OWNER'S MANUAL FOR END

CARRIAGE
ECN11-2562-A40996A0000-KE

English 02011470850010-0.ORD 02.01.2020

- - CC004518 -

Original instructions 020114708500103007-0 PS03485 02-01-2020

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

Table of contents

1 SAFETY INSTRUCTIONS.................................................................................................................. 3
1.1 Safety instructions for preparing to install the end carriage ..........................................................................3
1.2 Safety instructions for installing and operating the end carriage ..................................................................3
1.3 Safety instructions for servicing the end carriage .........................................................................................3
2 END CARRIAGE ................................................................................................................................ 4
2.1 General .........................................................................................................................................................4
2.2 The main components ..................................................................................................................................4
2.3 Assembling the end carriage ........................................................................................................................4
2.4 Inspection and servicing intervals .................................................................................................................5
2.5 Inspection and service procedure for end carriage ......................................................................................5
2.5.1 Wheel wearing limits .................................................................................................................................5
2.6 Maintenance work .........................................................................................................................................7
2.6.1 Detaching and replacing the driving wheel ...............................................................................................7
2.6.2 Detaching and replacing the idle wheel ....................................................................................................7
2.6.3 Assembly of the driving wheel ..................................................................................................................8
2.6.4 Assembly of the idle wheel .......................................................................................................................8
3 JOINT PLATE ASSEMBLY ................................................................................................................ 9
3.1 Joint plate assembly, top running end carriages ..........................................................................................9
3.1.1 Top joints (A3, A4, A6, B4, B6, L3-L6,H4-H9,K4-K9) ...............................................................................9
4 RECOMMENDED TIGHTENING TORQUES ................................................................................... 10

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 2/10
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL FOR END CARRIAGE

1 SAFETY INSTRUCTIONS

1.1 Safety instructions for preparing to install the end carriage

 Follow these instructions when preparing to install the end carriage:

 Ensure that installation personnel are professionally competent, professionally qualified and are provided with
adequate instructions for carrying out the installation work.
 Check for any dimensional nonconformance in drawings, instructions, parts and structural measurements.
 Beware of other moving machinery in the installation and servicing site, such as machines, other cranes and
automatic doors. The installation area must be arranged so that operation of other equipment does not
endanger installation work (or vice versa).
 Prevent unauthorized persons and bystanders from walking on or below the work site.

1.2 Safety instructions for installing and operating the end carriage

 Follow these instructions when installing the end carriage:

 Use proper safety equipment to prevent objects from falling when working in high places.
 Ensure that machinery and equipment cannot start up accidentally and cannot move during installation and
servicing.
 Keep installation and servicing locations, and walkways leading to them, clean and tidy.

 Follow these instructions when operating the end carriage:

 The useful lifetime of a end carriage depends very much on whether the end carriage is correctly used or not.
Use of the end carriage for other than the duty group classification for which it was designed changes its useful
lifetime.
 During travel motion, ensure that the moving parts do not collide with objects or people.
 If defects have been noticed in the end carriage, carry out the necessary inspections and servicing. Ensure that
the end carriage operates properly before you start to use it again.

1.3 Safety instructions for servicing the end carriage

 Follow these instructions when servicing the end carriage:

 Carry out regular inspections and preventive maintenance in compliance with the instructions. Keep a record of
inspections and servicing. Regular servicing and inspection procedures are necessary for the safe and efficient
operation of the end carriage. In uncertain or unusual cases, contact the supplier of the end carriage.
 Use trained servicing personnel authorized by the manufacturer of the end carriage for servicing the end
carriage. The person servicing the end carriage must be competent for the task and must be familiar with the
servicing and inspection instructions.
 Use only genuine spare parts approved by the manufacturer of the end carriage.
 Any modifications or additions made to the end carriage’s structures must first be discussed with the supplier of
the end carriage.

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 3/10
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL FOR END CARRIAGE

2 END CARRIAGE

2.1 General
The end carriage is designed to carry the crane or the hoisting trolley as a pair. Any other kind of use must be
designed case by case. End carriage is suitable for both indoor and outdoor use. Please note possible restrictions
for special environments (e.g. galvanization plants).

2.2 The main components

The main components of end carriage are the rail wheels. Standard end carriage is equipped with one driving and
one idle wheel, but it’s also possible to order with two driving wheels. The mounting holes of the end carriage allow
90° stepwise turn of machinery (read Owners manual for travelling machinery).

