XN10 I&M MANUAL 2010 0 Kone Cranes Hoist

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INSTALLATION AND
MAINTENANCE MANUAL
XN CHAIN HOIST
XN10 CHAIN HOIST
English
STD-K-KHA-F-CQD-ENG

This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not be
reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010) Konecranes Plc.
All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

THIS PAGE INTENTIONALLY LEFT BLANK

2/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not be
reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010) Konecranes Plc.
All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

m
m

CAUTION: Read the instructions supplied with the product before installation and
commissioning.
CAUTION: Keep the instructions in a safe place for future reference.

Table of contents

4
5

INTRODUCTION ........................................................................................................................................ 5
1.1
Contact Information ........................................................................................................................... 5
1.2
Warranty ............................................................................................................................................ 5
1.3
Disclaimer .......................................................................................................................................... 5
1.4
Safety ................................................................................................................................................. 6
1.5
Placards and Instructions .................................................................................................................. 8
INSTALLATION ......................................................................................................................................... 9
2.1
General .............................................................................................................................................. 9
2.2
Lubrication ......................................................................................................................................... 9
2.3
Mounting .......................................................................................................................................... 10
2.4
Load Hook Throat Opening ............................................................................................................. 10
2.5
Electrical Connection ....................................................................................................................... 11
2.6
Three Phase Power Connections .................................................................................................... 12
INITIAL START-UP .................................................................................................................................. 13
3.1
General ............................................................................................................................................ 13
3.2
Correcting the Direction of Hook Travel .......................................................................................... 13
3.3
Operational Checks – No Load ....................................................................................................... 14
3.4
Operational Checks – With Load ..................................................................................................... 14
HOIST OPERATION ................................................................................................................................ 15
LOW HEADROOM TROLLEY ................................................................................................................. 16
5.1
Description – Technical Characteristics (low headroom trolley)...................................................... 16
5.1.1 Technical Characteristics ............................................................................................................. 16
5.1.2 Environmental Data ..................................................................................................................... 17
5.1.3 Optional equipment ...................................................................................................................... 17
SWIVEL TROLLEY .................................................................................................................................. 18
6.1
Description – Technical Characteristics (swiveling trolley to 3.2 tons) ............................................ 18
6.1.1 Technical Characteristics ............................................................................................................. 18
6.2
Installation of Swivel Trolley ............................................................................................................ 19
6.3
Electric Swivel Trolley ...................................................................................................................... 20
6.3.1 Swiveling trolley (3.2 tons) ........................................................................................................... 21
6.3.2 Swiveling trolley (3.2 to 5.0 tons) (NOT LOCALLY AVAILABLE) ................................................ 21
6.3.3 Procedure to adjust swivel trolley guide rollers ........................................................................... 22
MAINTENANCE ....................................................................................................................................... 23
7.1
Basic Hoist Construction.................................................................................................................. 23
7.2
Motor / Body..................................................................................................................................... 23
7.3
Hoist Motor Brake and Load-Limiting Device .................................................................................. 24
7.4
Slip Clutch Adjustment..................................................................................................................... 24
7.4.1 Slip Clutch Adjustment after Installation ...................................................................................... 25
7.4.2 Hoist Motor Brake Adjustment ..................................................................................................... 26
7.4.3 Replacement Criteria for Motor Brakes ....................................................................................... 27
7.5
Load Chain....................................................................................................................................... 28
7.5.1 General ........................................................................................................................................ 28
7.5.2 Maintenance Inspection ............................................................................................................... 28
7.5.3 Load Chain Specifications (see Figure 13).................................................................................. 30
7.5.4 Removing the Load Chain ........................................................................................................... 30
7.5.5 Installing the Load Chain ............................................................................................................. 31
3/85

This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

7.6
Fall Stop Assembly .......................................................................................................................... 33
7.6.1 General ........................................................................................................................................ 33
7.6.2 Removing fall stop (Figure 16)..................................................................................................... 33
7.6.3 Fall Stop Installation (Figure 16) .................................................................................................. 33
7.7
Chain Container ............................................................................................................................... 34
7.7.1 Removing Chain Container (Figure 17) ....................................................................................... 34
7.7.2 Installing Chain Container (Figure 17) ......................................................................................... 34
7.8
Vinyl Chain Bag (optional) ............................................................................................................... 35
7.8.1 Installing Vinyl Chain Bag (Figure 18) ......................................................................................... 35
7.9
Limit Switches .................................................................................................................................. 36
7.9.1 Upper and Lower Travel Safety Limit Switch ............................................................................... 36
7.9.2 Upper and Lower Rotary Travel Limit Switch (Optional Only on 3-Phase units) ......................... 37
7.10 Hooks ............................................................................................................................................... 38
7.10.1
General .................................................................................................................................... 38
7.10.2
Hook Inspection ....................................................................................................................... 39
7.10.3
Top Hook ................................................................................................................................. 40
7.11 Control Changes and Fuses ............................................................................................................ 41
7.12 Single-Speed Solo Hoist – 208 Volt Wiring Diagram ...................................................................... 43
7.13 Single-Speed Solo Hoist – 230 Volt Wiring Diagram ...................................................................... 44
7.14 Single-speed Solo Hoist – 460 Volt Wiring Diagram ....................................................................... 45
7.15 Two-Speed Solo Hoist - 208 Volt Wiring Diagram........................................................................... 46
7.16 Two-Speed Solo Hoist - 230 Volt Wiring Diagram........................................................................... 47
7.17 Two-Speed Solo Hoist - 460 Volt Wiring Diagram........................................................................... 48
7.18 Two-Speed Solo Hoist – 575 Volt Wiring Diagram .......................................................................... 49
7.19 Single-Speed Hoist – Modular Crane – 208 Volt Diagram .............................................................. 50
7.20 Single-Speed Hoist – Modular Crane – 230 Volt Diagram .............................................................. 51
7.21 Single-Speed Hoist – Modular Crane – 460 Volt Diagram .............................................................. 52
7.22 Two-Speed Hoist – Modular Crane – 208 Volt Diagram ................................................................. 53
7.23 Two-Speed Hoist – Modular Crane – 230 Volt Diagram ................................................................. 54
7.24 Two-Speed Hoist – Modular Crane – 460 Volt Diagram ................................................................. 55
7.25 Two-Speed Hoist – Modular Crane – 575 Volt Diagram ................................................................. 56
7.26 Wiring Diagram – 3 Button – Push Button ....................................................................................... 57
7.27 Wiring Diagram – 5 Button – Push Button ....................................................................................... 58
7.28 Wiring Diagram – 7 Button – Push Button ....................................................................................... 59
8 PREVENTATIVE MAINTENANCE .......................................................................................................... 60
8.1
Maintenance and Inspection Table .................................................................................................. 60
8.2
Lubrication ....................................................................................................................................... 61
8.3
Recommended technical support for various spare parts ............................................................... 62
8.4
Screw Tightening Torque (lb-ft) Specifications ................................................................................ 62
8.5
Troubleshooting ............................................................................................................................... 63
9 PARTS ILLUSTRATION .......................................................................................................................... 64
9.1
Hoist Body........................................................................................................................................ 64
9.2
Gear Mechanism With Motor Brake ................................................................................................ 66
9.3
Lifting Assembly ............................................................................................................................... 68
9.4
Controls............................................................................................................................................ 70
9.5
Upper and Lower Limit Switch ......................................................................................................... 72
9.6
Double Brake Mechanism................................................................................................................ 73
9.7
Low Headroom Trolley..................................................................................................................... 74
9.7.1 Low Headroom Trolley (Drive Components) ............................................................................... 74
9.7.2 Low Headroom Trolley (Suspension Components) ..................................................................... 76
9.8
Electric trolley (Swiveling trolley 0 to 3.2 Tons (3200 Kg)) .............................................................. 78
9.9
Push Button Assembly – Horizontal Pairs of Buttons ...................................................................... 80
9.10 Push Button Assembly – Horizontal Pairs of Buttons ...................................................................... 81
9.11 Push Button Assembly – Vertical Pairs of Buttons (Option) ............................................................ 82
9.12 Push Button Assembly – Vertical Buttons (Option) ......................................................................... 84

4/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

1
1.1

INTRODUCTION
Contact Information

Please do not hesitate to use the following contact information in the event that you may need assistance:

Konecranes
4505 Gateway Boulevard
Springfield, OH 45502

General Telephone:

937 - 525-1190

Toll Free Telephone (US):

866 - 291-1754

General Fax:

937 - 328-5165

1.2

Warranty

All sales are subject to the Konecranes Standard Terms and Conditions of Sale and Product
Warranty. Copies are available upon request from Konecranes and are expressly incorporated by
reference hereto.

1.3

Disclaimer

This Manual has been prepared by Konecranes to provide information and suggestions for hoist installation,
maintenance, and inspection personnel. This manual should be used in conjunction with the XN Electric
Chain Hoist Operator’s Manual to teach safe operating practices to all personnel associated with hoist
operations and maintenance.

It is NOT intended that the recommendations in this manual take precedence over existing plant safety rules
and regulations or OSHA regulations. However, a thorough study of the following information should provide
a better understanding of proper installation, maintenance, and inspection procedures that are to be followed
in order to afford a greater margin of safety for people and machinery in the area of hoist operations.

It must be recognized that this is a manual of recommendations for the Hoist Installation, Maintenance, and
Inspection personnel and its use is permissive not mandatory. It is the responsibility of the hoist owner to
make personnel aware of all federal, state, and local codes and regulations. The owner is responsible for
providing instruction and insuring that certain installation, maintenance, and inspection personnel are
properly trained.

5/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

1.4

Safety

Read and understand this manual before using the hoist.

