further
consultation with advice on maintenance,
modernizations and future investments
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

6. TRANSFORM
YOUR EXISTING
CRANE
Modernizations can provide a complete
transformation of your existing crane as
an alternative to replacing it.
Modernizations can also give you an
opportunity to add current technologies.
Common modernizations include the
replacement of hoists, trolleys,
operator cabs and controls to achieve
increased capacity, speed, duty and
load control.
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

7. HOIST,
TROLLEY
AND CRANE
UPGRADES
Let Konecranes evaluate your
equipment and recommend
which modernization upgrade
is right for you.
GIRDERS
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

8. GIRDERS
MODIFICATIONS AND
REINFORCEMENTS
Konecranes can increase or decrease
the length of the girder span, which
may be required during building
expansions or when fitting a used
crane into an existing building.
Additionally, girders may need to be
repaired or reinforced, particularly when
the lifted capacity is being uprated.
UNITON TROLLEY
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

9. UNITON
TROLLEY
The UNITON™ trolley is available
with multiple configurations and a
wide range of hoisting speeds,
load control features, and load and
duty class options. With a lifting
capacity of up to 160 tons on a
single trolley (320 tons with two
trolleys), UNITON can be built to
meet project-specific requirements
in almost any application.
SMT TROLLEY
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

10. SMT
TROLLEY
The SMARTON® trolley is built
for heavy process industries. The
motor, gearbox and control unit
are designed and manufactured
in-house, which allows for
excellent lifting performance and
long life. The flange-mounted
motors have integrated brakes,
which support the proper
alignment of the machinery.
BRIDGE BUMPERS
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

11. BRIDGE
BUMPERS
Protect your crane and
your building by installing a
spring, hydraulic or rubber
bridge bumper.
PLATFORMS
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12. PLATFORMS
Increase safety by adding
or refurbishing walkways
and handrails.
END TRUCKS AND WHEEL ASSEMBLIES
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

13. END TRUCKS
AND WHEEL
ASSEMBLIES
Anti-friction bearings help
meet increased productivity
demands. Konecranes high-
capacity end trucks are designed
to extend wheel life and improve
crane tracking.
HOSIT GEAR CASE
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14. HOIST
GEAR CASE
Your gear case can be
overhauled or entirely
replaced to suit its operating
environment or to uprate the
lifting capacity, if needed.
Critical components such as
shafts, bearings and gears
can be precision machined
and heat-treated for long life.
SELF-ADJUSTING, SELF-ALIGNING BRAKES
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15. SELF-
ADJUSTING,
SELF-
ALIGNING
BRAKES
Reduce maintenance by
automatically compensating
for lining wear. DC AISE spring
set, electric release or AC
impulse-actuated shoe brakes
are available.
BRIDGE BRAKES
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

16. BRIDGE
BRAKES
Where bridge brakes are used,
typically on DC powered cranes,
these brakes can be arranged for
cab or floor operation.
Components to refurbish or
replace include electric and
hydraulic shoes, DC spring sets,
discs and release mechanisms.
BOTTOM BLOCKS
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

17. BOTTOM
BLOCKS
Konecranes stocks complete
bottom blocks in a wide variety of
sizes and configurations, as well
as common wear items such as
hooks, frames, pins, sheaves,
bearings and safety latches.
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

18. CONTROL
UPGRADES
You may want to increase speed
and lifting capacity, enhance
operator ergonomics and comfort,
or apply new safety features and
positioning capabilities. Select
from a variety power and control
upgrades.
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT
MOTORS

19. MOTORS
DC and AC long-life motors are
designed and built for harsh
environments and rugged use.
Many options are available
including AC squirrel cage
motors, external blower motors
and DC mill motors.
CONTROL SYSTEM UPGRADE
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

20. CONTROL
SYSTEM
UPGRADE
If your overhead crane uses an
older control system, upgrade to
current technology and more
advanced systems for
ergonomics and load control.
OPERATOR CAB
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

21. OPERATOR
CAB
Konecranes award-winning
operator cabs provide an
enclosed, insulated, air
conditioned workspace with
maximum visibility. A deluxe
console chair offers optimum
comfort to the operator.
BRIDGE DRIVES
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

22. BRIDGE
DRIVES
Drives can be upgraded with
heavy-duty foot mounted
gearboxes. Shaft mounted motor
reducers can also be applied.
POWER SUPPLY
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

23. POWER
SUPPLY
Festoon systems increase safety
by replacing wear-prone open
conductors and collectors. Energy
Chain is an alternative that
protects the power and control
cables from mechanical wear and
reduces the risk of external
damage.
RADIO CONTROL
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

24. RADIO
CONTROL
Floor operated controls allow the
operator to have a good view of
the load on the hook and to
manually assist it, if necessary.
These controls can be equipped
with real-time load data.
UPPER LIMIT SWITCHES
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

25. UPPER LIMIT
SWITCHES
Provide upper-limit protection to
prevent the bottom block from
damaging the drum and cable.
BRAKING
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

26. BRAKING
With regenerative braking, power
is sent back to the power grid
during every downward or
decelerated motion, instead of
being dissipated by resistors.
With more energy returned to the
grid, less energy needs to be
produced—leading to increased
cost-savings.
SMART FEATURES
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

27. SMART
FEATURES
Konecranes cranes are available
with software-based Smart
Features that improve safety and
productivity. You can upgrade
your crane with additional Smart
Features as your requirements
change.
AUTOMATION
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

28. AUTOMATION
Automated features improve
efficiency and precision while
allowing crane operators to pay
increased attention to the
surrounding work environment,
promoting safer and more
productive operations.
REMOTE MONITORING
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

29. REMOTE
MONITORING
TRUCONNECT Remote
Monitoring uses sensors to collect
data, such as running time, motor
starts, work cycles and emergency
stops, providing visibility to crane
usage. It also provides brake and
inverter monitoring. The data is
transmitted to the Remote Data
Center, where it is compiled and
made available on the
yourKONECRANES.com
customer portal.
WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT

30. Contact Konecranes to learn
more about modernizations.
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equipment and services that improve productivity in a wide variety of
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WHY MODERNIZE? CRANE RELIABILITY STUDY MODERNIZATIONS HOIST, TROLLEY AND CRANE CONTROLS CONTACT