Even More Happy Customers

Konecranes • More Happy Customers 1
Happy
CustomersAND OTHER SHORT STORIES FROM 2012

2 Konecranes • More Happy Customers Konecranes • More Happy Customers 3
Mission
NOT JUST LIFTING THINGS,
BUT ENTIRE BUSINESSES
Vision
“We know in real time how millions of lifting devices
and machine tools perform. We use this knowledge
around the clock to make our customers’ operations
safer and more productive.”
Values
Trust in People
We want to be known for our great people.
Total Service Commitment
We want to be known for always keeping
our promises.
Sustained Profitability
We want to be known as a financially
sound company.
Strategies
> Differentiation through service
and technology innovation
> Lifting people
> Global footprint and supply chain
> Dual-channel
> Real-time information

Contents
AUTOMOTIVE
Automotive Stamping Plant.................. 7
Automotive Stamping Plant.................. 8
Assembly Factory ............................... 9
Engine Assembly Plant...................... 10
Automotive Facility ........................... 11
GENERAL MANUFACTURING
Leading Manufacturing Company....... 13
Concrete Company............................ 14
Manufacturing Facility....................... 15
Manufacturer of Automobile Interior
Mechanisms..................................... 16
K.K. Tool Company ........................... 17
Toyota Lift of Minnesota.................... 18
Piper Valve Systems.......................... 20
Schlumberger Technology Corp.......... 22
Automated Material Handling Facility.... 23
Component Manufacturing Facility..... 24
Brewery............................................ 26
Chemical Plant.................................. 27
Offshore Drilling
Components Manufacturer................ 28
Bottling Factory................................ 29
Pound Cake Factory.......................... 30
Fabrication Plant............................... 31
Toyota Material Handling................... 32
Electrical Components Factory........... 33
Christie............................................ 34
Tencate Advanced Armor .................. 35
MACHINE TOOL SERVICE
Patterson Pump................................ 37
PETROCHEMICAL
Engineering Company........................ 39
Houston, Texas Oil Refinery............... 40
Oil Refinery....................................... 41
POWER
Los Angeles Department
of Water and Power........................... 43
Hydroelectric Plant............................ 44
Hydropower Plant.............................. 45
Los Angeles Department
of Water and Power........................... 46
ACCIONA.......................................... 47
Coal-Burning Power Plant................... 48
Power Plant.......................................... 49
Power Plant..............................................50
Massachusetts Clean Energy Center’s
Wind Technology Testing Center......... 51
ENERGY FROM WASTE
Energy-From-Waste Facility................ 53
PULP & PAPER
Paper Plant....................................... 55
Ahlstrom.............................................. 56
Southern California Paper Company... 57
Paper Plant....................................... 58
California Paper Mill.......................... 59
INTERMODAL & RAIL
CSX Corporation............................... 61
Railroad Yard.................................... 62
Locomotive Shop.............................. 63
STEEL & PRIMARY METALS
AM Castle Metals................................. 65
Brannon Steel.................................. 66
Steel Manufacturing Plant................. 67
Foundry............................................ 68
Alcoa............................................... 69
Metal Processing Plant...................... 70
Steel Plant....................................... 71
Steel Company................................. 72

AUTOMOTIVE At our automotive
stamping plant, our 75-
ton critical crane lifts
dies at full capacity in
order to meet production
needs. One morning,
our crane operators
were hard at work when
I witnessed something
unsettling: when the
crane attempted to make
a lift, the load suddenly
and unexpectedly drifted
back down to the ground.
The load had only drifted
down about six inches,
but we were all shaken by the event. Load drift is extremely serious and potentially
very dangerous. We needed to fix this issue immediately.
We tried to realign the brakes, thinking we could eliminate the problem, but the load
drift occurred on and off for six months. We called in several companies to look
at the brakes, including the original manufacturer, but no one was able to prevent
the loads from slipping. During this time, the cranes experienced emergency
breakdowns at least once or twice per week. When a crane broke down, we had to
call for an emergency repair, wait for the correct parts and then perform the actual
repair. The entire process could last anywhere from four to eight hours.
We needed to fix this problem immediately, so we called Konecranes. Their
technicians determined the factors causing the load drift: the stamping crane used
self-adjusting brakes, which were over-adjusting and pushing themselves out of
alignment. Though our cranes used variable frequency drives, they were an early
model. So when the brakes slipped, they did not have the technology to override the
motor to prevent the load drift.
Konecranes installed new variable frequency drives, which came with advanced
safety features. I like the “Brake Slip Detection” feature best: if the brake slips, the
inverter drive detects it, keeps the load steady and sounds an alarm. Konecranes
also installed new, more reliable brake adjusters. We felt much safer knowing this
new equipment minimized the potential for load drift.
Now, we trust Konecranes to care for all of our cranes. They provide monthly
inspections and make sure all our cranes are running properly. Thanks to them,
breakdowns at our plant have been decreased by 95% compared to last year.
A Slippery Slope
A Story of Strategic Upgrades
case study: customer’s perspective

case studycase study: crane doctor
At the Automotive Stamping Plant …
From the customer’s perspective
Have you ever heard the sound of metal scraping
against metal? It’s a sound that will make you cringe.
We heard that terrible noise at our plant as one of our
cranes traveled down the runway—the crane emitted
a large, piercing shriek that startled us all. Our safety
department locked the crane out of service right away.
We had chosen the lowest cost bidder to modify the
crane for a new runway. Well, I guess we got what
we paid for, because when we called the company
for help, they bluntly told us the crane was “as good as they can get it” and that
the runway was the problem—they even suggested we grease the runway with
lubrication sticks to minimize the shrieking. Of course, even with lubrication, the
crane did not track properly. To make matters worse, the crane was in the middle of
the stamping bay, blocking the other cranes. We needed to get this crane back into
service as quickly as possible, so we made an emergency call to Konecranes.
Meanwhile, at Konecranes …
From the Konecranes Branch Manager’s Perspective
When Konecranes got the call, every technician had
already been assigned to other jobs. So, I called
one of our most experienced engineers, a man we
nicknamed the “Crane Doctor.” I knew he was on
vacation, but I was desperate. Within two hours of the
initial call, he informed me he was leaving vacation
early to come fix the crane. Out of all the great
engineers and technicians I have worked with over the
years, I had never before seen one come off vacation
to fix a crane.
His initial inspection showed the crane’s internal
components weren’t in their correct positions, a
condition that had forced the wheels out of alignment.
Thanks to the “Crane Doctor,” the problem was
diagnosed and corrected over the weekend, just in
time to return the crane to service Monday morning.
Back at the Stamping Plant …
The crane ran smoothly and quietly down the runway
on Monday morning, and everyone breathed a collective sigh of relief. With the
safety department’s blessing, the crane was placed back into service.
From Vacation to House Call
“We were so
thankful the ‘Crane
Doctor’ was willing
to give up his
vacation time to
fix our crane. He
worked some long
and late hours to
accommodate our
schedule, and his
crane alignment
expertise was very
valuable to us.
Our crane is now
running as good
as ever.”
Stamping Plant
Branch Manager
Slowed down by
daily breakdowns
From the customer’s
perspective
In the busiest production
area of our assembly
factory, a standard
one-ton electric hoist
loads a 1,500 pound
steel truck frame to a
conveyor belt every 54
seconds. This process
repeats itself constantly,
as workers perform the
same action in double-shifts throughout the week. Because the crane was picking
at near capacity several times an hour, it was no surprise when the crane began to
breakdown almost daily.
A customized crane built to last
From a Konecranes technician’s perspective
We found two main problems: the control system and the duty cycle. The hoist
used contactor controls, which lacked high-quality speed control options and
caused intermittent damage to internal components. In addition, the crane was not
designed to withstand the heavy duty cycles it was performing.
Clearly, this standard one-ton crane was worn out and could no longer meet the
demands of the factory. So, we customized an extremely durable one-ton CXT
crane, built for severe duty, “Class E” service. The crane uses an advanced inverter
drive system, which provides smooth, controlled and precise movements. Radio
controls allowed crane operators to control the load remotely.
Keeping downtime to a minimum
We couldn’t be happier with Konecranes’ work—and with our new crane system, we
no longer have to worry about daily breakdowns.
Though the sturdy new crane system was built to last, we wanted to be sure that
downtime would not interrupt production. For that very reason, we keep an extra
hoist at the facility so we can switch out the hoist any time we need to perform a
repair, so that repairs can be completed quickly and accurately.
Konecranes Keeps
Us Trucking Along

case study: customer’s perspectivecase study: customer’s perspective
Old hoists –
a major hindrance
At our engine assembly
plant, we rely on cranes
to position engine
components on our
assembly line. We were
using old air-controlled
hoists which were now
obsolete. When we
started experiencing
problems, we couldn’t
purchase spare parts
because they were no
longer available.
Imagine trying to lift and
assemble 300 engines
per day when your hoist is
nearly impossible to use.
The hoists drifted without
warning and were extremely
difficult to adjust. We
couldn’t keep up with our
production rates with these
old hoists, so we decided to
scrap them and start fresh.
Konecranes improves lifting with AirBalancer
Konecranes came to our facility and demonstrated their dual balancer, and we
immediately fell in love. This hoist detects when it has a part, and will remain in the
air until the operator moves it. Ultimately, the AirBalancer is much easier to control
and way more effective than our old hoists.
Since Konecranes installed the new hoists, we haven’t had any issues with
breakdowns or unexpected load drift. Downtime at the plant has been drastically
reduced, and we are so pleased with our new AirBalancer that we’re planning to
install a second one!
Konecranes Makes
Lifting a Breeze
Two of a kind
In the past several years, Konecranes and the
maintenance team at our automotive facility have
worked in tandem: Konecranes performs annual
maintenance, while our in-house team inspects
our stamping cranes on a monthly basis. When
our maintenance staff is too busy for the monthly
inspection—Konecranes handles it, using our checklist,
which is based on the Ontario Green Book.
We trust them completely to carry out these
inspections—we believe that whatever deficiencies
Konecranes finds, our in-house team would have
found, too.
The one for us
Instead of relying on other crane service providers,
we are depending on Konecranes more and more—
eventually, they started performing inspections in our
body shop, too. Another crane service company had
previously handled our inspections in the assembly line
area, but when they proved to be unreliable, we granted
this area to Konecranes.
With critical inspections from Konecranes, our plant has not had a single production-
hindering breakdown in several years—clearly, we were right to trust them! We
couldn’t be happier with the unparalleled services they provide at our facility.
A dynamic duo
Konecranes Helps us Drastically
Reduce Breakdowns