Important issues to remember during installation, operation, maintenance, and inspection are provided at the
hoist control stations, at various locations on the hoist, in this manual, and in the XN Electric Chain Hoist
Operator’s Manual. These issues are indicated by DANGER, WARNING, or CAUTION instructions or
placards that alert personnel to potential hazards, proper operation, load limitations, and more.

m
DANGER:

Indicates an imminently hazardous situation, which, if not avoided, will result in death or
serious injury.

m
WARNING:

Indicates a potentially hazardous situation, which, if not avoided, could result in death or
serious injury.

m
CAUTION:

Indicates a potentially hazardous situation, which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against unsafe practices.

Taking precedence over any specific rule, however, is the most important rule of all:

“USE COMMON SENSE”

It is a responsibility of the hoist owner / user to establish programs to:
1. Train and designate hoist operators, and
2. Train and designate hoist inspectors / maintenance personnel.

6/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

The words SHALL and SHOULD are used throughout this manual in accordance with definitions in the
ASME B30 standards as follows:

SHALL

indicates a rule is mandatory and must be followed.

SHOULD

indicates a rule is a recommendation, the advisability of which depends on the facts
in each situation.

Hoist operation, hoist inspection, and hoist maintenance personnel training programs should be based on
requirements in accordance with the latest edition of:

ASME B30.16

Safety Standard for Overhead Hoists ( Underhung )

Such training should also provide information for compliance with any Federal, State, or Local Code
requirements, and existing plant safety rules and regulations.

If an overhead hoist is installed as part of an overhead crane or monorail system, training programs should
also include requirements in accordance with the latest editions, as applicable, of:

•

ASME B30.2

Safety Standard for Overhead and Gantry Cranes, Top Running Bridge,
Single or Multiple Girder, Top Running Trolley Hoist

•

ASME B30.11

Safety Standard for Monorails and Underhung Cranes

•

ASME B30.17

Safety Standard for Overhead and Gantry Cranes, Top Running Bridge,
Single Girder, Underhung Hoist.

7/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

NOTICE:

It is a responsibility of the owner / user to install, inspect, test, maintain, and operate
a hoist in accordance with the ASME B30.16 Safety Standard, OSHA Regulations,
and ANSI / NFPA 70, National Electric Code. If the hoist is installed as part of a total
lifting system, it is also the responsibility of the owner / user to comply with the
applicable ASME B30 volume that addresses other types of equipment used in the
system.
Further, it is the responsibility of the owner / user to require that all personnel who
will install, inspect, test, maintain, and operate a hoist read the contents of this
manual, XN Electric Chain Hoist Operator’s Manual, ASME B30.16 Safety Standards
for Overhead Hoists (Underhung), OSHA Regulations, and ANSI / NFPA 70, National
Electric Code. If the hoist is installed as part of a total lifting system, all personnel
must also read the applicable ASME B30 volume that addresses other types of
equipment used in the system.

DANGER: Failure to read and comply with any one of the limitations noted in this manual
can result in product failure, serious bodily injury or death, and / or property damage.

Konecranes has no direct involvement or control over the hoist’s operation and application. Conforming to
good safety practices is the responsibility of the owner, the user, and its operating personnel.

Only those Authorized and Qualified Personnel who have shown that they have read and have understood
this manual and the XN Electric Chain Hoist Operator’s Manual should be permitted to operate the hoist.

The owner / user SHALL insure that all Operators read and understand the XN Electric Chain Hoist
Operator’s Manual prior to operating the hoist.

1.5

Placards and Instructions

READ and OBEY all Danger, Warning, Caution, and Operating Instructions on the hoist and in this manual
and XN Electric Chain Hoist Operator’s Manual. Make sure that all placards are in place and legible.

Failure to comply with safety precautions in this manual and on the hoist is a safety violation that may result
in serious injury, death, or property damage.

8/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

INSTALLATION

m
2.1

DANGER: Before installing, removing, inspection, or performing any maintenance on a
hoist, the main switch shall be de-energized. Lock and tag the main switch in the deenergized position in accordance with ANSI Z244.1. Follow other maintenance procedures
outlined in this manual and ASME B30.16.

General

Prior to installation, the unit shall be checked thoroughly for damage during shipment or handling at the job
site.

Each complete electric chain hoist is load tested at the factory at 125% of the nameplate-rated capacity.

All hoists are designed for the type of mounting specified by the purchaser. The adequacy of the supporting
members (monorail beams, cranes, hangers, supports, framing, etc.) is the responsibility of user / owner and
shall be determined or verified by qualified personnel.

Read the instructions contained in this manual and the XN Electric Chain Hoist Operator’s Manual as well
as any other related manuals. Observe the warning tags attached to the unit before the installation is
started.

2.2

Lubrication

The hoist gear case comes completely pre-lubricated with grease.

Note: Open trolley wheel gearing has not been greased at the factory. See the trolley manual for proper
gear lubricant to use before installing hoist.

The load chain requires lubrication prior to first use. Chain lubricant is included with shipment of each new
chain hoist.

9/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

2.3

Mounting

Below are three types of mounting:
1.
2.
3.
4.

Hook Mounted
Base Mounted
Coupling Mounted
Trolley Mounted – NOT SHOWN – is accomplished via a Hook or Trolley Coupling to the Trolley
Assembly.

Figure 1. Mounting Types

For all trolley-mounted hoists, refer to appropriate trolley manual for trolley installation instructions.

After a trolley-mounted hoist has been assembled to a beam, check for balance. Each trolley-mounted hoist
is balanced at the factory for “as shipped” condition. Any auxiliary devices (radio control, lights, hose reels,
etc.) furnished and mounted by “others” may require additional counterweight. Hoists must hang straight
without a load or there will be a noticeable “kick” when a load is applied to hook. An unbalanced hoist /
trolley may result in damage to equipment.

2.4

Load Hook Throat Opening

CAUTION: ANSI B30.16-1998 recommends that the throat opening of a load hook be measured
and recorded prior to putting a hoist into service and that a gage be made to provide a quick
visual inspection for a bent hook as required during routine inspections. Record this
information before initial start-up. See Section 7.10 for more detailed hook information.

10/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

2.5

Electrical Connection

The user / owner must provide the main power supply hardware (cable, conductor bar, fuses, disconnect
switch, etc.).

CAUTION: Make sure that the power supply voltage is the same as that shown on hoist serial
plate / nameplate.

CAUTION: Make sure that fuses and other current overload devices are in place to protect the
power supply.

CAUTION: Make sure that power cable or conductors have sufficient capacity to maintain the
hoist supply voltage by ±5 percent of nominal voltage under all operating conditions. Poor
voltage regulation may cause motor overheating or sluggishness, and chattering / inoperative
motor brake(s) and controls.

CAUTION: Do not use power supply cables with solid conductors.

WARNING: Failure to properly ground the hoist presents the danger of electric shock.

WARNING: An improper or insufficient ground connection creates an electrical shock
hazard when touching any part of the hoist or trolley.

11/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

2.6

Three Phase Power Connections

Figure 2. Three Phase Control Box Power Connections

Minimum cable sections:
2

Power supply:

AWG 16 (1.50 mm )

Auxiliary current:

AWG 18 (0.75 mm )

Control box/hoist:

AWG 18 (1.00 mm )

2
2

12/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

INITIAL START-UP

WARNING:

3.1

Before connecting power to hoist, check all “motion” buttons on pendant control
assembly to make sure that they operate freely without binding or sticking. Check
pendant cable and strain relief connection to ensure that they are not damaged.

General

Initial start-up procedures are as follows:

Read all attached WARNING tags and placards affixed to hoist.
Oil load chain generously over entire length of chain.
Make sure that load chain is not twisted. If so, untwist load chain before using.
Make sure fall stop is placed at least 6” [150 mm] from last chain link on free end.
Install chain container.
If furnished, make sure that trolley wheels have proper spacing in relation to beam flange. See
appropriate trolley manual for details.
Check direction of hook travel to make certain that it corresponds to respective control button that is
depressed. That is, does hook travel “UP” when UP BUTTON is depressed? If OK, go to section 3.3. If
not, proceed to section 3.2 for correcting direction of travel.

3.2

Correcting the Direction of Hook Travel

WARNING: DO NOT change control leads in pushbutton enclosure or at motor relays. DO
NOT change nameplates on pushbutton assembly. The upper/lower safety limit switch is
wired in series with “UP” control circuit as furnished from factory. Changing pushbutton
control leads or nameplates will prevent the upper safety travel limit switch from functioning
properly.

Reversing any two power leads of a three-phase AC motor will reverse the direction of rotation.

Reverse any two leads of a three-phase power at the main power source or at connections to motor.
Do not change internal wiring of hoist.
After changing two of the main power leads, recheck direction of rotation. Press “UP” button only. If
hook travel goes in “UP” direction, proceed to section 3.3. If not, redo section 3.2.

13/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

3.3

Check hoist motor brake function. Run empty load block up or down to check that load block does not
drift more than 1.0 inch [25mm]. If so, adjust brake as described in Section 7.3 of this manual.
Run empty load block down to check that fall stop (located on free end of load chain) makes proper
contact with upper / lower travel safety limit switch and that limit switch functions properly.
Run empty load block up to check that load block makes proper contact with upper / lower travel safety
limit switch and that limit switch functions properly.
Run empty load block up and down several times while checking for proper tracking of load chain.

3.4

Operational Checks – No Load

Operational Checks – With Load

After completion of no-load operational tests, the user /owner should perform a full load test even though
each complete hoist is load tested at factory.
Lift a near capacity load about one (1) foot [30cm] above floor level. Check that the brake holds load.
Also, check stopping capability of brake when lifting to a stop and lowering to a stop.
Move trolley the full length of monorail or crane beam. Check for any binding of trolley wheels on flange
and/or interference at splice joints, hanger connections / bolts, etc.
Check contact with stops. Contact with stops SHALL only be made with trolley bumpers. Stops that are
designed to make contact with wheels SHALL NOT be used.

