Gis GKU 1250 Quick start guide

04.21 Translation 9500.9008.1
TRANSLATION OF THE
ORIGINAL INSTRUCTION MANUAL
CRANE COMPONENTS GKU

3Swiss Lifting Solutions
Table of contents
Spare parts / Ordering spare parts................................................................................................4
0 General information ..............................................................................................................5
0.1 General safety instructions ........................................................................................................................................................................... 5
0.1.1 Safety and hazard information...................................................................................................................................................................... 5
0.2 General safety regulations and organisational measures............................................................................................................................. 5
0.3 Particular safety instructions......................................................................................................................................................................... 5
0.4 Instructions for hazard protection ................................................................................................................................................................. 6
0.4.1 Hazards - Mechanical ................................................................................................................................................................................... 6
0.5 Technical status ............................................................................................................................................................................................ 6
0.5.1 Periodic checks............................................................................................................................................................................................. 6
0.5.2 Warranty ....................................................................................................................................................................................................... 6
0.6 Appropriate use ............................................................................................................................................................................................ 7
0.6.1 Use of the instruction manual ....................................................................................................................................................................... 7
1 Description ............................................................................................................................7
1.1 Operating conditions..................................................................................................................................................................................... 7
1.2 General description....................................................................................................................................................................................... 8
2 Start-up .................................................................................................................................9
2.1 Transport and assembly ............................................................................................................................................................................... 9
2.2 Assembly ...................................................................................................................................................................................................... 9
3 Care and maintenance........................................................................................................11
3.1 General guidelines for maintenance and repair.......................................................................................................................................... 11
3.2 Care and maintenance ............................................................................................................................................................................... 12
3.2.1 Care overview............................................................................................................................................................................................. 12
3.2.2 Maintenance overview ................................................................................................................................................................................ 12
3.2.3 Tightening torques ...................................................................................................................................................................................... 12
4 Disposal ..............................................................................................................................12
5 Annex..................................................................................................................................13
5.1 Technical data sheets ................................................................................................................................................................................. 13
5.2 EC Declaration of incorporation.................................................................................................................................................................. 18

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Resellers / Agent
Original spare parts for the crane components can be acquired from the following addresses:
Manufacturer
GIS AG
Swiss Lifting Solutions Tel. [phone]
Luzernerstrasse 50 [email protected]
CH-6247 Schötz www.gis-ag.ch
The correct order numbers for original spare parts can be obtained from the relevant dimensioned drawing. Please ensure that you have the
following data on your crane component type to hand. This will enable the correct spare parts to be supplied without delay.
Crane component type:
Wheel base:
Year of manufacture:
Load capacity:
Spare parts / Ordering spare parts

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Transport / Assembly:
• Single parts and large components should be carefully fixed to suitable and technically acceptable hoisting apparatus / load handling devices.
Start-up / operation:
• Before initial start-up, as well as daily start-up, carry out a visual check and carry out the stipulated user-checks routine.
• Damage to the crane components and changes in its operational characteristics must be reported immediately to the responsible person.
• Refrain from hazardous procedures.
• The maximum load of GKU crane components must not be exceeded.
See also operational parameters (Chapter 0.6).
Cleaning / service / repair / maintenance / refitting:
• Use working platforms provided for assembly work at high level.
• Do not use machine parts for this purpose.
• Check electrical cables for damage or wear.
• Reassemble and check safety devices that have been disassembled for maintenance or repair of the hoist once service and repair work
has been completed.
• Adhere to predefined testing and service intervals specified in the instruction manual.
• Follow the directions in the instruction manual regarding exchanging parts.
• Operating personnel should be informed before commencing special or repair work.
• Secure the repair working area.
• Attach warning plates.
• Retighten screw connections that have been loosened for repair or maintenance work.
• Replace non-reusable fixing elements (e.g. self-locking nuts, washers, cotter pins, O-rings and seals).
0.3 Particular safety instructions
The instruction manual for the crane system must always be available within the operating area of the crane system. The instruction manual
must be strictly adhered to. Furthermore, supplementary to the instruction manual, the statutory regulations governing general accident
prevention and environmental protection are to be enforced.
Operating and service personnel must have read and understood the instruction manual, in particular the safety instructions, before
commencing work. Protective equipment must be made available for operating and service personnel and worn at all times. The operator or
their representative is responsible for supervising operating personnel and ensuring they are aware of the hazards and safety implications of
working with the crane system.
The manufacturer reserves the right to make technical changes to the product or changes to these instructions and assumes no liability for the
completeness and up-to-dateness of these instructions. The original version of these instructions is in the German language. In case of doubt,
the original German original version is exclusively valid as a reference document.
0.2 General safety regulations and organisational measures
0.1.1 Safety and hazard information
The following symbols and terms are used in this instruction manual for safety and hazard instructions:
WARNING !
Non-compliance, either in part or full, with operating instructions with this symbol can result in serious personal injury or fatal
accidents. Warning information must be strictly adhered to.
ATTENTION !
Non-compliance, either in part or full, with operating instructions with this symbol can result in major damage to machinery,
property or material. Information in the "Caution" category is to be exactly adhered to.
NOTE
Following the instructions marked with this symbol will lead to more effective and straightforward operation. "Note" directions
make work easier.
0.1 General safety instructions
0 General information