case study: VIDEO
When a leading
manufacturing company
released a nationwide
bid to provide cranes in
their production facility in
Ohio, five overhead lifting
equipment companies
gave it their best shot.
After reviewing the
proposals, the company
decided Konecranes
was the most qualified
to handle the entire
project—from design to
installation.
Konecranes determined
the best equipment for the building, taking into consideration the building code
requirements, current layout and potential architectural challenges. At the
production site, Konecranes installed three low-headroom CXT hoists with close
end hook approaches, to maximize every inch of available space in the warehouse.
VIDEO: Watch a time lapse video of one of the crane installations here:
http://bit.ly/CXTcrane
Finding the Best Fit
MANUFACTURING

case study: customer’s perspectivecase study: salesperson’s perspective
Meet the new customer
Last year, I met
with a company that
manufactures concrete
to discuss Konecranes’
MAINMAN® program and
the benefits of preventive
maintenance.
As we toured the facility,
I asked, “How much
did you spend on crane
maintenance last year?”
“Well, between the
annual inspection,
several breakdowns and
emergency repairs, we probably spent between $15,000-20,000,” he said. “Those
breakdowns really slowed us down.”
“You should try our preventive maintenance plan, MAINMAN®,” I said. “The
plan is specifically designed to keep your cranes in better working condition, so
breakdowns and emergency repairs won’t be as frequent.”
The concrete company agreed to give MAINMAN® a try for one year, letting
Konecranes perform the quarterly and annual inspections and perform every
needed repair.
Performance review
One year later, the concrete company has not had a single breakdown. In fact,
no production time was lost at all, because each repair was performed during
scheduled downtime.
By using MAINMAN®, the company spent substantially less on maintenance. In fact,
they even saved enough money to buy a brand new hoist and still remain within
budget for the year.
Leaving Downtime in the Dust
The Day OSHA
came knocking
It was not a pleasant day
at our plant: we had an
unexpected OSHA audit
and were caught without
proper documentation
for our overhead crane
inspections. To be honest,
we didn’t even know we
needed these documents
before the audit!
In addition to the fine,
now we were required to
have a follow-up audit.
Needless to say, our cranes needed to be in tip-top shape (with all the right
documentations) before the follow-up visit.
Konecranes to the rescue
A colleague recommended Konecranes, a local crane service dealer, and I
decided to give them a shot. The Konecranes inspector made recommendations
based on the specific inspections we needed. To make sure we were thoroughly
prepared for the follow-up audit, he also trained our employees on OSHA
requirements for crane operators. Lastly, Konecranes repaired our cranes based
on the inspection results.
Ready for the reckoning
We gave Konecranes a tight, two week deadline to make the repair. They
understood the urgency of the situation and made this project a top priority, using
as many technicians as possible and rearranging welding and other schedules to
accommodate us. The repair took only one week to complete and the drum was
back in service in less than two weeks—what a relief!
Inspected to Meet OSHA
requirements, and beyond!

case studycase study
At the plant...
Lurking below the surface of the gear case, glittering specks of metal rested on a
thick sludge of oil inside the gear case. The gear case had been neglected for years
while another company serviced the cranes. With damage this bad, the crane could
have been moments away from catastrophic failure...
Things were about to change: the company, which manufactured automobile interior
mechanisms, released a bid for a new crane service provider, after a Konecranes
salesperson explained the benefits of thorough MAINMAN® inspections.
A shocking discovery
During the initial MAINMAN® inspection for the plant, a Konecranes inspector
peeled open the gear case cover to find the filthy state of the oil inside. When
he saw glittering specks of metal, he knew that pieces of the gear teeth were
disintegrating into the oil. Quickly, he alerted the plant safety manager and locked
the crane out of service.
The plant had been extremely close to disaster. If the gears had meshed improperly,
the crane could have dropped a steel die. Imagine the worst—the die plummeting
from the crane, colliding into the machinery or workers below, smashing into other
dies and creating thick cracks on the concrete floor.
Konecranes repaired the gears and explained the importance of regular gear case
inspections—the plant was extremely grateful. Now, Konecranes replaces the oil
and performs open gear case inspections at the facility regularly. With MAINMAN®
inspections, Konecranes hopes to help reduce the risk of close-calls like this in
the future.
How a MAINMAN®
Inspection Prevented an
Impending Catastrophe
Room to grow
With customer demand on the rise, K.K. Tool needed
to add several CNC machines to keep up. The
machines were squeezed into the existing shop,
wherever there was room. As demand continued
to increase, it soon became clear more space was
needed to handle the growing business.
K.K. Tool expanded their facility—adding a 4,000 foot
addition for the eight new machines. The company also
began exploring lifting options to streamline workflow
around the CNC machines.
Konecranes’ space-saving crane
After consulting with several companies, K.K. Tool
contacted Konecranes, who proposed a unique
solution—an XN trolley and hoist on a light-track
enclosed rail system. Suspended from the ceiling, one
crane could service all eight milling machines, while
keeping the floor area free for forklifts to maneuver.
Konecranes XN crane has a distinct feature – an articulated bridge which allows
one end to move ahead of or behind the other, by as much as three feet. This
ergonomic feature significantly reduces the amount of effort needed to move the
crane along the track and allows small adjustments to be made without moving
the entire bridge.
K.K. Tool has been using the XN system for about six months now, and is seeing
the productivity benefits. Due to the success of this crane system, the company is
exploring the possibility of adding another XN hoist to the existing track.
Right on Track
A Successful System
to Improve Productivity
Company Information: K.K. Tool Company is a family-owned enterprise in
Springfield, Ohio. Competing globally, the company creates stamping dies for
the heavy equipment industry and production machining products.
“The only way we can compete effectively is to work with
machinery that helps us to make a product faster. So, we have
to work smart by investing not only in employees and training,
but also by investing in equipment that allows us to produce
products in a more timely manner.” ”
Kris Koehler
K.K. Tool

Hidden hazard
Imagine trusting your crane service provider to inspect
your overhead lifting equipment—only to find out they
were not telling you about comprehensive inspections
that could be critical to the safety of your personnel.
That is what happened to Toyota-Lift of Minnesota,
who used another crane service provider for nearly 15
years without being informed of the safety benefits
involved with performing inspections on internal
components. “We had not been told about these
inspections, despite 14 annual inspections performed
by companies other than Konecranes,” said Kyle Thill,
Director of Service at Toyota-Lift of Minnesota.
The standard inspections performed at Toyota-Lift of
Minnesota relied mostly on visual observations and
measurements. However, not all defects can be seen
with the naked eye.
Toyota-Lift found Konecranes after a few failed
attempts to contact their vendor to schedule an
inspection. “Their failure to do so for approximately two
weeks made us look for alternative solutions, and we
discovered Konecranes,” said Thill.
Critical Inspection
Konecranes worked with Toyota-Lift to develop a customized inspection plan for
the 5-ton bridge crane. Based on the equipment’s use, environment and age of the
hoist, Konecranes advised Toyota-Lift to perform internal inspections on the gear
case, load block and hoist coupling.
The inspections revealed that the needle bearing in the gear case had started to
fail. Without this inspection, the tear could have led to a sudden and catastrophic
failure. Konecranes is now Toyota-Lift of Minnesota’s preferred vendor for crane
inspections and maintenance.
case study: customer’s perspectivecase study
Konecranes reduces risk
with gear case inspection
Company Information: Established in 1978, Toyota Lift of Minnesota currently
offers a full line of high-quality lift trucks, aerial equipment, personnel and burden
carriers as well as warehouse and material handling systems.
“Now we have the comfort of knowing this piece of equipment is
operating safely.”
Kyle Thill
Director of Service
New facility needs
a brand new crane
Last December, our
company needed a one-
ton workstation crane for
the new facility we were
building. The project was
complex for a number
of reasons: our facility
utilized boilers for heat
treating, which required
piping on the walls. So,
the workstation needed
to work around the
pipes. Our building was
nearly finished, so we
needed to get a quote as
soon as possible.
Konecranes proves to be the right choice
We gathered quotes from several crane companies, but we still weren’t satisfied.
That’s when our production supervisor suggested that we call Konecranes, since
they had been performing our overhead crane inspections for the past three years.
They prepared a quote for the project in just one day and proved to be the most
cost-effective option when we considered total cost of ownership.
Konecranes delivered the one-ton XM workstation with two half-ton bridges in just
three weeks. With the chain pendants and the push/pull bridges and trolleys, we
can move products in and out of our heat treatment system with ease. Better
yet, this freestanding system doesn’t interfere with the piping. Overall, this new
process is much faster, and the lightweight crane proves to be much easier
on the workers.
New Building? New Crane?
No Problem!