14/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

HOIST OPERATION

m
m
m

WARNING: BEFORE PROCEEDING WITH THE NORMAL OPERATION OF THIS HOIST, THE
OPERATOR/(S) SHALL BE TRAINED IN ACCORDANCE WITH THE XN Electric Chain Hoist
Operator’s Manual AS SUPPLIED WITH THIS HOIST.
WARNING: FAILURE TO READ AND COMPLY WITH ANY ONE OF THE LIMITATIONS NOTED
IN THIS MANUAL AND THE XN Electric Chain Hoist Operator’s Manual FURNISHED WITH
THIS HOIST CAN RESULT IN PRODUCT FAILURE, SERIOUS BODILY INJURY OR DEATH,
AND / OR PROPERTY DAMAGE.
WARNING: REFER TO SECTION 1.0 OF THIS MANUAL FOR CONTACT INFORMATION IF
ADDITIONAL ASSISTANCE IS NEEDED.

15/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

LOW HEADROOM TROLLEY

Figure 3. Low headroom trolley

5.1

Description – Technical Characteristics (low headroom trolley)

NOTE: The trolley you have just purchased must be used only with the nominal load indicated on the
rating plate.

NOTE: The trolley’s service life will depend upon the level of duty, the average operating time, the
number of starts and the maintenance applied to it.

5.1.1 Technical Characteristics
The low headroom trolley can be used for loads from 60 kg up to 5000 kg with all our electrical chain hoists.
It can be driven with an inverter drive unit or a dual or single speed unit.

16/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

5.1.2 Environmental Data
Ambient temperature:

-10°C to +40°C

Protection degree:

IP55 as standard

Sound level:

70 decibels at 1 m

5.1.3 Optional equipment

Limit Switch: This cuts off the directional movement when the trolley reaches the end of its run.

Electric Actuation Device: This actuates the supply line; the slide block must not exceed the rolling
profile (A).

Brush: This allows for earthing, due to the brush rubbing on the profile element.

Raceway Stops: Not supplied: These must be fitted on the profile element, at the end of the trolley run.

17/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

SWIVEL TROLLEY

6.1 Description – Technical Characteristics (swiveling trolley to 3.2
tons)

NOTE: The trolley you have just purchased must be used only with the nominal load indicated on the
rating plate.

NOTE: The trolley’s service life will depend on the level of duty, the average operating time, the
number of starts and the maintenance applied to it.

6.1.1 Technical Characteristics

Fem Class
IP
Insulation class
Duty factor
Operating temperature
Power supply frequency
Standard speed
Default acceleration time (Deceleration time)
Thermal protection for motor
Thermal protection for frequency converter
Noise level

Type 1

Type 2

30 Hz

100 Hz

≤1000 kg

>1000 kg

IP55

40%

-10°C, +40°C

60 Hz

20/5 m/min 80/20 fpm

2.5 s

Option

Std.

70 db

18/85
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Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

6.2

Installation of Swivel Trolley

The service life of the trolley depends upon the way it is installed. The instructions in this manual must be
followed carefully for the installation, use and maintenance of the hoist. Any use contrary to these
instructions can be dangerous. Do not use hoist until this manual has been fully read and understood.
Always keep this manual near the hoist, available to the operator and the person in charge of maintenance.
Make sure that the safety rules are followed (harness, clearance of work areas, posting of instructions to be
followed in the area, etc.).
The Trolley can be mounted on any type of standard profile (see: setting of the flange width).

NOTE: Check the width of the runaway rail and adapt the spacing of the flanges of the trolley as
indicated by the tables.

Make sure:

That the profile is secured.
That the profile is suitable to the loads to be supported.
That the dimensions are compatible with the trolley that is to be installed.
That the electrical characteristics of the mains network conform to those of the motor.

Carry out:
1 – Disassembly of the trolley:

Remove the side plate on the counterweight side.

Position the trolley on the beam.

Refit the side plate.
(see: Tightening torques)
2 – Without disassembly of the trolley:

Install the trolley on the profile, by the end.

Fit the travel limit stops (not provided) at the end of the runway.

Check that the nuts are correctly tightened.
(see: Tightening torques)
After these checks, perform the following test with care:
1. Drive in one direction with the slow speed for a few seconds.
2. Accelerate up to the high speed and keep the high speed for 5-10 seconds.
3. Follow the same procedure in the other direction.
4. If the trolley drives in the wrong direction, swap the cables (blue and white) of the motor or the wires on
D1 and D2.
5. Check the function of the slow down and end limit switches.

19/85
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XN10 I&M MANUAL/EN/11.30.2010

Figure 4. Drive wheel and idler wheel/side plates

Adjust drive wheel and idler wheel/side plates as shown above.

6.3

Electric Swivel Trolley

Figure 5. Electric swivel trolley

Table 1. Electric swivel trolley
HOIST TYPE

SWIVELING
TROLLEY
TYPE

CAPACITY

NUMBER OF
WHEELS

WHEEL
DIAMETER

MOTOR TYPE

C05

SWIV32

0 – 1 ton

100

2 x TMU 1 (35
Hz)

C10

SWIV32

0 – 2 tons

100

2 x TMU 2 (100
Hz)

C16-20-25

SWIV32

0 – 3.2 tons

100

2 x TMU 2 (100
Hz)

20/85
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XN10 I&M MANUAL/EN/11.30.2010

6.3.1 Swiveling trolley (3.2 tons)
Figure 6. Swiveling trolley (3.2 tons)

CAPACITY MAX 3.2 TONS (3200 KG)

RAY OF CURVE MINI 2.6 FEET

6.3.2 Swiveling trolley (3.2 to 5.0 tons) (NOT LOCALLY AVAILABLE)
Figure 7. Swiveling trolley (3.2 to 5.0 tons)

CAPACITY MAX 3.2 TO 5 TONS (3200 TO 5000 KG)

RAY OF CURVE MINI 3.9 FEET

21/85
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XN10 I&M MANUAL/EN/11.30.2010

6.3.3 Procedure to adjust swivel trolley guide rollers
1.
2.
3.
4.
5.
6.

Loosen nut “A” (8 plcs).
Adjust guide rollers the maximum distance away from beam.
Place swivel trolley on beam.
Move trolley to curve section of beam.
Adjust guide rollers allowing approximately 3/16” (4-5 mm) clearance per side using screw “B.”
Tighten nut “A” (8 plcs).

Figure 8. Swivel trolley guide rollers

NOTE: Adjustments should be made with swivel trolley in radius of monorail.

22/85
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XN10 I&M MANUAL/EN/11.30.2010

MAINTENANCE

7.1

Basic Hoist Construction

Figure 9. Basic Hoist Components

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

7.2

LOAD BLOCK ASSEMBLY (2-FALL SHOWN)
LOAD CHAIN
ELECTRICAL CONTROL ENCLOSURE
TOP HOOK
HOIST GEAR BOX ASSEMBLY
CHAIN CONTAINER & HARDWARE
HOIST BODY / MOTOR
LOAD HOOK SAFETY LATCH
FASTENER
PIN

Motor / Body

The hoist motors are designed to provide dependable hoisting service. The standard motors are enclosed
for IP55 rated protection against normal hazards of dust and moisture. The motor bearings are sealed and
do not require further greasing.

The hoist body is constructed of aluminum and requires no maintenance. Remove from service and replace
the hoist body if damaged.

23/85
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be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
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XN10 I&M MANUAL/EN/11.30.2010

7.3

Hoist Motor Brake and Load-Limiting Device

The hoisting motor is equipped with a D.C. electromagnetic disc brake. The brake brings the load to a
smooth and quick stop and holds the load when the motor is not energized. An energized coil releases the
hoist brake to allow the hoisting motor to run freely when in use.

The load-limiting device is a slip clutch and it is integrated into the design of the hoist motor brake. Even if
the clutch slips, once power is removed, the brake will engage to stop and hold the load.

7.4

Slip Clutch Adjustment

Figure 10. Slip Clutch Adjustment

24/85
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XN10 I&M MANUAL/EN/11.30.2010

CAUTION:

SEE Figure 10.
Make sure the motor is not running before placing tool on the nut (ITEM 5) to adjust
it. Do not touch any moving components.
The slip-clutch generates heat when slipping. ITEMS 3 & 4 absorb this heat. When
these items become too hot, clutch adjustment may be difficult due to unstable
behavior of friction surfaces. If this happens, allow brake & clutch assembly to cool
before trying to re-adjust slip-clutch.
Decreasing torque too much when adjusting slip-clutch will allow a suspended load
to free-fall when trying to lift. If this occurs, release the motion button and the brake
will engage to stop and hold the load.

7.4.1 Slip Clutch Adjustment after Installation
1.
2.
3.
4.
5.

Hook a load of at least 110 percent but not more than 125 percent of nameplate capacity.
Remove plastic cap from inspection hole in brake cover.
Raise load at slow speed and fast speed to test slip clutch operation.
Insert a socket (13mm) through inspection hole, and slide it over nut (ITEM 5 - Figure 10).
Turn nut in required direction:

Turn nut clockwise to increase the torque.

Turn nut counterclockwise to decrease the torque.
6. Repeat steps 3 and 4 until load can be barely lifted in fast speed. CAUTION: DO NOT OVERHEAT.
If overheated, clutch may not adjust due to instability of friction surfaces.
7. Once adjustment is completed, install plastic cap.
8. Check function of clutch at 100 percent of nameplate-capacity while in fast speed.

NOTICE:

The slip clutch / Torque Limiter is a safety device to prevent overloading of the hoist.
This device is not intended for use as means to measure the weight of load being
lifted.