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0.5.2 Warranty
The warranty is void if the assembly, operation, testing and maintenance is not carried in accordance with this instruction manual. Repairs and
troubleshooting under warranty may only be carried out by qualified persons after consultation and agreement with the manufacturer / supplier.
Any modifications to the product or the use of non-original spare parts will void the warranty.
0.5.1 Periodic checks
Each device/unit operator should adequately note all checks, maintenance and inspections performed in the inspection pass, and have these
confirmed by the competent person in charge. Incorrect or missing entries will lead to forfeiture of the manufacturer's warranty.
Devices and cranes are to be checked periodically by a specialist. Primarily, visual and functional checks are to be carried out,
whereby the state of components with respect to damage, wear, corrosion or any other changes is determined. In addition, safety
equipment is assessed for completeness and efficiency. It may be necessary to dismantle the equipment to correctly assess wear
parts.
Load-bearing parts must be inspected over their entire length, including covered or hidden parts.
All periodical inspections should be arranged by the operator.
This instruction manual was issued in 2021. It corresponds to directive 2006/42/EC of the European Parliament and council of 17 May 2006
(including its amendments).
0.5 Technical status
0.4.1 Hazards - Mechanical
Physical injury:
Unconsciousness and injury through:
• crushing, shearing, cutting and twisting
• drawing in, ramming, piercing and rubbing
• slipping, stumbling and falling
Causes:
• crushing, shearing and twisting
• parts rupturing or bursting
Safety options:
• keep floor, equipment and machinery clean
• observe the required safety distance
Hazardous areas must be clearly marked by warning plates and cordoned off. It must be ensured that warnings regarding hazardous areas are
given due attention.
Hazards can stem from:
• incorrect application
• not following safety directions properly
• not carrying out test and service work thoroughly
0.4 Instructions for hazard protection

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The corresponding GIS standard trolleys are to be used as longitudinal trolleys:
GKU 1250......: GHF 1250, GMF 1250
GKU 2500......: GHF 2500, GMF 2500
GKU 5000......: GHF 5000, GMF 4000/5000
1.1 Operating conditions
The series includes the following models: GKU.
1 Description
0.6.1 Use of the instruction manual
This instruction manual includes the following chapters:
0 General information 3 Care and maintenance
1 Description 4 Disposal
2 Start-up 5 Annex
Supplementary to the instruction manual, the following documentation from the operator must be noted:
• EC Declaration of incorporation
• Technical data sheets
Page and figure numbering:
The pages are consecutively numbered. Blank pages are not numbered, however are calculated together with the consecutive pages.
Figures are numbered consecutively by chapter. Example: Figure 3-1 means: in Chapter 3, Figure 1.
Improper use comprises:
• exceeding the defined maximum permissible load capacity
• pulling loads at an angle
• heaving, pulling or dragging the load
• transporting persons
• moving loads over persons
• transporting excessive loads
• failing to observe the load constantly
• use in an explosive environment
Refer also to Chapter 0.3.
General operating conditions:
• Ambient temperature ................................: -15 °C to +50 °C
• Humidity....................................................: max. 80 % relative humidity
We recommend equipping GIS crane components operating outdoors with a protective cover to protect against the effects of the weather.
Special operating conditions can be agreed in individual cases with the manufacturer. After consultation, appropriate, optimised equipment, and
important information for safe, low-wear use can be supplied. The intended use of the crane components likewise assumes adherence to the
operating, maintenance and servicing prescribed by the manufacturer. The maximum permissible payload must take into account the weight of
the crane bridge and the additional strain brought about by the overhang load.
The crane components of the GKU series are used as end carriages for underslung standard travelling cranes. The crane components are
manufactured in accordance with the latest technical developments and recognised safety standards, and are tested for safe operation by the
manufacturer. The GKU crane components may only be used together with standard GIS trolleys. Crane components of the above series may
only be used when in an acceptable technical condition, in accordance with their intended use, by trained personnel in a safe and responsible
manner. No modifications that would impair the strength values may be made to the crane components.
0.6 Appropriate use