MAINMAN® catches
major problem
When we first tried
Konecranes MAINMAN®
inspections, we noticed a
vast difference. Instead
of a simple checklist for
“Compliant” or “Non-
Compliant” items, the
MAINMAN inspection
involved details, graphs
and a plan of action. Not
only that, the inspections
included components our
checklists missed – namely, our trolley gauges, which needed to be re-adjusted. We
are glad these problems were spotted so the proper adjustments could be made:
this damage could have led to derailment, skewing or a load drop.
Reaching far beyond inspections
After Konecranes solved this problem for us, we had another major need in our
valve-testing area. We had only one jib to cover two bays. Our forklift trucks would
attempt to attach the valves to the jib, but the grated floors prevented the trucks
from moving all the way into the testing space. Then, our workers needed to scoot
the valves the rest of the way with manual push pallets. Clearly, this situation was
not efficient or safe.
Thankfully, Konecranes custom-built a solution: Workstation Lifting System jib
cranes with a bridge in between them. Because this system was mounted directly to
the wall, it did not require any floor space and spanned much more floor space than
an additional jib could have. Now, our XN chain hoist can travel through the entire
testing area, which lets us transport valves twice as fast as our original situation.
Thanks to Konecranes, our plant is well-maintained and running smoothly!
Konecranes Gives our Plant
a Much-Needed Makeover
Company Information: Piper Valve Systems produces compact high pressure valves
and manifold system components for the oil and gas industry.
Limited mobility leads
to limited productivity
At our facility, we rely
on our overhead cranes
to lift molds into a
plastic injection molding
machine. Our original
system was outdated
and not very productive:
the machine was
misaligned and couldn’t
move left to right.
This meant that our
employees had to push
the crane by hand, and
force the molds into place. Not only was this extremely difficult, but it also slowed
things down significantly at the plant. On top of that, the cranes used pendant
controls. Since the cords were not very long, employees often had to stand on the
machine to operate it.
It was time for a change—we needed a new system that would eliminate these
mobility issues and increase our efficiency.
Konecranes sets plant in motion with new crane system
Konecranes had the perfect solution: two 175’ long, two-ton capacity freestanding
workstation cranes with radio controls. Now, we no longer have to worry about
pushing the cranes by hand. Instead, the new workstation cranes lift and load our
molds with speed and precision. The radio controls allow our operators to maintain
a comfortable distance from the cranes, since they are no longer limited by cords.
Overall, we’re very pleased with our new cranes. Konecranes technicians were able
to install the new system without interrupting production. Now, we feel confident
that our plant can run efficiently!
Konecranes Keeps us Moving
with Workstation Cranes

case studycase study: customer’s perspective
Looking for a
brand-new crane
At our new facility in
Horsehead, N.Y., we
needed a crane as soon
as possible to aid us
in routine maintenance
of our Coil Tubing
Services truck and trailer
fleet. This crane also
needed to be capable
of lifting the devices we
produce—some of which
can weigh up to 4,000
pounds. Because our
business is constantly growing and expanding, we needed to find a crane company
who could not only provide us with reliable equipment, but also with fast, excellent
service.
Konecranes proves to be the perfect fit
LeChase Construction Services recommended that we call Konecranes—they had
purchased cranes from Konecranes in the past and assured us they were reliable.
After careful consideration, we decided to go with Konecranes for five of the six
overhead cranes in our facility.
Konecranes installed a 5-ton single girder top-running crane for us. With inverters on
the bridge and trolley, our cranes run smoothly. The two-speed hoists with remote
controls give us the control we need to operate the crane and lift with ease. We were
impressed with their outstanding service and fast follow-up. In fact, now Konecranes
is servicing all of the cranes in our plant. Clearly, we made the right choice.
The Perfect Combination
of Equipment and Service
Company Information: Schlumberger Technology Corporation is the world’s leading
oilfield services company supplying technology, information solutions and integrated
project management that optimize reservoir performance for customers working in
the oil and gas industry.
Before…
Back in the day, an
automated material
handling facility used two
12-foot jib cranes in its
manufacturing process–
producing components
for conveyor systems.
With the long, 12-foot jib
cranes in the middle of
the runway, it became
difficult to load and
unload their product.
After…
Konecranes replaced both jib cranes with two overhead cranes—one on a 50’
runway and one on a 100’ runway system. Now, they have the entire floor space
to load and unload their product.
Going the Distance

An inefficient system
At our component
manufacturing facility,
we were in the midst
of putting in a new
process, a hand peening
booth, where workers
could chip away at the
metal surfaces of the
400-pound tractor-trailer
axles we manufacture.
We had a small handful
of employees working
on this process, which
involved moving the
axles using a combination of manual labor, forklift trucks and an overhead crane
with a chain host.
We needed a new crane system that would allow us to lift and place the axles faster.
Konecranes sets plant in motion with new crane system
Konecranes installed two free-standing XM Workstation cranes in order to eliminate
the issues we were having. About halfway through the installation, the Konecranes
team and I came to the realization that this system wasn’t going to work for us.
We had hired more employees, so we needed more workstations for them to
use. Konecranes immediately began to help us re-strategize: in order to be more
productive, we needed to be able to have more employees lifting and working on the
axles at one time. Konecranes suggested that we add more bridges, which would
give us more flexibility and add additional workstations for our employees to use.
The perfect fix
Rather than having us purchase an entirely new system, Konecranes engineers
used all the existing components of the XM Workstation cranes to develop an
entirely new system, which saved us a good bit of money. Now, instead of three
bridge workstations, we have 10, and we couldn’t be happier with our new system!
Konecranes Redesigns Crane
System to Suit our Needs
Time for a change
When our original crane
service provider was
acquired by Konecranes
several years ago, we
were required to change
our maintenance plan.
Konecranes worked with
us extensively to ensure
that our transition went
as smoothly as possible,
especially since we were
already accustomed to
our regular maintenance
plan. As we worked with
Konecranes on a new contract, they took extra care to make sure their employees
were well-equipped to take care of our facility—each employee underwent specialized
training so they would know our safety policies and operating procedures.
Konecranes MAINMAN proves to be the best
I was a little reluctant to try Konecranes’ MAINMAN inspection program, especially
since I had been satisfied with our previous inspection contract. As soon as we
started working with Konecranes, I immediately fell in love — I was impressed
by how convenient it was to plan repairs in advance and check the progress of
inspections and repairs online!
Konecranes continues to work closely with us to make sure all our equipment is
kept in top condition. We were so impressed with Konecranes’ ability to handle our
inspections that we started to trust them with larger projects as well — now, they’re
working on two full-scale engineering jobs at our refinery.
Making the Switch:
Konecranes Eases the
Transition to MAINMAN®

case study: salesperson’s perspective
A difficult mission
A chemical plant located in Texas needed to increase the stability of their cranes by
upgrading to inverter drives. The air-controlled cranes regularly performed high lifts
at nearly full capacity. The heavy duty cycle, combined with the hot environment of
Texas, caused the mechanical load brake to overheat frequently.
Inverter drives would eliminate the need for a mechanical load brake and would
ease the plant’s problems. There was just one catch—due to the high levels
of chemicals in the plant, the new control system would need to be specifically
engineered to withstand explosive environments.
Konecranes engineers face the challenge head-on
While other competitors shied away from the project, Konecranes had both the
resources and the expertise to develop a system to allow inverters to run in the
highly-reactive environment.
With top-of-the-line equipment, Konecranes engineered explosion-proof panels
designed to prevent chemicals from entering the control box. For added protection,
the engineers developed a system to pump a constant flow of pressurized air into
the control box. The pressurized air was also designed to protect the controls
from heat damage. Now, the plant can reap the benefits of inverter drives in an
environment where the drives normally could not exist.
Mission: Impossible?
Konecranes Performs
Advanced Modernization
in Hazardous Environment
case study
Monthly breakdowns
reveal the need
for a more proactive
maintenance plan
A brewery in Ohio utilizes
hundreds of overhead
lifting equipment
throughout their facility.
Their crane maintenance
team performed
regular inspections as
required, but did not
proactively seek to
reduce breakdowns. In a
particularly high volume
area, a few of the cranes regularly broke down on a monthly basis.
They needed to find a way to reduce these monthly breakdowns in order to increase
productivity.
Working to prolong crane life
Konecranes performed an in-depth inspection on each crane, searching for defects
and deficiencies. Experienced technicians followed the Konecranes MAINMAN®
process, evaluating the condition of every crane in the building and ranking the
cranes based on safety and production needs. A customized maintenance plan was
created based on the condition of the equipment and the production needs.
The brewery made each repair in a timely manner, with hopes to reduce downtime
due to breakdowns. Technicians replaced brake pads, which had been wearing thin.
Without the thorough brake inspection, the worn brakes could have led to a load
failure. Any chain hoists with defects, rust or corrosion were replaced with new
Konecranes XN hoists.
With every item thoroughly inspected and repaired, breakdowns and repair costs
have been drastically reduced.
Proactive Care Reduces
Breakdowns by 99%