25/85
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XN10 I&M MANUAL/EN/11.30.2010

7.4.2 Hoist Motor Brake Adjustment
Figure 11. Cross Section of Hoist Motor Brake

If maximum air gap of brake has been reached or will be exceeded before next inspection, readjust air gap.
Minimum air gap
X = 0.008” [ 0.2 mm ]

Maximum air gap
X = 0.020” [ 0.5 mm ]

Before adjusting brake, remove load. Per ANSI Z244.1, lockout and tag main disconnect switch in deenergized position. Follow other maintenance procedures outlined in this manual and ASME B30.16.
1. Remove brake cover and gasket.
2. With a feeler gauge, check three (3) places near each mounting bolts to measure air gap ( X )
between brake thrust disc (item 7) and coil (item 6).
3. To adjust air gap use a 0.008” feeler gauge and proceed as follows:
A. Slightly loosen motor brake mounting screws (item 10), so that adjusting nut (item 11) still
touches brake housing.
B. To reduce air gap, turn adjusting nut (item 11) counterclockwise.
C. To increase air gap, turn adjusting nut (item 11) clockwise.
D. Check air gap after adjusting the brake. Make certain the (3) screws (item 10) are tightened per
Torque specification. See Section 8.4.
4. Check brake operation. Run load block up and down several times without a load to test operation of
brake. Then, lift a capacity load about one foot above floor, stop, and check that brake holds load.
5. Install gasket and brake cover.

26/85
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
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XN10 I&M MANUAL/EN/11.30.2010

7.4.3 Replacement Criteria for Motor Brakes
Table 2. Replacement criteria for motor brakes
THICKNESS AS NEW

REPLACE WHEN

XN 01
XN 05
XN 10
XN 16

0.260 inches
0.370 inches
0.055 inches
0.406 inches

0.220 inches
0.330 inches
0.016 inches
0.366 inches

XN 20
XN 25

0.406 inches (10.3 mm)
0.406 inches (10.3 mm)

(6.6 mm)
(9.4 mm)
(1.4 mm)
(10.3 mm)

(5.6 mm)
(8.4 mm)
(0.4 mm)
(9.3 mm)

0.366 inches (9.3 mm)
0.366 inches (9.3 mm)

Figure 12. Replacement criteria for motor brakes

XN 01 / 05 / 10 MODELS

XN 16 / 20 / 25 MODELS

27/85
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XN10 I&M MANUAL/EN/11.30.2010

7.5

Load Chain

7.5.1

General

7.5.2

CAUTION: A hoist SHALL NEVER be used if the load chain shows any evidence of
mechanical damage or excessive wear. Never use the load chain as a sling. Use only
original equipment chain as supplied by a factory authorized source. Improper load chain
storage or installation can render the load chain unusable prior to the first lift.

Maintenance Inspection

A qualified person SHALL be designated to routinely conduct an in-depth inspection of the load chain (See
Section 8 – Preventative Maintenance for schedule recommendations). This designated person SHALL
inspect load chain using good judgment in evaluating the remaining service life. Any deterioration of load
chain resulting in appreciable loss of original strength SHALL be noted and evaluated.
An in-depth inspection SHALL include a written record that is dated and signed by the inspector.

28/85
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be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

Figure 13. Chain Dimensions

11 t

t
Ød
P25004
Measure the following chain dimensions at several points on chain: (Figure 13)
Dimensions of one link ( d x t ) where, d = diameter and t = pitch
Length over 11 links ( 11 t )
Replace load chain if any one of these dimensions exceeds maximum allowed wear.

Maximum allowed wear:
Minimum link diameter allowed

(d):

0.240”

Maximum pitch allowed

(t):

0.736” [18.7 mm]

MAXIMUM

7.862” [199.7 mm]

MAXIMUM

Maximum length allowed

(11t):

[6.1 mm]

MINIMUM

NOTE: If load chain needs replaced, then inspect chain guide and chain (load) wheel
on hoist and idler sprocket in 2-fall load block for excessive wear. A chain sprocket
showing evidence of scored pockets or sharp edges generated from wear SHALL be
replaced. A worn chain sprocket or idler sprocket can greatly reduce the life of load
chain.

29/85
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be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

7.5.3

Load Chain Specifications (see Figure 13)

Chain type:

Standard Load Chain

Diameter (d) / pitch (t):

0.268” (6.8 mm) /0.701” (17.8 mm)

Class:

DAT

Grade:

H8S or HE G80 RAS

Maximum working stress:

19,595 lbs/in (135.1 N/mm )

Hardened surface:

580 or 700 HV (Vickers Hardness)

Thickness:

0.006” (0.14 mm) to 0.011” (0.28 mm)

Standard:

DIN 5684 - 8

Marking (10 x t):

1 or 16

H 8 S or A 8
Maximum working load, 1 fall:

2200 lbs. (1000 kg)

Breaking load:

13,062.05 psf (58.1 kN)

Maximum breaking stress:

116 030 lbs/in (800 N/mm )

Total braking elongation:

>10% min.

Weight for 100 links:

2.38 lbs. (1.08 kg)

7.5.4 Removing the Load Chain
1-FALL CHAIN
1. Remove load from hook block assembly.
2. Remove load block assembly from load chain. Some disassembly of 1-fall load block is required.
3. Attach the chain insert tool to the end of bottom block end of the chain.
4. Run hoist in “UP” direction until all of chain is in container. Stop the hoist with the insertion tool
remaining in the hoist ready for the new chain.
5. Remove chain container with all of old chain in chain container.
6. Remove fall stop from old chain and save for use with new chain.
2-FALL CHAIN
1.
2.
3.
4.

Remove load from hook block assembly.
Run hoist in “UP” direction until hook block assembly is about 1.0 foot [30cm] from hoist body.
Unfasten load chain from chain anchor mounted on hoist body.
Remove load block assembly from load chain by allowing chain to run through it. Attach the chain
insertion tool to the bottom block end of the chain.
5. Run hoist in “UP” direction until all of the chain is in the container. Stop the hoist with the insertion tool
remaining in the hoist ready for the new chain.
6. Remove chain container with old chain.
7. Remove fall stop from old chain and save for use with new chain.

30/85
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XN10 I&M MANUAL/EN/11.30.2010

7.5.5 Installing the Load Chain
Figure 14. Chain installation

Figure 15. Chain orientation

1-FALL CHAIN INSTALLATION
1. Attach last link of chain onto hook of CHAIN INSERTION TOOL (item 1, Figure 14).
2. If the insertion tool is not in the hoist (removal procedure), insert other end of CHAIN INSERTION TOOL
into chain opening closest to chain container side.

CAUTION: Make sure the chain weld on chain link faces inward toward chain wheel
pocket on hoist load sprocket. See Figure 15.

3. Run hoist “DOWN” in slow speed to feed chain through chain sprocket and out other side.
4. Attach fall stop at least 6.0 inches [150 mm] from end of chain (chain container side). Attach load block
assembly on other end of load chain. Refer to Figure 15 for details.
5. Make sure that load chain is not twisted or deformed.
6. Attach chain container.

31/85
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XN10 I&M MANUAL/EN/11.30.2010

2-FALL CHAIN INSTALLATION
1. If the chain insertion tool is not in the hoist (removal procedure), attach last link of chain onto hook of
CHAIN INSERTION TOOL (item 1, Figure 14).
2. Insert other end of CHAIN INSERTION TOOL into chain opening closest to chain container.

CAUTION: For a 2-Fall load block assembly, make sure the chain weld on chain link
faces inward toward chain wheel pocket on hoist and away from idler sprocket of
hook block assembly. See figure 5.6. Follow steps outlined below:

3. Run hoist in slow speed to feed chain through chain sprocket. Continue running until about 2.0 feet
[60cm] of chain is available out the other side.
4. Slide chain onto idler sprocket of load block making sure not to twist chain while inserting it. Link
weld must face away from idler sprocket on load block assembly.
5. Attach chain anchor and chain to hoist body. Tighten chain anchor bolts per recommended torque
settings in Section 8.4.
6. Attach fall stop 6.0 inches [150 mm] from end of chain (chain container side). See Figure 16 for
details.
7. Make sure that chain is not twisted or kinked.
8. Attach chain container
After chain installation:
1. Without a load, run chain up and down a few times to make sure load chain is not twisted. If so,
remove chain twist.
2. Lubricate load chain.

32/85
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XN10 I&M MANUAL/EN/11.30.2010

7.6

Fall Stop Assembly

7.6.1 General
The slack fall stop is a safety stop, not a functional stop. The fall stop must be located at least six
(6.0) inches [150mm] from end of last chain link.
Figure 16. Cross Section of Slack Fall Stop

1
2

6''

7.6.2 Removing fall stop (Figure 16)
1.
2.
3.
4.

Remove cotter pin (item 1).
Slide up the tube (item 2).
Remove the two fall stop halves (item 3).
Slide tube (item 2) off load chain.

7.6.3 Fall Stop Installation (Figure 16)
1. Slide tube (item 2) onto load chain.
2. Position two fall stop halves (item 3) on a chain link so that the fall stop will be at least 6 inches [150mm]
from end of load chain.
3. Slide tube (item 2) down over two fall stop halves (item 3).
4. Insert and secure cotter pin (item 1).

33/85
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XN10 I&M MANUAL/EN/11.30.2010

7.7

Chain Container

Figure 17. Chain Container Installation

CAUTION: Chain container must be installed for effective operation of travel limit switch.

7.7.1 Removing Chain Container (Figure 17)
1. Remove cotter pin (item 5) from end of pin (item 3).
2. Pull pin (item 3) out while supporting chain container (item 2).
3. Remove chain container (item 2).