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The GKU crane components are designed as a crane bridge kit. An end carriage consists of 2 primed sheet steel parts that are bolted together.
A kit is required to construct an underslung travelling crane with a single or double crane bridge.
The scope of delivery and the hole pattern to be prepared on site can be found on the technical data sheets. The GKU type is determined by the
maximum permissible payload of the crane and by the span width of the crane bridges. The layout is determined by a calculation program.
5) Buffer
6) Scales
7) Single crane bridge
1) Crane track
2) Manual/push trolley
3) End carriage
4) Motorised trolley
4
5
6
7
1
2
3
Figure 1-2 GKU 5000
4) Motorised trolley
5) Buffer
6) End carriage
1) Crane track
2) Manual/push trolley
3) Double crane bridge
4
5
6
1
2
3
Figure 1-1 GKU 1250/2500
1.2 General description

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Before assembling the crane components, check whether the existing GKU type corresponds to the specifications on the technical
data sheet and whether it is suitable for the crane system to be assembled.
The first step is to fit the end carriages onto the single or double crane bridge. The corresponding drill holes and screw fittings must be made
by the crane builder in accordance with the specifications on the technical data sheet. For the GKU 5000 series, a lining plate must also be
installed for the single crane girder.
2.2 Assembly
The safety directions for handling loads should be followed (see Chapter 0.3) when transporting and assembling the crane components. Crane
components must be assembled by qualified staff, always bearing in mind the accident prevention directions in Chapter 0.2. Before assembly,
the crane components must be stored in an closed room or covered area. Should the crane components be destined for operation outdoors,
then it is recommended that a protective cover is erected to shield it from the effects of the weather.
Wherever possible, the crane components should be transported in their original packaging. The goods delivered should be checked for
completeness and the packaging disposed in an environmentally sound manner. It is advisable to have the crane components assembled on-
site by trained skilled personnel.
2.1 Transport and assembly
Mechanical adjustments may be performed by authorised specialists. If no tightening torques are specified for screw connections,
the general information in Chapter 3.2.3 applies.
Operating staff must carefully read the instruction manual of the crane components before initial start-up and carry out all the
checks. The crane components shall be put back into operation only after operational safety has been established. Unauthorised
persons must not fit the crane components or carry out work with them.
The operator must create an inspection pass during the start-up of the crane components. The inspection pass contains all the
technical data and the date of start-up. It provides a record of all servicing and maintenance work.
2 Start-up

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Figure 2-2 GKU 5000
Figure 2-1 GKU 1250/2500
Assembling the end carriages:
• 2 buffers are mounted on the end face of each end carriage.
• Only original GIS trolleys may be used as push trolleys (see Chapter 0.6).
• The GKU 1250/2500 series is mounted directly on the trolleys as shown in Figure 2-1.
• The GKU 5000 series is mounted with an additional suspension part as shown in Figure 2-2.
• One side of the single or double crane bridge must be designed as a fixed bearing (see Figure 2-3). The opposite side must be designed as
a floating bearing to compensate for crane track inaccuracies (see Figure 2-4).
• Assembly of the supplied adjusting rings is carried out according to the illustration on the technical data sheet.
The trolleys must be assembled in accordance with the original instruction manual for GHF/GMF trolleys.

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Operating failures in crane components affecting the safe operation of the device should be remedied immediately.
Maintenance and repair work on the crane components may only be carried out by qualified and trained personnel.
If the operator performs maintenance work on the crane components on their own, the type of maintenance performed together with
the date carried out must be entered in the inspection pass.
Alterations, as well as modifications and additions to crane components, which may affect safety, must be authorised by the manufacturer in
advance. Structural alterations to crane components not authorised by the manufacturer exempt the manufacturer from liability in the event
of damage. Material warranty claims will only be recognised as valid if original manufacturer's spare parts are used exclusively. We explicitly
advise that original parts and accessories not delivered by us are also not checked or approved by us.
General:
Care and maintenance tasks are preventive measures designed to preserve the full functionality of crane components. Non-compliance with
care and maintenance routines can result in limited use and damage to crane components.
Care and maintenance should be carried out in accordance with the instruction manual at predefined time intervals (Table 3-1 and 3-2). During
care and maintenance work, general accident prevention directions, special safety directions (Chapter 0.3) as well as hazard protection
instructions (Chapter 0.4) should be followed.
Care and maintenance work should be performed only on crane components with no loads. The main switch of the crane must be
off.
3.1 General guidelines for maintenance and repair
3 Care and maintenance
Figure 2-3 Fixed bearing Figure 2-4 Floating bearing