My aching back
I’ve been working at a bottling factory in
Columbus, Ohio, for years. As bottles spin
across the conveyor belt, a machine wraps
the labels around them. In the past, when
the labels needed to be replaced, we had
to lift a 75 pound block of labels and feed
it into the machine. I left work every day
feeling exhausted and sore. I started to
dread having to lift those labels because
it strained my back so much. I knew other
employees felt the same way, so I finally
decided to take action.
A better way to lift labels
The factory manager agreed when I told him
that something needed to be done, so he
called Konecranes and started discussing
some possibilities. After reviewing a lot of
different lifting devices, he decided that an XM freestanding aluminum system with an
AirBalancer hoist was the best choice. Konecranes installed the entire crane system
in only two days, and I couldn’t wait to start using it.
Konecranes AirBalancer provides much needed relief
The AirBalancer is great for so many reasons— first, the custom-built runway covers
the length of all three of our labeling stations, so everyone can use the hoist.
Second, the AirBalancer instantly senses and counteracts the weight of the label
blocks, so the load feels practically weightless to me! And then, with just a flip of a
switch, the air hoist turns into a manipulator, so I can move and place the labeling
blocks without straining my back. So now, lifting those labels is no problem!
AirBalancer’s Got My Back
case study
Konecranes provides
comprehensive,
hands-on training
The Konecranes Training
Institute’s relationship
with this offshore drilling
components manufacturer
began in 2008. Several of
their facilities throughout
the country have received
on-site, Train-the-Trainer
instruction from the
Institute. Crane operators
with varying levels of
experience, from as
few as two years to as
many as 25, have participated in the training program. Instructors of the Institute
put knowledge in layman’s terms and perform hands-on training to show employees
proper rigging techniques, load ratings and inspections on their equipment.
The training continues
Today, the training relationship continues to
evolve and now includes training for Rigging,
Mobile Crane Operator and Hand Signal Training.
Konecranes provided eight courses for them in
2011 and continues to offer classes in 2012.
Jim Lang, General Manager for the Konecranes
Training Institute said, “In 2011, we trained over
80 of their personnel in our customized Train-the-
Trainer program.”
Enhancing Safety with
Crane Operator Training
“Even employees with
more than 15 years’
experience said they
came away from the
course having learned
something new.”
Regional Manager

Tired of heavy lifting
At our plant, we needed a new crane to help us
perform machining and tooling tasks and load
products into fabrication machines. We received a
new machine tool, and desperately needed a new
crane for that workstation area.
Light as air
When Konecranes came to demonstrate AirBalancer,
an air-controlled hoist and manipulator on an
extremely lightweight, freestanding aluminum system,
we all immediately fell in love with it. The hoist made
items feel practically weightless!
Konecranes installed a 500-pound capacity aluminum
XA crane with a 100-pound capacity AirBalancer
in only a few days. The freestanding crane system
improved our whole situation in general. Because
it spans the entire workstation area, we are able to
move the hoist exactly where we need it. We can
even add more units as we grow. With AirBalancer,
employees can perform all machining and tooling
tasks with ease.
AirBalancer Allows
Employees to Lift with Ease
Then...
At our pound cake factory, we were stuck with
an obsolete, out-of-date overhead crane. The
crane was crucial because it was used to perform
maintenance on our conveyor belt. But because
the crane was so old, we were constantly dealing
with breakdowns and the crane needed to be
repaired frequently. Whenever the crane broke
down, we lost hours of production time.
Several of our other facilities were using
Konecranes hoists, and were very enthusiastic
about these cranes. So, we decided to follow suit.
Now...
After touring our facility, Konecranes recommended
a 1-ton capacity XN hoist, with a food-grade hoist
so it would not contaminate the product. As soon
as they installed our new crane, we were impressed!
Now, Konecranes provides yearly inspections and preventive maintenance to ensure
that the new crane doesn’t break down. With fewer breakdowns, we can focus on
our pound cake instead of worrying about expensive emergency repairs!
With Konecranes, Reducing
Breakdowns is a Piece of Cake

case study
Company claims
brake “obsolete”
The overhead crane at
an electrical components
factory broke down after
a bridge brake failed. The
crane was an essential
part of the manufacturing
process, as workers
used it to transport
steel to fabrication
machines. When the
facility asked their
crane service provider to replace the part, the service provider claimed the part
was obsolete. There seemed to be only two options: replace the crane entirely or
custom manufacture a new part. Both options would be expensive and could require
months of downtime.
Konecranes finds correct part
The facility contacted Konecranes for a second opinion before moving forward
with a new crane. Konecranes assured them the problem could be easily solved,
and the part needed was not actually obsolete. Konecranes technicians gathered
information from the brake plates and used this information to determine the
correct brake style for the crane.
Part ordered and installed in two weeks
Konecranes technicians set the brake according to OEM requirements. After performing
an operational test, the crane was placed back into service—only two weeks after the
breakdown. With the quick brake installation, Konecranes saved the facility thousands
of dollars in remanufactured parts and weeks of unnecessary downtime.
Quick Thinking Saves Customer
Weeks of Downtime
case study
The Konecranes SMV lift truck
knocks out the competition
Better, faster, stronger:
Lift trucks
Company Information: Toyota Material Handling is Northern California’s leading full
service Material Handling dealer of everything from lift trucks to utility vehicles.
It was time for us at Toyota Material Handling Northern
California to make a tough decision: Which lift truck should
we choose for our customers? We had three rounds to
decide, based on Maintenance, Strength and Cost.
Stepping into the ring, the SMV Konecranes lift truck shows
tremendous reliability, with a load sensing hydraulic system
that only needs to be serviced every 4,000 hours. What a
tough number to beat!
Here comes the rest of the competition, with service required every 1-2,000 hours.
The First Round goes to … Konecranes SMV
But lift trucks need more than just low maintenance costs; they need to be tough.
Which lift truck is stronger, tougher and more durable than the rest?
In a test of strength, the Konecranes SMV is the clear winner. On average,
Konecranes’ box section frame is twice as strong as the channel “C” frame the
competition uses.
The Second Round goes to … Konecranes SMV
The crowd is anxious for the final, and possibly most important, round. Which truck
is the most cost-effective? Knocking out the competition, the Konecranes Lift Truck
shows off an astonishingly reasonable price tag!
And the Winner is … Konecranes SMV!
“At Toyota Material Handling of Northern California, we know a
champion product when we see one. That’s why we chose to
supply the Konecranes SMV Lift Truck to our customers.”

case study: then and now
Then…
The odds were against Tencate Advanced
Armor. They desperately wanted to bid
on a multi-million dollar order to create
bulletproof lining for vehicles, and they had
an extremely short time frame to prove
themselves. Relying on forklift trucks,
they were only producing 50 armored
linings per day—a mere third of what the
new order required. If they were going to
win this order, they needed to triple their
production rate, and they needed to do it
immediately.
With time running out and the odds
stacked against them, Tencate called
Konecranes. Working as quickly as they
could, Konecranes determined several
options. Given the time constraints, it
would be impossible to install overhead
cranes—that would take weeks. There had
to be another solution…
That’s when it hit them: freestanding XM cranes with vacuum lifter attachments.
They were installed in a matter of days—no time was wasted. Four days later,
Tencate had a brand new system that allowed them to change the aluminum dies
with speed and precision.
Now…
So, did their plan work? Were they able to succeed? Yes! Because the upgrade
was completed so quickly, Tencate won the order by proving that they had what it
took to meet the production requirements. Now, they produce a record-breaking
200 aluminum molds in one day—above and beyond any amount they could have
produced when they were using their forklift trucks.
Hitting the Target
Konecranes Helps Tencate Win
Multi-Million Dollar Bid
Company Information: Tencate Advanced Armor manufactures armor lining for
North American military vehicles. The bullet-proof armor fabric protects military
vehicles from bullets, fire and improvised explosive devices (IEDs).
Wanted: sleek,
top-of-the-line cranes
Christie was building a
new showroom for its high-
end projector systems so
clients could preview their
installations. They needed
new cranes that could
assemble their rear-view
projectors with precision
and care, especially
since these components
could cost up to a million
dollars. Christie not only
wanted a reliable system, but also wanted cranes that would be visually compatible
with their sleek, modern equipment.
Konecranes installs brand new XN system
Konecranes provided exactly what Christie needed: a brand new XN enclosed track
system. This system suited Christie’s needs for a number of reasons: first, the two
workstation cranes were highly ergonomic, with variable speed drives for bridge and
trolley motions. Second, the cranes were capable of supporting centers up to 30 feet
along the runway, which reduced the need for additional support. Third, the system
was easy to operate and moved with precision. Finally, the entire system had a clean,
uncluttered look, so aesthetically, it was an easy fit into Christie’s showroom.
Reliable cranes a big hit
Overall, Christie was pleased with their new installation. Luis Laino, manufacturing
engineer at Christie’s showroom said, “I can lift a $50,000 component, and if it
falls, it will fall all over a project that someone has paid up to a million dollars for.
[These cranes] are reliable—that is my favorite feature! Over the last year and half,
absolutely nothing has happened to them or the loads they’ve handled.”
More than just a pretty crane
Reliability and Precision
Protect Christie’s Projectors
Company Information: Christie is a global visual technologies company offering
solutions for business, and entertainment. Audiences have been awestruck by
their over-the-top projected virtual reality events at venues such as the 2010
Vancouver Olympics.
case study

case study
machine tool
service
Konecranes Machine Tool
Service Provides Decades
of Excellent Service
A facility filled with
critical machine tools
Patterson Pump, a manufacturer
of some of the world’s largest
water pumps, relies primarily on
large sophisticated machine tools
to manufacture a variety of their
products. These machine tools
are in production 24/7 and are
the lifeline of their business. With
machine tool downtime potentially
costing the plant anywhere
between $200-600 an hour, it is
essential these machine tools are
kept in excellent condition.
Machine Tool Service keeps facility running in peak condition
The experts at Konecranes Machine Tool Service have been supporting Patterson
Pump for over 20 years – prior to October 2009 operating as Machine Tool
Solutions Unlimited. As Konecranes Machine Tool Service, they continue to provide
the same quality rebuilding, retrofitting and preventive maintenance services today.
When a flash flood left every machine tool in their facility damaged, Patterson Pump
contacted Konecranes Machine Tool Service to handle the recovery process. Under
the direction of Harold Schoch, Machine Tool Services Director of Sales, numerous
Machine Tool Service specialists were deployed, along with several Konecranes
crane specialists, to support the recovery.
Working in concert with Patterson Pump employees, Konecranes machine tool
and crane specialists repaired all of the machine tools and placed them back into
operation in a timely and efficient manner. This prompt workmanship resulted in
substantial savings to Patterson Pump.
Beyond Machine Tools
Patterson Pump was recently looking to purchase two 75-ton overhead bridge cranes.
Due to the excellent service Konecranes Machine Tool Services provided to the
facility, Patterson Pump decided to purchase this new equipment from Konecranes.
Company Information: Patterson Pump is a world leader in fire protection and
municipal pumps, using the latest in computer aided pump design to offer
customers state-of-the-art products.