 Wheels are pre aligned in factory, there is no possibility for afterwards alignment.

 Any kind of welding after machining may effect to wheel alignment. Thus, any welding after machining is not
allowed at all.

2.3 Assembling the end carriage

 Ensure that the working area is safe and the machine cannot be started accidentally
when making the assembly work.

 Align the end carriage to the main girder using crosswise measurement holes (wheel base on top surface) or
pin holes in joint plate.
 Both flanges of wheel are machined and can be used for measuring rail gauge (span).
 Joint plate can be aligned and welded to main girder separately from end carriage

 If the joint plate has been separately from end carriage be sure that all parts will be in their places before
reassembling and using the crane (e.g. friction rings, support plates).

 Tighten the fixing bolts to a correct torque (see section ‘Recommended tightening torques’).

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 4/10
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL FOR END CARRIAGE

 On delivery the joint plate bolts are just preassembled.

2.4 Inspection and servicing intervals

 Inspection and servicing procedures may only be carried out by a serviceman authorized by the end carriage
manufacturer or service personnel adequately trained by the manufacturer.

The inspection and servicing interval for end carriage is 12 calendar months in 1-shift work. However, end carriage
unit can be mounted on a crane or a hoist, which inspection and servicing intervals are defined by Safe Working
Periods (SWPs). In these cases the servicing procedure must always be carried out at the end of the servicing
period (SWP%) of a crane or a hoist, or by the end of the stated number of calendar months, whichever comes
first. End carriage in intermittent duty should be inspected before being used.

 For ensuring the usability of the end carriage the servicing intervals can be shorten.

 Also if any defects or abnormalities are observed, they must be investigated and corrective action must be taken in
accordance with the instructions.

2.5 Inspection and service procedure for end carriage

Carry out the following inspections and servicing procedures at regular intervals. See section 'Inspection and
servicing intervals' for the period of time between inspections and services.
 Check the tightness of the fixing bolts.
 Check the wheel for wearing. The Permissible wearing limits are shown in the section 'Wheel wearing limits'.

2.5.1 Wheel wearing limits

 Small wearing is normal for rail wheels. If wearing affects the movement of crane or even one of the wearing limits
(d1, b1, B*, ∆ bf, t) has been increased, the wheel must be replaced. For criteria for wheel change, see the
following tables.
Wearing limits of 2-flange wheels
New wheel Old wheel, d1 New wheel New wheel New wheel Old wheel Old wheel
Wheel diameter Min wheel Max groove Min flange Min flange Max increase of Min flange
diameter thickness (*) thickness (**) groove thickness (*)
d d1 b bf bf_min Δ_bf b1
[mm] [mm] [mm] [mm] [mm] [mm] [mm]
90 86 70 10 9.7 6 6
110 105 87 12 12.0 6 8
140 135 84 13.5 12.5 6 8
160 154 84 13 12.9 6 9
200 193 99 15.5 15.2 6 11
250 242 99 16.5 16.1 6 12
315 307 99 17.5 17.2 7 13
400 392 120 20.5 20.3 8 15
500 492 130 22.5 22.4 8 17
(*) with max groove width, actual value for wheel
(**) with max groove width, min. requirement acc. to EN 13135

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 5/10
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL FOR END CARRIAGE

Additional criteria for wheel change

Inspection method
The groove (t) with a depth of ≥ Measurement with vernier
2.0 mm has been worn in the callipers
surface of the rail wheel, or there
is a pit in the rolling surface.

The angle of the rail wheel flange Measurement

(α) does not conform to the
following values: 2-10° reference
value 6°.
B* = max allowed groove (old wheel)
α = 6°
Corner angle (α) is first what wears out and can be indication that the
alignment of wheel(s) or runway is not correct.

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 6/10
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL FOR END CARRIAGE

2.6 Maintenance work

 Ensure that the working area is safe and the machine cannot be started accidentally
when making the assembly work. Be sure to switch off securely the electric power
from the device to avoid the electric shock and sudden start.

 Mechanical or electrical maintenance work requires special tools and skills and to assure safety and reliable
operation ONLY authorized personnel by the component manufacturer can perform this kind of maintenance work.

2.6.1 Detaching and replacing the driving wheel

 Disconnect power supply plug from the motor.
 Open the fixing bolts of the machinery and remove the bolts.
 Pull out the machinery from the wheel spline.