7.7.2 Installing Chain Container (Figure 17)
1. Insert load chain into chain container (item 2). Position chain container (item 2) onto hoist mounting
bracket (item 1).
2. Align holes and insert pin (item 3) through container (item 2) and hoist mounting bracket (item 1).
3. Place washer (item 4) onto pin (item 3).
4. Insert and secure cotter pin (item 5).

34/85
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XN10 I&M MANUAL/EN/11.30.2010

7.8

Vinyl Chain Bag (optional)

Figure 18. Vinyl Chain Bag Installation Connection

7.8.1 Installing Vinyl Chain Bag (Figure 18)
1. Insert load chain into vinyl chain bag. Position vinyl chain bag onto hoist mounting bracket.
2. Align holes and insert cotter pin through appropriate bag connection holes for the specific model.
2.1. Use Item 1 connection holes for the Model 10 hoist.
3. Place washer onto pin.
4. Insert and secure cotter pin.

35/85
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XN10 I&M MANUAL/EN/11.30.2010

7.9

Limit Switches

7.9.1 Upper and Lower Travel Safety Limit Switch
The Upper and Lower Travel Limit Switch is an automatic reset type switch and connected to the control
circuit. The switch housing is recessed into the underside of hoist body.

The upper and lower limit switches are emergency protection devices and are not to be used as a continuous
stop.

The hook block activates the upper limit switch as it contacts the limit switch that is located on bottom side of
hoist body. Once the switch is activated, the “UP” circuit is opened. The fall stop activates the lower limit
switch when hook block is lowered to its lowest travel position. The limit switch is activated and opens the
“down” circuit.
The lower limit position is adjustable between the lowest travel and maximum lift. It is adjusted by
repositioning the fall stop assembly on free end of load chain. The fall stop SHALL always be located at
least 6 inches [150mm] from end of last chain link. The upper limit position is adjustable only when an
additional fall stop assembly is added between the hook block assembly and the hoist body.

36/85
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XN10 I&M MANUAL/EN/11.30.2010

7.9.2 Upper and Lower Rotary Travel Limit Switch (Optional Only on 3-Phase units)
The rotary limit switch is adjustable and provides over-travel protection for the upper and lower limits of hoist
travel. The limit switch is connected to the control circuit.

Note: Not available on Single Phase – 115 Volt Models
Note: Rotary limit switch assembly cannot be added to a Hoist. The Hoist must have
the rotary limit switch assembly provided at time of initial production.

Adjustment
The position of the air-gap between the two discs (red – gray) determines the stopping place. This position
can be found by gently turning the two discs. The length of air gap determines length of reset play in
opposite direction.

Figure 19. Air Gap Adjustment

To reset the rotary limit once it has tripped, the load block assembly must travel approximately 11” [27cm] in
opposite direction.

37/85
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XN10 I&M MANUAL/EN/11.30.2010

7.10 Hooks
7.10.1 General
Check hooks for deformation or cracks. Hooks must be replaced if throat opening has increased by more
than 15%, or if throat opening has more than 10-degree twist from plane of straight hook.
Figure 20. Measuring Hook Deformation

Due to many types and sizes of hooks that can be furnished and/or specified by the user / owner, it is
recommended that user / owner measure the actual throat opening of hook as originally furnished. See
Figure 20. Record the throat dimension on above sketch. Retain as a permanent record. This record can
then be used for determining when hook must be replaced due to deformation or excessive throat opening.

m
m
m
m

CAUTION: Abuse or overloading of hoist is indicated when any hook is twisted or has a
throat opening in excess of normal. Other load bearing components SHALL be checked for
damage.
CAUTION: Safety latches SHALL be replaced if missing, bent, or broken.
CAUTION: A safety latch SHALL function properly at all times.
CAUTION: Repairing hooks by welding or reshaping is strictly forbidden.

38/85
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XN10 I&M MANUAL/EN/11.30.2010

7.10.2 Hook Inspection
The wear on the top hook and the load hook SHALL be checked routinely. Measure the throat
opening (dimension a2 - FIGURE 21). If the throat opening exceeds the maximum opening allowed,
replace the hook. Damaged safety latches shall be replaced immediately.
Figure 21. Hook Dimensions

LOAD
CAPACITY
(LBS)
1389
2205
2756
4409

TEST
LOAD

FALLS

MINIMUM
FAILURE
LOAD

CLASS

2778
4409
5512
8818

1
1
2
2

8752
11023
17361
22046

025T
025T
05T
05T

HOOK DIMENSIONS – INCHES
ØM

Øa1

0.630
0.630
0.787
0.787

1.417
1.417
1.693
1.693

1.024
1.024
1.339
1.339

1.614
1.614
1.929
1.929

0.866
0.866
1.142
1.142

0.748
0.748
0.945
0.945

3.780
3.780
4.134
4.134

1.102
1.102
1.457
1.457

0.945
0.945
1.221
1.221

1.496
1.496
1.496
1.496

0.512
0.512
0.551
0.551

Initial Dimension – a2

Max. Allowed Dimension

Mark: ISO 2766

1.024 inches

1.178 inches maximum

DIN Model Number: 15401

1.339 inches

1.540 inches maximum

DIN 15400 Class: T
DIN 15401 Material: 35 CD 4

39/85
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XN10 I&M MANUAL/EN/11.30.2010

7.10.3 Top Hook
Figure 22. Top Hook Orientation

CHAIN
CONTAINER
BRACKET

CAUTION: Before removing Top Hook, de-energize the power to the hoist per ANSI Z244.1
and make certain that any load is removed from the load hook. Also support the total
weight of the hoist, including chain, prior to removing the Top Hook.

Removing Top Hook
1. Place hoist on workbench. Protect limit switches on bottom side of hoist.
2. Remove screw and locking plate.
3. Pull pins out and remove hook.

CAUTION: Proper installation of top hook is critical for hoist balance.

Installing Top Hook
1. Place hoist on workbench. Protect limit switches on bottom side of hoist.
2. Determine number of chain falls: 1-fall or 2-fall. Reference Figure 22.
3. Select proper placement of top hook relative to number of chain falls:

If 1-fall, align top hook so that tip of hook faces toward chain container.

If 2-fall, align top hook so that tip of hook faces away from chain container.
4. Place hook into the slot on hoist body. Verify that top hook saddle and load hook saddle are in line with
each other. Install pins and locking plate. Secure locking plate with screw.

40/85
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XN10 I&M MANUAL/EN/11.30.2010

7.11 Control Changes and Fuses
The layouts and wiring diagrams found within this section are for standard hoist controls. Single speed
hoists are available for 208, 230, and 460 volt three-phase power supplies; but not for 575 volts.

Two-speed hoists are available for 208, 230, 460, and 575 volt, three-phase power supplies. The two-speed
hoists can only be connected to the specified voltage on the hoist serial plate.

Control Circuit Fuse

The control circuit fuse holder is located on terminal strip X1. The fuse holder top flips up to facilitate
changing a defective fuse.
Table 3. Control Circuit Fuse
POWER

CONTROL

FUSE

SUPPLY

VOLTAGE

SIZE

3 – PHASE

115 VAC

630 mA

Three-phase Single-speed Voltage Changes:

The Single-speed models may be changed to accommodate 208/230/460 volt power supplies. A hoist
supplied with a motorized trolley CANNOT be reconnected.

Note: Motorized trolley drives are not voltage re-connectable.
motorized trolley manual if a voltage change over is required.

Consult the

Refer to the respective Single-speed wiring diagrams and make the following connections for the following
voltages:

41/85
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XN10 I&M MANUAL/EN/11.30.2010

208 / 230 VOLT (SEE 208/230 VOLT SINGLE SPEED CONTROL LAYOUT & WIRING DIAGRAM)
1. Connect motor brake lead (-) to terminal strip X1 terminal 14. Connect (+) to K21 terminal 4.
2. Motor Leads:
a. T1 & T7 connect to main line contactor K10 terminal 1.
b. T2 & T8 connect to DOWN contactor K22 terminal 2.
c. T3 & T9 connect to DOWN contactor K22 terminal 6.
d. T4 connect to terminal strip X1 terminal 11.
e. T5 connect to terminal strip X1 terminal 12.
f. T6 connect to terminal strip X1 terminal 13.
g. Jumper wires on terminal strip X1 to connect terminals 11, 12, and 13.
3. Control transformer connections:
a. Jumper connections terminals 230 to 230 and terminals 01 to 02. See control panel layouts and
wiring diagrams.

460 VOLT (REFER TO 460 VOLT SINGLE SPEED WIRING DIAGRAM)
1. Connect motor brake lead (-) to contactor K21 terminal 2.
2. Motor leads:
a. T1 connect to main line contactor K10 terminal 1.
b. T2 connect to DOWN contactor K22 terminal 2.
c. T3 connect to DOWN contactor K22 terminal 6.
d. T4 & T7 connect to terminal strip X1 terminal 11.
e. T5 & T8 connect to terminal strip X1 terminal 12.
f. T6 & T9 connect to terminal strip X1 terminal 13.
3. Control transformer connections:
a. Jumper connections for 460 volt (see wiring diagram).