case study: QUICK FIX
PETROCHEMICAL
How a Simple Modernization
Added Multiple Production
Hours to the Day
Just out of reach
Our engineering company used to deliver tanks from
the paint shop directly to the loading dock. When we
changed our manufacturing process and stopped
painting these tanks, we had to change the location
of our loading dock. This change should have been
seamless, yet it turned out to be a major problem. Our
overhead crane had a limitation setting built to suit
our prior needs. This feature forced the crane to stop
at a certain location along the runway—which now
happened to be a few feet short of the loading dock.
We tried to override this setting to allow the crane to
travel the last part of the runway to the loading dock,
but with the crane’s limited control system, it simply
was not possible.
For nearly four months, we compensated–using lift trucks to carry the load the last four
feet. This maxed out the lift trucks and wasted valuable time; after lowering the load
from the crane, the rigging was removed and then the load was strapped to the lift
trucks for the remainder of the journey. The system also presented a potential safety
hazard. As manual labor increased, injury potential also increased.
Konecranes’ quick fix
For many years, we had been dissatisfied with our crane service provider, which is
why we decided to contact Konecranes.
Konecranes modernization engineers quickly relocated the travel zone limit to give
the crane access to the newly-required loading area. This modernization saved 10
minutes per load. With an average of 20 loads per day, this quick fix added over
three hours to our production day!
Picture this: An overhead crane lifts an oil refinery tank, and it floats through the
factory like a massive white cylinder in the air. It’s quite a sight to see—that is,
until the crane abruptly stops along the runway—just four feet before reaching the
loading dock.

case studycase study: salesperson’s perspective
An oil refinery outside of
Houston, Texas has over
600 pieces of equipment,
all of which need to be
inspected monthly. I send
in my best, most qualified
technicians to work on-
site to help keep the plant
100% OSHA compliant.
With thorough inspections
completed every month,
the repairs are done
as quickly as possible.
However, our relationship
extends far beyond
these detailed monthly
inspections.
Sometimes the refinery
asks us for help with more
specialized projects. For
example, when hurricane
winds were coming, they
were worried they did not
have a great way to lock
down their equipment. So,
we helped design wind
locks for them. These
wind anchors, which are designed to lock outdoor cranes into place during severe
weather, helped the refinery keep their equipment safe during the harsh storm.
We’ve been working with this refinery since 1995, and it’s clear that our relationship
has been built to last.
More than Just
Fair Weather Friends
Cracked drum requires
immediate attention
When employees at this
oil refinery spotted cracks
on the drum of their
heavy duty coker crane,
they knew they needed
to act quickly. Results
could be tragic. If the
crane was out of service
too long and unable to
produce petroleum for an
extended period of time,
the entire refinery could
be forced to shut down.
Konecranes sent an experienced modernization engineer to assess the situation.
Using his years of experience, he worked quickly to diagnose the drum. He soon
determined a failure had occurred between the gear and the drum. Because the
shaft was hollow, it did not provide the stability required for the crane—there was
too much pressure on the shaft as it entered the drum.
Modernization to save the drum
The engineer made the necessary repairs at Crane Pro Parts, Konecranes’ parts
organization. With great precision and care, he increased the diameter inside the
hoist drum and redesigned the shaft – making it completely solid. The redesigned
shaft had the necessary strength to prolong the life of this coker crane.
Konecranes Enhances the Life
of a Critical Coker Crane

power
case study: dual perspectives
How Konecranes helped keep
the Los Angeles City Lights On
Company Information: The Los Angeles Department of Water and Power provides
reliable electric service and safe, affordable water to the city’s 3.8 million residents
and businesses.
The power for the city of Los
Angeles comes from a most
unusual, yet scenic location.
The Castaic Power Plant
is cut into the mountains
surrounding the Castaic Lake.
The plant passes water from
local reservoirs in order to
generate hydroelectric power
for the city.
A minuscule window of opportunity
Written from the Customer’s Perspective
Last spring, our generator was scheduled for a complete overhaul in only a few
months, but we had a major problem. When our generator needs maintenance,
two massive bridge cranes work in tandem to lift and carry it over 500 feet of
railway. With the city of Los Angeles depending on the generator for a portion of
their power supply, our window of opportunity for repairs is very small. However,
our cranes were not ready to lift the generator. The rails were outside of tolerance
requirements, which had caused excessive wheel wear.
Our goal was to replace all 500 feet of railway, along with 32 bogey end truck
wheels in two months—otherwise, we were going to miss the deadline for upgrading
our generator.
Meticulous planning pays off
Written from the Konecranes On-Site Manager’s Perspective
My priority was to make sure this wheel assembly and rail replacement was carried
out safely and efficiently. Each day, I sat down with the branch and went over the
plan for that day, working to avoid potential safety issues. Everything needed to
be scheduled to the last detail because this was a logistically difficult project. We
devised a system to work on the railway and the wheels simultaneously. Because
the wheels had to be driven two hours to a Konecranes service branch in order to
be repaired, we even took traffic time into consideration to make sure everything
went smoothly.
Ahead of schedule, breathing a sigh of relief
Written from the Customer’s Perspective
Thanks to Konecranes’ efficient work schedule, the replacements were completed
two full weeks ahead of schedule. I was so pleased with their extensive planning,
hard work and dedication to the project. Konecranes went above and beyond to
ensure we would be able to upgrade our generator.

case study: branch manager’s perspective
An unusual request
One day, to our surprise,
a competitor called our
local office requesting
our technician’s help. A
hydroelectric plant was
experiencing load brake
issues with one of their
cranes. The plant needed
to repair the crane in
time for a scheduled
turbine change. By the
time the competitor
called us, the crane had
been out of commission
for several days, and they
were unsure of how to
solve the problem.
Speedy repair leads to new relationship
Though this was an unusual situation, Konecranes decided to step in and help.
Our modernization representative worked in conjunction with two of our most
experienced technicians to repair the crane. In just a couple of days, the crane was
up and running—just in time for the turbine change.
After our repair, the plant was no longer interested in working with our competitor.
Because many of their cranes are decades old, we started to work with the facility to
upgrade the cranes. They awarded Konecranes with an annual MAINMAN® Inspection
contract not only with that specific plant, but with all six plants in the area.
Konecranes Comes
Through in a Bind
case study: Branch manager’s perspective
Worn down components
pose problems
During a Konecranes
MAINMAN® inspection
of a hydropower plant’s
80-ton Turbine Room
crane, we came across
a major problem:
the upper and lower
sheave blocks showed
excessive wear, which
could, if left unattended,
lead to a breakdown.
Though the crane was
used infrequently, it
was essential to the facility, as they used it to lift their enormous turbines. With a
scheduled turbine replacement on the horizon for AEP, this crane needed to be in
top condition. After speaking with one of our modernization engineers, we advised
AEP that they replace the sheaves in the upper sheave nest and lower block
assembly, and upgrade from bronze brushing to a newer, roller bearing for the new
sheaves. They asked us to do the upgrades because of our expertise, as well as
our willingness to adapt to their safety regulations.
An essential repair
During the inspection, we also discovered a second problem. The festoon had
been installed in the wrong location by another crane company during a previous
repair. We quickly adapted the scope of the project to include moving this festoon
into the proper place. The turbine room crane was repaired and returned to service
immediately following the work. Even with the last minute festoon relocation, we
were able to complete the project in time for their scheduled turbine replacement.
Since the repair, the crane has been performing in top condition. In the future,
our goal is to help the plant reduce the need for extreme and costly repairs by
implementing a preventive maintenance plan.
Konecranes Demonstrates the
Importance of Proactive Care

case study
Out of time, out of options
At the Los Angeles Department of Water and Power (LADWP), two massive 375-
ton cranes lie in wait. Though used infrequently, the two overhead lifting devices
are essential. Working in tandem, the plant depends on these cranes to lift hydro
turbines out of the building for scheduled maintenance.
LADWP had a small window of opportunity to perform maintenance work on the
turbines, and the wheels had worn too thin to safely perform the lift.
Working together for faster speed
LADWP began searching for a provider to keep the maintenance work on schedule.
Konecranes won the competitive bid to design, manufacture and install wheels. To
meet the deadline, Konecranes depended on the strong partnership between its
service and parts departments.
To determine the specific needs of LADWP, a product manager from Konecranes
parts department, Crane Pro Parts, and the local service branch traveled to LADWP’s
site. While at the site, Konecranes analyzed the equipment, took preliminary
measurements and discussed the customer’s expectations. The Crane Pro Parts
product manager also made recommendations to upgrade the raw material
specifications, test certification and performance requirements and simultaneously
replace the axles to prevent damage during removal and/or installation.
The Konecranes parts manufacturing facility pushed the project forward quickly,
delivering the two sets of 16 wheel assemblies ahead of schedule. The Konecranes
service team replaced all 32 wheel assemblies, allowing LADWP to complete the
scheduled maintenance on time.
Konecranes service and parts departments were able to partner together to help
the end user:
• Understand the scope of the challenge
• Recommend a solution
• Deliver the recommended solution – ahead of schedule
By partnering together, the two departments were able to demonstrate the overall
capabilities of Konecranes.
No Time? No Problem!
Crane Pro Parts Delivers
Wheels in a Flash
Company Information: The Los Angeles Department of Water and Power provides
reliable electric service and safe, affordable water to the city’s 3.8 million residents
and businesses.
An impressive feat
The moment of truth
had arrived: 75 invited
guests—including
business partners,
elected officials and
economic development
leaders — stood
alongside our 100
employees inside our
massive assembly plant.
As the crane lifted the
cover onto the wind
turbine, the audience
applauded enthusiastically. This was a remarkable achievement for Acciona and
another major step toward renewable energy solutions.
The right crane for the job
At our brand new facility in Iowa, we needed a crane that could perform a very
specific, extremely important task. We needed a crane that could, when the
time was right, lift the 3,000-pound cover off our 130-ton wind turbine and then
transport the turbines out of the facility for delivery. This AW3000 wind turbine, a
new, more powerful and efficient wind turbine, was the first of its kind to be built
in North America. We needed a reliable crane to do the job. That’s why we chose
Konecranes to provide a 190-ton overhead crane for our plant.
Without Konecranes, none of this would have been possible. Their reliable
equipment allowed us not only to assemble our wind turbine, but to demonstrate a
bright future for wind technology.
A Brighter Future
with Konecranes’ Help
Company Information: ACCIONA, a global leader in alternative energy solutions, has
been pioneering renewable energy for over 20 years and is active in all of the five
major renewable-energy solutions. For more information about ACCIONA’s AW3000
wind turbine, visit www.aw3000.com.