Jack up End Carriage

1
end
2 Support wheel to rail
Remove End Carriage’s
3 end plate (A) bolts and
plate
4 Remove fixing bolts (5)
Pull out bearing
5
housings (2), (3)
Remove wheel (1) from
6
end of the End Carriage
Pull out bearings (4)
7
from wheel
Replace new wheel,
assembly in opposite
8 order, see section
‘Assembly of the driving
wheel’

2.6.2 Detaching and replacing the idle wheel

Jack up End Carriage
1
end
2 Support wheel to rail
Remove End Carriage’s
3 end plate (A) bolts and
plate
Remove retaining rings
4
(5)
5 Remove sleeves (3)
6 Remove shaft (2)
Remove wheel (1) from
7
end of the End Carriage
Pull out bearings (4)
8
from wheel
Replace new wheel,
assembly in opposite
9 order, see section
‘Assembly of the idle
wheel’

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 7/10
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL FOR END CARRIAGE

2.6.3 Assembly of the driving wheel

Press bearings (4) into
1 wheel, avoid pressing
from inner ring
Put wheel (1) including
bearings into End
2
Carriage from bottom
end of the End Carriage
Mount bearing housings
(2),(3) into End Carriage
and tighten bolts (5)
3
according to section
‘Recommended
tightening torques’

Fix the end plate (A) and

tighten the bolts
4 according to section
‘Recommended
tightening torques’

In the end:
 Attach the travelling machinery to the wheel spline of End Carriage
 Tighten the fixing bolts of the machinery to a correct torque (see section ‘Recommended tightening torques’)
 Connect the power supply plug to the motor

2.6.4 Assembly of the idle wheel

Press bearings (4) into
1 wheel, avoid pressing
from inner ring
Put wheel (1) including
bearings into End
2
Carriage from end of the
End Carriage
Mount shaft (2) and
3
sleeves (3)
Lock shaft with retaining
4
rings (5)

Fix the end plate (A) and

tighten the bolts
5 according to section
‘Recommended
tightening torques’

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 8/10
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL FOR END CARRIAGE

3 JOINT PLATE ASSEMBLY

3.1 Joint plate assembly, top running end carriages

3.1.1 Top joints (A3, A4, A6, B4, B6, L3-L6,H4-H9,K4-K9)

 Position the friction springs to the top holes of the end truck (figure 1).
 Make sure that the friction springs are positioned correctly. Approximately three-quarters of the top spiral
should be located outside of the bolt hole (figure 2).
 Position the joint plate (welded to the end of the main girder) on top of the end truck. Make sure that the friction
springs stay on their positions.
 Hit guiding pins (pos. 6) through the joint plate and the end carriage top flange. Make sure that the friction
springs stay on their positions (figure 3).
 Fix bolts, washers and nuts (fig 4). Use hand holes on the side of the truck to fix the bolts (fig 5, pos. B).
 Measure the bolt size and tighten the bolts to the correct torque according to the table “Recommended
tightening torques”.
 Tightening of the bolts must be checked after crane tests.

In joint connection areas, marked with “A” in the picture, only workshop primer paint
NOTICE
(thickness 20 microns) is allowed.

Recommended tightening torques

Screw size Tightening torque
M16-10.9 300 Nm
M20-10.9 590 Nm

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 9/10
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.
OWNER'S MANUAL FOR END CARRIAGE

4 RECOMMENDED TIGHTENING TORQUES

Recommended tightening torques for screws and nuts.
Tightening torque
Size Strength 8.8 Strength 10.9
Nm Ft lb Nm Ft lb
M4 2.7 2.0 4.0 2.9
M5 5.4 4.0 7.9 5.8
M6 9.3 6.8 14 10.3
M8 23 17.0 33 24
M10 45 33.0 66 48.5
M12 77 56.6 115 84.6
M14 125 92 180 132
M16 190 140 300 221
M18 275 202 390 287
M20 410 302 590 435
M22 530 390 750 552
M24 660 485 950 699
M27 980 721 1400 1030
M30 1350 993 1900 1398

This document and the information contained herein, is the exclusive property of Konecranes Global Corporation and represents a non-public, confidential and proprietary 10/10
trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Konecranes Global Corporation. Copyright 2020 © Konecranes Global Corporation. All rights reserved.