Table 4. Wiring Diagram
Power & Motor
Supply
L1
L2
L3
K21-2
K21-4
K10-1
K22-4
K22-6
X1-11
X1-12
X1-13

Hoist power supply
Hoist power supply
Hoist power supply
+ brake
- brake
T1, T7 motor supply
T3, T9 motor supply
T2, T8 motor supply
T4 motor supply
T5 motor supply
T6 motor supply
Ground Terminals
Description
Motor

PE
PE
PE

Control panel
Trolley connection
Power supply

Pendant Plug X23
Description
Common
Hoist UP
Hoist DOWN
Hoist FAST
Emergency stop
Trolley FWD
Trolley REV
Trolley FAST

Pin
No:
1
2
3
4
5
6
7
8

Tag strip X1
Terminal No:
10
1
4
6
7
8
9
1-2
2-3
4-5
K10
K21

Control Panel
Description
SD: low speed
Hoist UP
Hoist DOWN
D2: Trolley FWD
D1: Trolley REV
F: Trolley Fast
Control voltage
Thermal protection
Upper limit switch
Lower limit switch
Mainline contactor
Hoist UP contactor

K22

Hoist
DOWN
Contactor
Hoist FAST
Control Transformer
Counter (option)
Counter (option)
630 mA

K25
T100
9
K22-22
F100

Plug Pin
No:
2

5
4
3
1

42/85
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7.12 Single-Speed Solo Hoist – 208 Volt Wiring Diagram
Figure 23. Single-speed solo hoist – 208 volt wiring diagram

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Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

7.13 Single-Speed Solo Hoist – 230 Volt Wiring Diagram
Figure 24. Single-speed solo hoist – 230 volt wiring diagram

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XN10 I&M MANUAL/EN/11.30.2010

7.14 Single-speed Solo Hoist – 460 Volt Wiring Diagram
Figure 25. Single-speed solo hoist – 460 volt wiring diagram

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Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

7.15 Two-Speed Solo Hoist - 208 Volt Wiring Diagram
Figure 26. Two-speed solo hoist – 208 volt wiring diagram

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Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

7.16 Two-Speed Solo Hoist - 230 Volt Wiring Diagram
Figure 27. Two-speed solo hoist – 230 volt wiring diagram

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XN10 I&M MANUAL/EN/11.30.2010

7.17 Two-Speed Solo Hoist - 460 Volt Wiring Diagram
Figure 28. Two-speed solo hoist – 460 volt wiring diagram

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XN10 I&M MANUAL/EN/11.30.2010

7.18 Two-Speed Solo Hoist – 575 Volt Wiring Diagram
Figure 29. Two-speed solo hoist – 575 volt wiring diagram

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7.19 Single-Speed Hoist – Modular Crane – 208 Volt Diagram
Figure 30. Single-speed hoist – modular crane – 208 volt diagram

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XN10 I&M MANUAL/EN/11.30.2010

7.20 Single-Speed Hoist – Modular Crane – 230 Volt Diagram
Figure 31. Single-speed hoist – modular crane – 230 volt diagram

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XN10 I&M MANUAL/EN/11.30.2010

7.21 Single-Speed Hoist – Modular Crane – 460 Volt Diagram
Figure 32. Single-speed hoist – modular crane – 460 volt diagram

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XN10 I&M MANUAL/EN/11.30.2010

7.22 Two-Speed Hoist – Modular Crane – 208 Volt Diagram
Figure 33. Two-speed hoist – modular crane – 208 volt diagram

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XN10 I&M MANUAL/EN/11.30.2010

7.23 Two-Speed Hoist – Modular Crane – 230 Volt Diagram
Figure 34. Two-speed hoist – modular crane – 230 volt diagram

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XN10 I&M MANUAL/EN/11.30.2010

7.24 Two-Speed Hoist – Modular Crane – 460 Volt Diagram
Figure 35. Two-speed hoist – modular crane -460 volt diagram

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XN10 I&M MANUAL/EN/11.30.2010

7.25 Two-Speed Hoist – Modular Crane – 575 Volt Diagram
Figure 36. Two-speed hoist – modular crane – 575 volt diagram

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7.26 Wiring Diagram – 3 Button – Push Button
Figure 37. Wiring diagram – 3 button – push button

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XN10 I&M MANUAL/EN/11.30.2010

7.27 Wiring Diagram – 5 Button – Push Button
Figure 38. Wiring diagram – 5 button – push button

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XN10 I&M MANUAL/EN/11.30.2010

7.28 Wiring Diagram – 7 Button – Push Button
Figure 39. Wiring diagram – 7 button – push button

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XN10 I&M MANUAL/EN/11.30.2010

PREVENTATIVE MAINTENANCE

8.1

Maintenance and Inspection Table

Table 5. Maintenance Schedule
INSPECTION CHECK

INTERVAL

QUALIFIED PERSON

BRAKE OPERATION FOR HOLDING AND RELEASING

DAILY

OPERATOR

LOAD CHAIN FOR DAMAGE

DAILY

OPERATOR

SUSPENSION SUPPORT OF P/ B ASSEMBLY

DAILY

OPERATOR

MONTHLY

OPERATOR

DAILY

OPERATOR

CHECK LOAD CHAIN FOR WEAR – MEASURE AND RECORD

EVERY 3 MONTHS

QUALIFIED INSPECTOR

CHECK HOOKS FOR WEAR MEASURE AND RECORD

EVERY 3 MONTHS

QUALIFIED INSPECTOR

CHECK LOAD BLOCK HARDWARE TO VERIFY TIGHTNESS

EVERY 3 MONTHS

OPERATOR

CHECK TOP HOOK / COUPLING HARDWARE FOR TIGHTNESS

EVERY 3 MONTHS

OPERATOR

CHECK SLIP CLUTCH & HOIST BRAKE ADJUSTMENT

EVERY 3 -6 MONTHS

QUALIFIED MECHANIC

CHECK LUBRICATION OF OPEN WHEEL GEARING

EVERY 3 -6 MONTHS

QUALIFIED MECHANIC

SEMI-ANNUALLY

QUALIFIED MECHANIC

LUBRICATE 2-FALL LOAD BLOCK SPROCKET

ANNUALLY

OPERATOR

CHECK ALL HARDWARE FOR TIGHTNESS AND CORROSION

ANNUALLY

QUALIFIED MECHANIC

CLEAN MOTOR COOLING FINS

ANNUALLY

QUALIFIED MECHANIC

LUBRICATE ALL GEARING

ANNUALLY

QUALIFIED MECHANIC

INSPECT LOAD BLOCK THRUST BEARING

ANNUALLY

QUALIFIED MECHANIC

CLEANLINESS & LUBRICATION OF LOAD CHAIN
UPPER / LOWER LIMIT SWITCHES

CHECK WIRE TERMINALS TIGHTNESS

CAUTION: INSPECTION AND MAINTENANCE INTERVALS SHOULD BE ADJUSTED BASED
UPON OWNER / USER KNOWLEDGE OF APPLICATION, ENVIRONMENT, AND FREQUENCY
OF USE TO PREVENT DAMAGE TO PEOPLE, EQUIPMENT, AND FACILITIES.

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XN10 I&M MANUAL/EN/11.30.2010

8.2

Lubrication

Table 6. Lubrication Specifications
LUBRICATION
POINT

SPECIFICATIONS

Chain

Oil or Liquid grease

Idler sprocket
Slide bearing +
bearing

Grease (without MoS2)
KP 2 (DIN 51 502)
Soap-based lithium
Approx. drip point
+ 500°F
Worked penetration
509-563°F
Operating temperature - 4°F - +266°F
KP 0 K grease (DIN 51502)
Soap-based lithium + MoS 2
Approx. drip point + 180°C
Worked penetration 355 - 385°C
Operating temperature -30°C to + 130°C

Gears

ACCEPTABLE LUBRICANTS

QUANTITY

Chain lubricating fluid (Ceplattyn As required
or similar) EP-90
BP: BP Energrease LS - EP 2 As required
Esso: Unirex N2
Mobil: Mobilgrease HP
Shell: Shell Alvanio EP Grease 2

Mobil: Mobilgrease special
BP: Multi-purpose grease L 21 M
Shell: Shell Retimax AM
Texaco: Molytex grease EP 2

0.05 liter

Open Wheel Gearing: EP1 Mobilux or equivalent.

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XN10 I&M MANUAL/EN/11.30.2010

8.3

Recommended technical support for various spare parts

Table 7. Recommended Technical Support for Various Spare Parts
SPARE PART

Upper chain guide

Qualified Electrician & Mechanic

Output shaft

Qualified Electrician & Mechanic

PG cable gland

Qualified Electrician

Gear shaft + nuts

Qualified Mechanic

Motor end cap

Qualified Mechanic

Gearing (1st/2nd stage)

Qualified Electrician & Mechanic

Brake & end cap sealing

Qualified Mechanic

Other seals and O-rings

Qualified Mechanic

Brake-limiter

Qualified Electrician

Brake end cap

Qualified Mechanic

Lower chain guide

Qualified Mechanic

Rubber buffer

Qualified Mechanic

Electric box

Qualified Electrician

PC-board

Qualified Electrician

Plugs

Qualified Electrician

Chain

Qualified Mechanic

Chain bucket

Qualified Mechanic

Slack fall stop

Qualified Mechanic

Suspension hook

Qualified Mechanic

Hook block assembly

Qualified Mechanic

Control box

Qualified Electrician

8.4

REPLACED BY

NOTE: Once a part has been replaced, perform an operational check of hoist per
Sections 3.3 and 3.4.

Screw Tightening Torque (lb-ft) Specifications

Table 8. Screw Tightening Torque Specifications
TYPE
STANDARD SCREWS
SELF-TAPPING SCREWS

M5
4
4

M6
7
6

M8
18
15

M10
35
30

M12
61
53

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XN10 I&M MANUAL/EN/11.30.2010

8.5

Troubleshooting

Table 9. Troubleshooting
PROBLEM
Hoist does not lift or lower load

Hoist does not lift load

POSSIBLE CAUSE
Emergency stop button is
activated

Deactivate button

Blown fuse

Replace the fuse

Motor thermal protection
activated

Allow motor to cool down

Pendant plug pin pushed out

Reinstall plug pin

Contactor terminal screws loose

Tighten screws

Mainline switch shut off

Turn switch on

Overload condition

Reduce load

Slip clutch worn or incorrectly
adjusted

Replace wear items or readjust
slip clutch torque
Check brake coil resistance.
Check air gap setting. Adjust if
necessary.
Check rectifier output voltage.
Replace wear items as
necessary
Adjust air gap setting

Brake not releasing

Load drifts more than 4 inches
[100mm]
Travel direction does not
correspond to that indicated on
push button
Abnormal noises while lifting or
lowering

POSSIBLE SOLUTION

Brake lining worn
Air gap on brake is too wide
Power supply incorrectly
connected

See SECTION 3

Load chain and its components
are not lubricated

Clean and lubricate load chain.