case study: Branch manager’s perspective
Controls in need
of repair
When this coal-burning
power plant was faced
with a major problem,
they immediately called
us. Their original Static
Stepless crane controls
had become unreliable
and needed to be
repaired as soon as
possible. Because we
had been performing
inspection repairs at their
facility for several years,
they asked us to quote
the project—and we were awarded the bid over three direct competitors based on
our project proposal and ability to complete the project on time.
A successful upgrade
Because very few companies know how to repair and
maintain Static Stepless controls, we knew this project
was going to be a challenge. We sent one of our most
skilled Konecranes technicians to upgrade the crane to
new inverter drives as well as remote controls—but he
didn’t stop there. To improve the crane’s performance,
he replaced all gear case and running gear bearings.
Without his dedication and technical know-how, we
never would’ve been able to complete the project on
time. Since the upgrade, the power plant has had very
limited breakdowns and has a complete set of spare
parts. They were so pleased with our cost-saving
upgrade, they asked us to perform the same upgrade
on their other turbine crane.
Konecranes Wows Facility
with Crane Upgrade
“Konecranes always
provides excellent
service—and
like always, they
impressed us with
this crane upgrade.
Our crane runs
better than ever and
we are thrilled that
they’re working on
our other crane!”
Plant Manager
case study: Extreme crane makeover
A serious undertaking
Written from the customer’s perspective
It was a critical time or us at the plant. We
were in a panic because the Department
of Energy had just posed more stringent
requirements for overhead cranes, which
meant that our 50-year-old crane wasn’t
compliant anymore. But that wasn’t even the
worst of it! We needed to upgrade our crane
immediately, which was going to be challenging
for several reasons: first, the crane was
unbalanced and located in a very tight space,
so moving it was going to be tricky. Second,
and most importantly, the crane was located in
a contamination area—which meant this could
be a hazardous process. We needed to find
a company who could face these challenges
head on and modernize our crane quickly, but
even more importantly, we wanted a company
who could do this with zero safety incidents.
Taking charge of the transformation
Written from a Konecranes technician’s perspective
We needed to remove the existing trolley from the crane, take it out for disposal and
put a new trolley on the bridge—all with limited time and space. The project had a
potential for a 1% bonus on the multiple million dollar contract if the work could be
carried out with no safety incidents. We were ready to take on the challenge.
Dressed in protective gear to shield us from the contamination, we lifted the 40-
ton trolley off the girders from below, and then rotate it to bring it down into the
constrained space. Once we removed the girder, the area was decontaminated so
we could do the rest of the modernization in our street clothes. We then installed
a new custom-designed crane system that would fit their facility and meet the new
standards. The entire modernization was completed in 11 weeks, and our safe,
efficient work earned us the safety bonus.
A safer, more efficient workplace
Written from the customer’s perspective
Konecranes proved they are the experts in the crane field. They really pulled off
a tremendous project here. Our new system has two hoists, designed to perform
balanced tandem lifts. Also, they installed a custom hook on our bottom block,
so now we can lift all types of containerized loads—no matter the shape, size or
source. Overall, I couldn’t be more pleased with the modernization.
Warning! Extreme
Crane Makeover Ahead!

Several months ago, we
invited Konecranes to our
quarterly maintenance
management meeting
to present a Gear Case
seminar to maintenance
managers from our nine
plants in Oklahoma.
Konecranes showed
us how important it is
to have our gear cases
inspected regularly. We
quickly learned in the
seminar that small cracks
in the gears can lead to serious maintenance and operational matters, including in
some instances, unexpected load drop. Unlike other crane issues, this is a “silent
killer;” there’s no noise, no indication whatsoever—the load just drops!
Due to age and duty cycle, our cranes were at risk. We decided that each crane
needed an in-depth, open gear case inspection to detect any defects or deficiencies
that cannot be seen during standard visual inspections.
We knew right away that we needed to work with Konecranes to develop an
inspection plan—we didn’t want to experience a catastrophic failure! So far, we
have had gear case inspections for four of our locations, and inspections are lined
up for the rest.
Creating a Long-Term
Maintenance Mindset
case study
One crane at a time...
How a Konecranes Crane
Can Help Save the World
Testing massive blades
Wind turbine blade testing is critical to maintaining
high standards of reliability and meeting international
certification standards. As they were designing the
testing facility, the Massachusetts Clean Energy
Center realized they needed an overhead crane to
transport the turbine blades to the facility. Their
testing facility would be the first in the United States
to allow researchers to test blades up to 300 feet in
length—roughly the length of a football field.
The right crane for the job
Konecranes won the order to provide a 50-ton crane,
with two 25-ton auxiliary hoists, by providing the most
advanced features at a cost-effective price. The two-
speed crane was equipped with synchronization features, which allowed the hoists
to operate in tandem, maximizing the lifting capacity of the crane.
Promoting clean energy
Without the overhead crane, it would be impossible to verify the quality of the
blades. The tests reduce the need for costly and time-consuming repairs to
damaged blades. Thanks to their successful crane installation, Konecranes has
helped create a future in clean and alternative power generation.
Company Information: The Massachusetts Clean Energy Center’s Wind
Technology Testing Center is the first in the United States to test turbine blades
up to 300 ft. in length.

case study: crane detective
Mysterious motor failure
For years, Konecranes had been servicing the crane
motors at an energy-from-waste facility. Suddenly, the
motors started failing—in just a few short weeks, five or
six motors mysteriously failed.
The Konecranes crane detective takes the case
Right away, I met with the customer and the consultant
who designed the motors to search for clues.
The first thing I asked for was a duty cycle analysis.
If an employee had been abusing the equipment—like slamming the grapple or
something of that nature—the report would tell us. Furthermore, if the motors were
experiencing any type of abuse, I would be able to deduce during which shift the
damage had occurred.
I spoke to the plant manager as well. We soon discovered there was a sudden
surge of current into the motors—50% more than usual. After calling the
Philadelphia service branch, I determined the spike in electricity was caused by an
error in the controls. After I adjusted the controls, the problem was corrected.
Another case closed!
The adventures of the crane detective:
the Motor Failure Mystery
energy
from waste

case study
Pulp & Paper The squeaky monorail
The monorail crane system at the paper plant winds
around the mile-long facility, with sharp turns,
similar to a maze. The tight 90 degree corners of the
system are critical for maneuvering rolls of paper
throughout the building.
When employees at the plant began hearing high-
pitched squealing noises coming from the crane, they
instantly began to worry.
The self-diagnosis
Immediately the plant was convinced the rails were the problem. If this was the
case and the rails needed to be replaced, they would have to shut down the line
for weeks. With downtime costing upwards of $25,000 per hour, the plant was in a
panic. Luckily, they called Konecranes to make the emergency repair.
The doctor steps in
Konecranes sent in one of their most experienced technicians. He diagnosed the
problem in less than two hours: it wasn’t the rails that were the problem—it was
the wheels, which had worn down and needed to be repaired. Moving quickly, he
made the repairs in as little time as possible, which saved the plant thousands of
dollars in downtime and lost productivity.
When Self-Diagnosis Goes
Wrong, Call Konecranes

case studycase study
Out with the old, in with the new:
New crane nearly
eliminates breakdowns
Company Information: With facilities in more than 20 countries, Ahlstrom is a high
performance materials company that partners with well-known global businesses to
provide products such as filters, wall covers, flooring, labels and food packaging.
A crane past its prime
The 40 year-old dry end
crane at an Ahlstrom
facility in Brazil was not
designed to function in
the dusty environment
of a paper mill. Without
dust-proof enclosures
or air conditioning, the
electrical controls and
components deteriorated
at an accelerated rate. The
crane still used its original
contactor controls, which
did not have precise speed
control options necessary
for careful load positioning and ultimately caused premature wear to the gears, motor
and brakes. As a result, the dry end crane broke down on a monthly basis.
Ahlstrom made plans to rebuild the crane, but quickly encountered a major
obstacle: due to the crane’s age, many parts were obsolete and would need to be
custom-made. The crane was critical to production and could not be out of service
for an extended period of time.
New crane proves its worth
Konecranes successfully demonstrated the value of purchasing a new 20-ton
capacity, three-trolley dry end crane. The crane’s sealed enclosures protected against
water, humidity and dust. The new inverter technology placed less stress on internal
components, minimized equipment wear and reduced load sway.
To minimize downtime, Konecranes technicians installed and commissioned the
new crane before removing the old crane during scheduled downtime. This strategic
installation allowed Ahlstrom to remain productive throughout the entire process.
Since its installation five months ago, the crane has not had a single breakdown.
Not your
average upgrade
A paper company in
Southern California
asked Konecranes to
install a new power
bar system, but there
was a catch: the crane
would need to remain
in service throughout
the entire project.
Furthermore, the power
bar was located above the drive controls for the paper machine, which would
make accessing the conductor bar difficult.
Konecranes devised a plan for their workers to remain safe during the
installation, keep downtime to a minimum, and meet the tight, 10-day deadline.
Successful installed ahead of schedule
Thinking creatively, the Konecranes technicians built a workstation platform on the
crane with scaffolding, which gave them complete access to the conductor bar. To
reduce the risk of electric shock while working, the technicians mounted conductor
staff on the end truck and runway rail to maintain constant ground.
In the high heat paper mill environment, the technicians replaced the rusted metal
clips with more substantial ones, and installed a heavy-duty conductor bar along
the building. The new four conductor bar system was insulated, finger-safe and met
OSHA safety requirements. Konecranes completed the project in only seven days—
three full days ahead of schedule.
Creative Power Bar Replacement
Keeps Paper Mill Going Strong

case study
From twenty pinches to a single “bite”
A paper mill in California previously offloaded wood
yard sites with an excavator, which was not efficient
for loading and unloading trucks. The excavator’s set
of pinchers took 20 pinches to unload a truck filled
with wood. So, the company decided to try a rotator
crane from Konecranes, which operates from an 80-
foot tall tower on a circular track and can offload an
entire truck in a single bite.
The paper mill was excited to have the crane—it would
save hours every day. There was only one problem: no
one in the facility knew how to use it.
Konecranes provides hands-on training
The Konecranes Training Institute was thoroughly
prepared to train the team on the operation of the
crane. After a presentation on crane safety and an overview of the crane’s features,
the employees’ curiosity was peaked. The Konecranes instructors then moved into
hands-on operator training where the crew learned how to offload a truck in only two
minutes, while maintaining complete control of the load.
Konecranes Goes the Extra
Mile with Operator Training
“Thanks to Konecranes, we not only have quality equipment,
but we also know how to operate it safely and efficiently. To me,
that’s just as important.”
Paper Mill Manager
case study: Customer’s perspective
I would like to send
a sincere thanks
to our Konecranes
on-site manager
for going above
and beyond at our
paper plant. He
spoke up about a
safety issue when
he noticed a cord
reel electrical
outlet sitting in
water. It should have been on a ground fault indicator, as we
require. If he had not mentioned it, we would not have found it,
and one of our guys could have been electrocuted, or suffered a
serious electric shock. This went far beyond simply caring about
our equipment—he was watching out for the safety of the entire
plant. We were very fortunate that he spotted this safety issue
before anyone was injured, and for that, all of us at the plant
are truly grateful!
Union Chief Steward
A satisfied customer shares his story
Konecranes to the rescue

case study
intermodal
& RAIL
Working Together to Improve
Efficiency and Safety
A solid, trust-based relationship
The Huntington Service Branch has built a solid
relationship with the local CSX Locomotive Shop
over the past five years. Recently, we sat down with
them to discuss the benefits of Non Destructive
Testing (NDT) of hooks and below-the-hook devices,
with a specific focus on the existing 250-ton
J-Hooks that are used to lift locomotives in the
facility. CSX agreed this inspection process would
improve the efficiency of their operations and the
overall safety of their cranes.
Inspection reveals a cracked hook
We worked with CSX to develop an inspection process that would not interfere with
their day-to-day business. Our technicians completed the testing of the J-Hooks in
just one day.
NDT revealed that one of the J-hooks was cracked. The Konecranes inspector
contacted an engineering office to evaluate the hook and determine whether or
not repairing the hook was a possibility. The engineering department approved the
repair, the work was completed over the weekend, and the hook was returned to
service on the following Tuesday.
Success leads to proactive maintenance
Because the repair only caused production to be down for one day, the CSX plant
was extremely pleased with the outcome. To prevent any hook-related issues in the
future, the J-Hooks for the 250 ton crane are now checked annually. Since the initial
repair, there have been zero lost production days from hook-related issues.
Company Information: CSX Corporation, one of the United States leading
transportation suppliers, provides rail-based transportation services, including
traditional rail service and the transport of intermodal containers and trailers.

case studycase study: customer’s perspective
A major decision
At our railroad yard, our
trains and repair shops
never rest. We stay busy
24 hours a day, seven
days a week. With the
fast-paced nature of
the railroad, our lifting
equipment needs to be
kept in peak condition at
all times—we can’t afford
to have any breakdowns.
So, you can imagine
how frustrated we were
when one of our critical
overhead cranes started
vibrating violently. We
needed to get this crane back into service right away, so we contacted several crane
companies, hoping to fix the problem as soon as possible. We soon discovered we
were going to have to replace the entire hoist—a repair that was going to be both
extremely expensive and time consuming.
We didn’t want to spend the money on a brand new hoist without exploring every
option, so we called Konecranes for a second opinion. We wanted to make sure that
a replacement was absolutely necessary.
Konecranes proved to be the right choice
Good thing we called Konecranes, because it turns out we didn’t have to replace
the hoist! Konecranes technicians performed a visual inspection on the open gear
case to find the source of the malfunction. After looking at the gear case, they
showed us that the gears were improperly timed. In a matter of hours, Konecranes
technicians reassembled the gears into the proper positions.
Overall, our decision to call Konecranes was the right one. Their fast repair saved
us thousands of dollars and weeks of unnecessary downtime to replace the hoist.
Now, our hoist functions properly, and we haven’t had any breakdowns.
The Second Opinion that Saved
us Thousands of Dollars
Too dark...
At a busy locomotive shop, workers relied on an
overhead crane to repair locomotives, but the crane
could not be used at night, when the sky was pitch
black. Due to an increase in customer demand, the shop
needed to begin running the crane at night.
The shop decided that lights would allow them
continued use of the crane after the sun went down.
So, the locomotive shop ordered two Konecranes jib
cranes with 5-ton capacity hoists, with bright lights that shined all night.
Too heavy...
But, day after day of moving the manual jibs grew tough. The heavy loads grew
cumbersome. Productivity began to decline. The shop needed to find a way to make
the cranes more efficient.
So, Konecranes modernized the jib cranes to include motors.
Just right...
The shop now has the proper means to perform the needed tasks thus increasing
the level of productivity at the facility. The motorized jib unit allows the staff to
effortlessly move the materials with precision. In addition, employees were able
to increase the total throughput of the facility by increasing the number of units
repaired in a set period of time.
The locomotive shop is pleased to have a crane that is just right.
Finding the Crane
that is “Just right”

case study
steel &
primary metals
Making Vintage Cranes
a Thing of the Past
Vintage cranes in need of modernization
AM Castle Metals owned two vintage 20-ton P&H™
cranes built in 1968 that were already in place when
they bought the facility. The cranes ran on open span
copper wires attached to the bridge which posed
a potential electrocution hazard to anyone working
around the crane with a forklift. In addition, the
constant vibration of over 40 years of use had caused
broken wire and switch issues, and parts were
becoming difficult or impossible to find for the wound-
rotor controls.
Updating cranes with this millennium’s technology
Modernization specialists from Konecranes developed a solution. They recommended
replacing the 1968-era magnetic controls with modern variable frequency drives,
designed to provide smooth acceleration and deceleration speeds, reducing wear and
tear on the drive train and decreasing load swing.
To avoid lost production time, Konecranes scheduled the modernization so the
plant experienced no downtime, and both cranes were back in service within a
week. More importantly, a modern festoon system with closed circuit switching
replaced the open span copper wiring, enhancing the safety of the working
environment.
Modern crane reduces breakdowns by almost 100%
Prior to the modernization, $15,000 was spent in 2008 and again in 2009 on repair
and maintenance on this crane. After the modernization, throughout 2010, repair
costs were zero. According to AM Castle Metal’s operations and quality manager
Jerome Mead, they have not experienced a single breakdown or lost crane hour
since the work was completed.
Company Information: AM Castle Metals supplies specialty products in bar, tube,
plate and sheet to metal users worldwide.
If your crane hasn’t been updated since Nixon was
president, then it’s probably time for a change.
“Konecranes provided us with a much safer way to run our
cranes. We have gained in productivity, safety, and we’ve had
no inspection or detection problems since we’ve done this work.
There have also been no repairs whatsoever. In the long run,
this modernization is going to save us a lot of money. And when
it comes to safety, we can’t put a price on it. That’s priceless.”
Jerome Mead
Operations and Quality Manager