Load chain is worn

Replace chain

Chain wheel or chain guide is
worn

Replace chain wheel or chain
guide

Idler sprocket is worn

Replace idler sprocket

A supply phase is missing

Connect the three phases

Twist or kink in load chain

Remove twist or kink

63/85
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XN10 I&M MANUAL/EN/11.30.2010

9
9.1

PARTS ILLUSTRATION
Hoist Body

Figure 40. Hoist body

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XN10 I&M MANUAL/EN/11.30.2010

Table 10. Hoist Body Parts List
ITEM

PART
NUMBER

DESCRIPTION

QTY

STATOR

2249955

SUSPENSION HOOK ASSEMBLY - PERPENDICULAR MOUNTING

2242017

SAFETY LATCH – STEEL PLATE TYPE

2242011

2249921

2249954

SUSPENSION MEMBER
SUSPENSION BRACKET ASSEMBLY WITH AXLE AND SCREWS –
PERPENDICULAR MOUNTING (NOT SHOWN)
SUSPENSION HOOK ASSEMBLY – PARALLEL MOUNTING

2242017

2249920

1
1

2249904

SAFETY LATCH – STEEL PLATE TYPE
SUSPENSION BRACKET ASSEMBLY WITH AXLE AND SCREWS –
PARALLEL MOUNTING
SUSPENSION BRACKET ASSEMBLY WITH AXLE AND SCREWS –
PERPENDICULAR MOUNTING (FOR KPT TROLLEY)
MOTOR END CAP ASSEMBLY

2249903

BRAKE END CAP ASSEMBLY

2240011

BRAKE CAP ASSEMBLY

2218000

PUSHBUTTON CABLE FASTENING BRACKET

52340376

STICKERS AND COVERS XN 10

2218004

CABLE GUIDE

2240013

SEALING RING AND O-RING FOR BRAKE CAP

MOTOR DATA PLATE

2213309008

CAPACITY STICKER – 500 kg

2213309009

CAPACITY STICKER – 1000 kg

2213309016

CAPACITY STICKER – 1500 kg

2213309010

CAPACITY STICKER – 2000 kg

2213309002

CAPACITY STICKER – ½ ton

2213309003

CAPACITY STICKER – 1 ton

2213309014

CAPACITY STICKER – 1.5 ton

2213309004

CAPACITY STICKER – 2 ton

52312841

1
1
1

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XN10 I&M MANUAL/EN/11.30.2010

9.2

Gear Mechanism With Motor Brake

Figure 41. Gear mechanism with motor brake

ITEM QTY
1
2
3
4
5
5
6
6
6
7
8
8
8
9
10

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

PART NO.
2249940
2245025
2249941
2249937
2249938
2249951
2241074
2241073
2241072
2249972
2248001
2248000
2248003
2240012
2241501

DESCRIPTION
Slipping clutch spring with motor shaft
Rotor assembly - 1 and 2-speed type
Chain sprocket assembly
Planetary gear train - 1st step Planetary gear train - 2nd step - 8M/MN (reducing 58)
Planetary gear train - 2nd step - 16M/mn (reducing 29)
Brake assembly complete with brake cap – 190 VDC / 380-480 VAC
Brake assembly complete with brake cap – 100 VDC / 208-230 VAC
Brake assembly complete with brake cap – 230 VDC / 575 VAC
Slipping clutch friction assembly
Brake, complete 190 VDC / 380-480 VAC
Brake, complete 100 VDC / 208-230 VAC
Brake, complete 230VDC / 575 VAC
Set of seals for brake cap
Motor shaft

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XN10 I&M MANUAL/EN/11.30.2010

9.3

Lifting Assembly

Figure 42. Lifting assembly

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XN10 I&M MANUAL/EN/11.30.2010

Table 11. Lifting Assembly Parts List
ITEM PART NUMBER

DESCRIPTION

QTY

2249983

1-FALL LIFTING HOOK BLOCK – STANDARD TYPE

2242018

1-FALL LIFTING HOOK BLOCK – SELF-LOCKING TYPE

001515

SAFETY LATCH – STEEL WIRE TYPE - 1 FALL

2212017

SAFETY LATCH – STEEL PLATE TYPE - 1 FALL

2217004

1-FALL LIFTING HOOK – STANDARD TYPE

2247015

1-FALL LIFTING HOOK – SELF-LOCKING TYPE

2249976

SET OF 2 HALF-CASINGS WITH AXLE AND SCREWS

2213333002

CAPACITY STICKER – ½ TON – 1 FALL

2213333004

CAPACITY STICKER – 1 TON – 1 FALL

2213333009

CAPACITY STICKER – 500 kg – 1 FALL

2213333011

CAPACITY STICKER – 1000 kg – 1 FALL

2249984

2-FALL LIFTING HOOK BLOCK – STANDARD TYPE

2242028

2-FALL LIFTING HOOK BLOCK – SELF-LOCKING TYPE

001513

SAFETY LATCH – STEEL WIRE TYPE – 2 FALLS

2242017

SAFETY LATCH – STEEL PLATE TYPE – 2 FALLS

2242021

2-FALL LIFTING HOOK – STANDARD TYPE

2267015

2249978

2213333004

2-FALL LIFTING HOOK – SELF-LOCKING TYPE
SET OF 2 HALF-CASINGS WITH AXLE, RETURN SPROCKET AND
SCREWS
CAPACITY STICKER – 1 TON – 2 FALLS

2213333005

CAPACITY STICKER – 2 TON – 2 FALLS

2213333011

CAPACITY STICKER – 1000 kg – 2 FALLS

2213333012

CAPACITY STICKER – 2000 kg – 2 FALLS

2243523

52293746

2244008

CHAIN ANCHOR ASSEMBLY
UPPER AND LOWER CHAIN GUIDE ASSEMBLY WITH RUBBER
BUFFER
RUBBER BUFFER

2244011

UPPER CHAIN GUIDE

2249925

CHAIN BUCKET – 25FT [8M] MAXIMUM CHAIN LENGTH

2249926

CHAIN BUCKET – 50FT [16M] MAXIMUM CHAIN LENGTH

2249932

CHAIN BUCKET – 75FT [30M] MAXIMUM CHAIN LENGTH

2249933

CHAIN BUCKET – 150FT [50M] MAXIMUM CHAIN LENGTH

2249942

SLACK FALL STOP ASSEMBLY

2243500

LOAD CHAIN – GALVANIZED TYPE

2243501

LOAD CHAIN – BLACK TYPE

2243502

LOAD CHAIN – STAINLESS STEEL TYPE

2241045

LOAD CHAIN INSERTION TOOL

9995008

CHAIN LUBRICANT

1
1

* NOTE: REFER TO CHAIN HOIST LIFT AND NUMBER OF FALLS FOR CHAIN QUANTITY

69/85
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9.4

Controls

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XN10 I&M MANUAL/EN/11.30.2010

Table 12. Controls Parts List

PART
NUMBER
2249965

2243016

2243017

2243018

52339762

2a
2b

ITEM

DESCRIPTION

QTY
1

2213028

ELECTRIC CUBICLE (LID, COVER AND SCREWS)
PRINTED CIRCUIT BOARD – 2 SPEED HOISTING + ON-OFF – 575V
60 Hz 115V AC
PRINTED CIRCUIT BOARD – 2 SPEED HOISTING + ON-OFF – 460V
60 Hz 115V AC
PRINTED CIRCUIT BOARD – 2 SPEED HOISTING + ON-OFF – 230V
60 Hz 115V AC
PRINTED CIRCUIT BOARD – SINGLE SPEED HOISTING + ON-OFF –
208/230V/460V 60 Hz 115V AC RECONNECTABLE
HOUR COUNTER 115V AC 60 Hz

7983055

EMERGENCY STOP CONTACTOR K10 115V AC

7983056

REVERSING CONTACTOR K21 or K22 115V AC (coef. 2)

7983057

SELECTING CONTACTOR K25 115V AC

7983029

TRANSFORMER 400V 50&60Hz 115V AC

7983027

TRANSFORMER 575V 60Hz 115V AC

7983026

TRANSFORMER 230V/460V 60Hz 115V AC

2243060

RECTIFIER 230V/400V/460V500V/575V

2243061

RECTIFIER 230V/460V - RECONNECTABLE

52330744

SET OF10 FUSES (115V)

2249947

CABLE GLAND ASSEMBLY

2219814

CLOSING PLATE ASSEMBLY

2249945

CONNECTING PLUG SET FOR PUSHBUTTON BOX

2249946

CONNECTING PLUG SET FOR PUSHBUTTON FOR TROLLEY

2249982

CONNECTING PLUG SET FOR POWER SUPPLY

1
1
1
1
1

71/85
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Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

9.5

Upper and Lower Limit Switch

Figure 43. Upper and lower limit switch

Table 13. Chain Guide Assembly with Limit Switches Parts List
ITEM
1
2
3
4
5

PART NUMBER
2243050
52295974
7291040
52337705

DESCRIPTION
MICRO-SWITCHES ASSEMBLY
SPRING ASSEMBLY AND SUPPORT
MICRO SWITCHES
CABLE GUIDE
SLIDES

QTY
1
1
1
1
2

CAUTION: Cut off the main power supply before doing any work on the electrical cubicle.

72/85
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Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

9.6

Double Brake Mechanism

Table 14. Double Brake Mechanism Parts List
ITEM

PART NUMBER

2245025

ROTOR ASSEMBLY

2249941

CHAIN SPROCKET ASSEMBLY

2249938

PLANETARY GEAR TRAIN - 2nd STEP - 8M/MN (REDUCING 58)

2249951

DESCRIPTION

QTY

PLANETARY GEAR TRAIN - 2 STEP - 16M/mn (REDUCING 29)
ST

2249937

PLANETARY GEAR TRAIN – 1

2249006

BRAKE ASSEMBLY COMPLETE WITH BRAKE CAP – 1ST BRAKE – 190 VDC / 380-480 VAC

STEP

1
1

2249016

BRAKE ASSEMBLY COMPLETE WITH BRAKE CAP – 1

6
7

BRAKE – 100 VDC / 208-230 VAC

2249054

PINION

2249007

BRAKE ASSEMBLY COMPLETE WITH BRAKE CAP – 2nd BRAKES – 190 VDC / 380-480 VAC

2249017

BRAKE ASSEMBLY COMPLETE WITH BRAKE CAP – 2nd BRAKES – 100 VDC / 208-230 VAC

2249051

DOUBLE BRAKE MOTOR SHAFT

73/85
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be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2010)
Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

9.7

Low Headroom Trolley

9.7.1 Low Headroom Trolley (Drive Components)

74/85
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Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

Table 15. Low Headroom Trolley Short Outreach (Drive Components)
ITEM

C10 SHORT

DESCRIPTION
460V
Complete 2-speed motor drive 115Vc

575V

≤ 2 Ton
(2000 Kg)

208/230V
1

460V
Complete inverter motor drive 115Vc

575V
208/230V

> 1 Ton
(1000 Kg)
> 1 Ton
≤ 2 Ton

QTY

CODE

52306026

52306027

52306028

52299090

52304881

Geared drive side plates

52391073

Ungeared idler side plates

52391072

Pinion drive assy

52311194

XHEAD assy 2.28 - 4.33 in. (set of 4)

556902

XHEAD assy 4.45 - 6.69 in. (set of 4)

556903

XHEAD assy 7.00 – 9.45 in. (set of 4)

556904

XHEAD assy 9.76 – 12.20 in. (set of 4)

556905

Rubber buffer

558993

460V

52304748

575V

52304749

208/230V

52304746

2309848001

Transformer for inverter trolley

Transformer mounting bracket

* Not shown in diagram

75/85
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XN10 I&M MANUAL/EN/11.30.2010

9.7.2 Low Headroom Trolley (Suspension Components)
Figure 44. Low headroom trolley (suspension components)

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Konecranes Plc. All rights reserved.

XN10 I&M MANUAL/EN/11.30.2010

Table 16. Low Headroom Trolley (Suspension Components)
ITEM

C10 SHORT

DESCRIPTION

QTY

CODE

LH Short Outreach Frame Assy

52391066

Fixed point assy (not applicable for 1-fall hoists)

52391076

to 65 ft.

52333407

66 to130 ft.

52328053

Chain bag (from 0 to 30 m)

Lifting chain galva. (Length: HOL + 5 ft.)

2243500

Lower hook block assy 1 fall

52387611

Counterweight for 1 fall hook

557939

Lower hook block assy 2 falls

52387610

Chain guide

52425117

NOTE: When hoists are mounted on a low headroom trolley, they are supplied with aluminum chain
guide.

77/85
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XN10 I&M MANUAL/EN/11.30.2010

9.8

Electric trolley (Swiveling trolley 0 to 3.2 Tons (3200 Kg))

Figure 45. Electric trolley (swiveling trolley 0 to 3.2 tons (3200 Kg))

NOTE: ECH is attached to swivel trolley through a mechanical connection. No top hook connection
available.

78/85
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XN10 I&M MANUAL/EN/11.30.2010

Table 17. Electric trolley (Swiveling trolley 0 to 3.2 Tons (3200 Kg))
ITEM

DESCRIPTION
Complete 2-speed motor drive
115Vc

460V
575V

≤ 3.2 Ton
(3200 Kg)

208/230V
1

Complete inverter motor drive
115Vc

460V
575V
208/230V

≤ 1 Ton
(1000 Kg)
> 1 Ton
≤ 3.2 Ton

QTY

CODE

52306026

52306027

52306028

52299090

52304881

Idler side plate

52326596

Drive side plate

52326597

Swivel CHRD Kit 2.60 – 4.33 in. (set of 4)

556966

Swivel CHRD Kit 2.60 – 4.33 in. (set of 4)

556967

Swivel CHRD Kit 2.60 – 4.33 in. (set of 4)

556968

Swivel CHRD Kit 2.60 – 4.33 in. (set of 4)

556969

Cross bar set for C05

52326598

Cross bar set for C10

52326599

Cross bar set for C16/20/25

52326602

79/85
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XN10 I&M MANUAL/EN/11.30.2010

9.9

Push Button Assembly – Horizontal Pairs of Buttons

Figure 46. Push button assembly – horizontal pairs of buttons

Table 18. Push Button Assembly (Horizontal Pairs of Buttons) Parts List
ITEM

PART NUMBER

2309765010

P/B ASSEMBLY 10 FT, E-STOP, TWO SPEED HOIST

DESCRIPTION

QTY
1

2309765015

P/B ASSEMBLY 15 FT, E-STOP, TWO SPEED HOIST

2309765020

P/B ASSEMBLY 20 FT, E-STOP, TWO SPEED HOIST

2309767010

P/B ASSEMBLY 10 FT, E-STOP, TWO SPEED HOIST, TWO SPEED TROLLEY

2309767015

P/B ASSEMBLY 15 FT, E-STOP, TWO SPEED HOIST, TWO SPEED TROLLEY

2309767020

P/B ASSEMBLY 20 FT, E-STOP, TWO SPEED HOIST, TWO SPEED TROLLEY

52301832

P/B ENCLOSURE ASSEMBLY – E-STOP – TS HOIST

2213466004

P/B ENCLOSURE ASSEMBLY – E-STOP – TS HOIST, TWO SPEED TROLLEY

2218000

UPPER SUSPENSION KIT

7285036

P/B ASSEMBLY - PLUG KIT

558073

SUSPENSION UNIT

52292266

PUSH BUTTON ELECTRICAL CABLE 16 GAUGE / 12 CONDUCTOR RPC

2309414004

XN OPERATOR’S WARNING TAG - ENGLISH

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XN10 I&M MANUAL/EN/11.30.2010

9.10 Push Button Assembly – Horizontal Pairs of Buttons
Figure 47. Push button assembly – horizontal pairs of buttons

Table 19. Push Button Assembly – Horizontal Pairs of Buttons Parts List
ITEM

PART NUMBER

DESCRIPTION

QTY

52301832

PISTOL GRIP P/B CONTROL ASSEMBLY – TWO SPEED

2213466004

P/B CONTROL ASSEMBLY – TWO SPEED – 5 BUTTON

2213466005

P/B CONTROL ASSEMBLY – TWO SPEED – 7 BUTTON

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XN10 I&M MANUAL/EN/11.30.2010

9.11 Push Button Assembly – Vertical Pairs of Buttons (Option)
Figure 48. Push button assembly – vertical pairs of buttons

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XN10 I&M MANUAL/EN/11.30.2010

Table 20. Push Button Assembly – Vertical Pairs of Buttons (Option) Parts List
ITEM

PART
NUMBER

2309673010

E-STOP, SINGLE SPEED HOIST – 10 FT P/B ASSEMBLY

2309673015

E-STOP, SINGLE SPEED HOIST – 15 FT P/B ASSEMBLY

2309673020

E-STOP, SINGLE SPEED HOIST – 20 FT P/B ASSEMBLY

2309674010

E-STOP, TWO SPEED HOIST – 10 FT P/B ASSEMBLY

2309674015

E-STOP, TWO SPEED HOIST – 15 FT P/B ASSEMBLY

2309674020

E-STOP, TWO SPEED HOIST – 20 FT P/B ASSEMBLY

2212932011

E-STOP, SS HOIST PUSHBUTTON ENCLOSURE ASSEMBLY

2212932012

E-STOP, TS HOIST PUSHBUTTON ENCLOSURE ASSEMBLY

2218000

UPPER SUSPENSION KIT

7285036

PLUG KIT

558073

SUSPENSION UNIT

52292266

PUSH BUTTON ELECTRICAL CONTROL CABLE

2309414004

XN PUSHBUTTON WARNING TAG - ENGLISH

DESCRIPTION

QTY

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XN10 I&M MANUAL/EN/11.30.2010

9.12 Push Button Assembly – Vertical Buttons (Option)
Figure 49. Push button assembly – vertical buttons

Table 21. Push Button Assembly - Vertical Buttons (Option) Parts List
ITEM

PART
NUMBER

2212932011

3 BUTTON P/B TELEMECANIQUE – S*, 1H

2212932012

3 BUTTON P/B TELEMECANIQUE – S*, 2H

2212932032

5 BUTTON P/B TELEMECANIQUE – S*, 1H, 2T

2212932033

5 BUTTON P/B TELEMECANIQUE – S*, 2H, 2T

2212932034

7 BUTTON P/B TELEMECANIQUE – S*, 2H, 2T, 2B

2212932035

7 BUTTON P/B TELEMECANIQUE – S*, 1H, 2T, 1B

2212932036

7 BUTTON P/B TELEMECANIQUE – S*, 2H, 2T, 1B

2212932037

7 BUTTON P/B TELEMECANIQUE – S*, 1H, 2T, 2B

DESCRIPTION

QTY

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