case study: then & nowcase study: salesperson’s perspective
A Satisfied Customer
Shares his story
To Whom it May Concern:
I am writing this letter on behalf of Brannon Steel concerning one of your
technicians. I would like you to know that he is one of the most requested
technicians for service calls at our facilities at all times. And there are many
reasons for this. Not only are his skills second to none as far as we are concerned,
but also his positive attitude and willingness to help make him a delight to work
with. He is constantly giving us advice and teaching us how to better take care
of our equipment. I would describe this gentleman as the perfect representative
of your company and we are sure you are very proud to have him and other great
technicians like him on your staff. When we look for suppliers and service providers,
one of the major things we are looking for is people we enjoy working with. So, keep
up the good work!
Sincerely,
Dave Lee
Special Projects Manager
Brannon Steel
Company Information: Since 1968, Brannon Steel has been an industry leader
supplying quality carbon steel parts to OEMs and custom fabricators throughout
Canada and the United States.
Then…
This steel manufacturing
plant relied on 20 double-
girder, top-running cranes
and two stacker cranes to
handle slit coil. Installed
when their facility opened
in 1965, these cranes
were equipped with single-
trolley magnetic five-step
controls operated from a
pendant station. Because
the plant was only
handling coils, a single C
hook was enough.
Things were about to
change at this plant. They needed to be capable of working with long pieces of
structural steel and pipe up to 60 feet long—meaning they needed to add a second
hoist to each crane to lift these long pipes. In addition, the plant decided it was
time to upgrade their drives and controls to improve the operation and reliability of
their cranes.
Now…
Since they had been providing superior maintenance service and minor crane
enhancements to the plant for many years, Konecranes won the bid over three
other companies to complete the upgrade. The plant had confidence that
Konecranes would complete the modernization in a professional manner and on
time. In just six weeks, Konecranes equipped the first of three of the plant’s cranes
with rebuilt trolleys, new inverter controls, festoon wiring, bridge motor and gear
reducers and radio control. The other two cranes followed immediately after the first
one was finished.
Brand new inverter drives allow the cranes to run smoothly and efficiently. Rather
than using pendant controls attached to the crane, operators are now safer and
more mobile with the new radio controls. The plant is so pleased, they are making
plans to upgrade the rest of their cranes.
Konecranes Performs
Much-Needed Upgrade
“Thanks to Konecranes’ upgrades, our plant is more productive
than ever. The new drives and radio controls make it so much
easier to operate our cranes—and as soon as the new hoists
were installed, we started moving pipes by the truckload.”
Plant Manager

case study: customer’S perspective
Getting Back on
Track with RailQ
Six years ago, our
plant was faced with
the challenges of old
equipment: around
60% of our production
cranes are over 40
years old, which led to
major crane alignment
problems, resulting in
squeaky wheels. Overall,
we used to have a lot of
plant-wide crane issues,
and we were constantly
changing wheels, cables
and bearings. When the
cranes went down, we
stopped moving.
Konecranes technicians performed a RailQ runway survey, which showed us graphs
of the railway alignment. That’s when we found out that the wheels weren’t the
problem. We used to replace crane wheels fairly frequently, but RailQ showed that
we needed to replace the crane rail in several bays and adjust the elevation. Since
then, we haven’t needed to replace any wheels.
As long as annual inspections continue, we can now expect crane wheels to last
a long time. In any case, I’ll be long gone by then! Konecranes workers, along
with the RailQ survey, have really made a huge difference. In the past two years
there have only been about three times when I’ve had to use my engineers to
get a crane working again. Previously, it was every day. Now, we have hardly any
unscheduled downtime.
Company Information: The Aluminum Company of America (Alcoa) is the world’s
leading aluminum producer, spanning 31 countries and providing services to
several industries, including aerospace, automotive, packaging, construction and
commercial transportation.
case study
Gear case implosion
catches foundry off-guard
Deep in this hot, dusty
foundry, a 30-year-old
hot metal crane mass-
produced nearly 50
engine blocks every day.
One day, the gear case
suddenly imploded, leaving
employees stunned.
“We heard a booming
noise from the gear
case,” an employee
described. “Then the
crane started skewing so
badly, we thought it might
come off the track!”
Because the foundry could potentially lose millions of dollars in lost production time,
they gave Konecranes a tight, two-week deadline to complete the massive repair.
A crane in desperate need of an upgrade
The problem was obvious to the Konecranes technicians: the crane was performing
more rigorous lifts than its intended design.
“It’s not surprising the gear case failed. This was a Class ‘D’ crane performing the
work of a Class ‘F’ crane,” explained a Konecranes technician.
After upgrading the gearing, the technicians performed inverter upgrades to reduce
wear on internal components and improve speed control options. As a final boost
to enhance safety, the technicians upgraded the radio controls, to function with the
new inverter drives, allowing the operators to lift and tilt the ladle from a distance,
keeping them further away from the blazing furnace.
Working 16 hour days, the Konecranes team completed the repairs and upgrades in
only 10 days—four days ahead of the deadline. It has been year since the upgrade,
and downtime at the plant has significantly decreased.
Konecranes Saves an
Overworked Crane with
a Speedy Upgrade

case study: branch manager’s perspective
The charge ladle crane was commissioned in 2005,
but vibration on the main hoist became a problem
in the last few years. Eventually, the hoist had to be
taken out of service. Several service companies,
along with steel plant personnel, could not solve the
problem. Frustrated the issue still hadn’t been fixed,
they called Konecranes—the original manufacturer
of the crane. After spending thousands of dollars to
repair this crane, they wanted another opinion, so
we agreed to take a look at the crane. As the OEM,
we had access to all of the documents we needed to
assess the situation. After my initial visit, I called the “Crane Doctor,” one of our
best Engineers, hoping he could provide some insight.
Without even looking at the crane, he told me over the phone what he thought the
problem was and assured me he’d be able to fix it. As we drove to the plant, he
said, “I can’t wait to hear what they have to say when we finally fix this problem.”
As soon as he looked at the crane, he showed where the shaft had split due to
severe misalignment. After seven hours of shimming, checking gear mesh and
making alignment changes to gear sets both vertically and horizontally, the crane
ran smoothly and quietly. The steel plant was amazed at how quickly and accurately
the “Crane Doctor” corrected the problem.
The “Crane Doctor” Successfully
Revives another Crane
“This was excellent work done in a very short period of time,
and I would recommend this engineer’s services to anybody,
anytime to solve very difficult problems.”
Steel Plant Manager
case study: then and now
Then …
Heavy crane causes worker strain
The overhead crane in this facility made the metal
finishing process hard work. Every day, their staff
would gather together to roll the 3-ton, under-running
girder crane into place. Once the device was pushed
initially, it moved steadily. Unfortunately, as the laws
of physics would explain, once it gained speed it could
be difficult to stop.
The manufacturing process involved two chemical
production lines, where parts passed from basket
to basket and from tank to tank in order to achieve
the appropriate finish. The crane’s movements were not smooth, which resulted in
the metal parts being dropped into the chemical solution—making it necessary for
employees to “fish” out the dropped items.
After the metal was dipped into the solution, there was not an effective draining
method. Using a forklift, the tubes were removed from the basket and propped
up against a skid to drain. Between the heavy crane and the less-than-ideal
draining process, the production process was time-consuming. Customer demand
was increasing, and the challenges derived from the crane were proving to be
unacceptable.
The metal processing plant desperately needed a new lifting device to enhance the
safety of their employees, improve ergonomics and streamline production.
Now …
XM Workstation Cranes reduced worker fatigue and improved production
With two new Konecranes XM workstation cranes with radio pendant controls, the
situation at the plant is much different. Now, the cranes travel the 180 foot length
of the runway with just the push of a button.
The new cranes were easily integrated with existing spreader bars and baskets.
The advanced radio controls allow the operator to isolate the hoists individually
or use them in tandem. By isolating the hoists, the operator can raise one end of
a suspended load higher than the other to drain the tubes directly over the tank,
which keeps the floor drier and minimizes solution waste. With better lifting control,
the employees no longer have to retrieve dropped items from the chemical tanks.
The XM workstation cranes have helped double production at the facility. Instead of
only coating two items at a time, the new configuration allows for at least four items
to be processed simultaneously.
WLS Crane improved
Productivity with
advanced Ergonomics

Jib cranes not getting
the job done
In our manufacturing
facility, we had several
jib cranes that we relied
on to load barrels of
welding wire onto skids.
To keep up with our busy
production schedule,
we need to move about
50 barrels a day. Our jib
cranes were outdated
and not performing
correctly. If one of the
cranes broke down, we
couldn’t manually lift the
heavy barrels. Instead, we had to use fork lift trucks—an operation which was slow,
cumbersome, inefficient and unsafe.
We knew we needed to upgrade our current system. Since Konecranes had been
performing our monthly inspections, we decided to contact them and order three
new XM cranes.
Konecranes makes vast improvements
When Konecranes technicians arrived to install our new cranes, they showed us
that our original cranes hadn’t been installed properly—no wonder we were having
so many problems!
Konecranes didn’t stop with the new crane installation. At our plant, we also use a
monorail system to load and unload reels of welding wire—but because it wasn’t
up to code, we had decided to stop using it altogether. Konecranes extended the
system and made the necessary repairs so that it was fully functional. Since then,
we haven’t had any crane-related issues, and our plant functions better than ever.
Konecranes Keeps us on Track
case study: MANAGER’S perspective
Rapid motor failures
For the past several
years, we have been
working with a steel
company that operates
class E cranes in a
high heat environment.
Konecranes Crane Pro
Parts motor shop had
been servicing their
powerful crane motors
to keep the cranes in top
condition. So, when some
of the rebuilt motors
began to fail within days
of installation, we had to
work quickly to determine
the cause.
Finding the root of the problem
I dug into the problem, along with a salesperson and an outside motor design
consultant. We discovered the motors were experiencing problems because the
controls were not set up properly. Our service technician came in over a holiday
weekend to check the controls set-up, test in-rush currents and examine other
critical values. He made several adjustments to the controls during the visit that
have improved the service life of the rebuilt motors.
In addition, we suggested the customer improve the cooling and brushes on the
motors so they could stay in top condition and would be less likely to break down.
Restoring Life to
High-Powered Motors
“Thanks to Crane Pro Parts, our motors are performing at a
much higher level and are lasting a lot longer—and we are
confident our cranes are in the best hands possible.”
Plant Manager

Even More Happy Customers

Recommandé

Recommandé

Contenu connexe

En vedette

En vedette (19)

Similaire à Even More Happy Customers

Similaire à Even More Happy Customers (20)

Dernier

Dernier (20)

Even More Happy Customers