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If the crane components can no longer be used, they must be disposed of in an environmentally safe manner. Metals and plastics are to be
recycled.
4 Disposal
M 8 M 10 M 12
40 Nm 80 Nm 135 Nm
3.2.3 Tightening torques
Torque values for screws of strength class 10.9 per DIN ISO 898:
Designation d 3 M 12 M Task Remark
1. End carriage x Function check with load
Check screw torques
Chapter 3.2.3
2. Buffer x Visual check for wear
3.2.2 Maintenance overview
Table 3-2 Maintenance overview
Designation d 3 M 12 M Task Remark
1. End carriage x Check for abnormal
Noise / deformation
2. Buffer x Visual check
3.2.1 Care overview
Table 3-1 Care overview
The crane components are largely maintenance-free. Unusual noises during daily use must be reported to the competent authority immediately.
A pending repair must be carried out immediately.
3.2 Care and maintenance
Care work encompasses visual checks and cleaning routines. Maintenance work includes additional functional checks. During the function
checks, all fixing elements must be checked for tightness.
Care and maintenance intervals are defined as follows:
d (daily), 3 M (quarterly), 12 M (annually)
The predefined care and maintenance intervals should be reduced when the loading of the crane components is exceptionally large or when
frequently operated in adverse conditions (e.g. dust, heat, humidity, steam, etc.).

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Model GKU 1250................ : Drawing number 9249.9218.1 (see page 14)
Model GKU 2500................ : Drawing number 9249.9219.1 (see page 15)
Model GKU 5000................ : Drawing number 9249.9220.1 (see page 16)
5.1 Technical data sheets
5 Annex

9247.3700.33Kopfträgerkit GKU 1250/12001 9247.3701.32Kopfträgerkit GKU 1250/16001 9247.3702.31Kopfträgerkit GKU 1250/20001
Artikel-NrPosWerkstoffBezeichnungA
1
1
2
2
3
3
4
4
A A
B B
C C
D D
Revision
-
Gezeichnet 10.05.2021 T.Keller
GKU 1250
1
A2
Massstab
1 : 5
Ersetzt durc h Ersatz fürKlasse
/
Massbild; Schematic draw; Liste de dim.
b
In Bearbeitung
9249.9218.1
Loose side Fixed side
Rev. Datum User
C 08.04.2021 P.ENGEL
w w w
60
Double crane bridge track width 900
L (wheel base)
L + 306
100
100

33
33.5
Scope of supply for end carriage kit:
2 end carriage assy. incl. buffer
4 adjusting rings, fixed side
4 adjusting rings, loose side
Support bolt
Adjusting
ring
Support bolt
Adjusting
ring
End carriage
29
14
14 Swiss Lifting Solutions

9248.3700.33Kopfträgerkit GKU 2500/12001 9248.3701.32Kopfträgerkit GKU 2500/20001 9248.3702.31Kopfträgerkit GKU 2500/28001
Artikel-NrPosWerkstoffBezeichnungA
1
1
2
2
3
3
4
4
A A
B B
C C
D D
Revision
-
Gezeichnet 10.05.2021 T.Keller
GKU 2500
1
A2
Massstab
1 : 5
Ersetzt durc h Ersatz fürKlasse
/
Massbild; Schematic draw; Liste de dim.
b
In Bearbeitung
9249.9219.1
Loose side Fixed side
Rev. Datum User
C 08.04.2021 P.ENGEL
ww w
76
Double crane bridge track width 900
L + 386
L (wheel base)
140
46.5

43
Scope of supply for end carriage kit:
2 end carriage assy. incl. buffer
4 adjusting rings, fixed side
4 adjusting rings, loose side
Support bolt
Adjusting
ring
Support bolt
Adjusting
ring
End carriage
35
18
15Swiss Lifting Solutions

9249.3700.33Kopfträgerkit GKU 5000/12001 9249.3701.32Kopfträgerkit GKU 5000/20001 9249.3702.31Kopfträgerkit GKU 5000/28001
Artikel-NrPosWerkstoffBezeichnungA
1
1
2
2
3
3
4
4
A A
B B
C C
D D
Revision
-
Gezeichnet 10.05.2021 T.Keller
GKU 5000
1
A2
Massstab
1 : 5
Ersetzt durc h Ersatz fürKlasse
/
Massbild; Schematic draw; Liste de dim.
b
In Bearbeitung
9249.9220.1
Loose side Fixed side
Rev. Datum User
-
ww w
86
Double crane bridge track width 900
197160
L
L + 394
23
120
Scope of supply:
2 end carriage assy. incl. buffer
4 adjusting rings, fixed side
4 adjusting rings, loose side
4 scales
4 lining plates (single bridge)

48
12
27.5
Support bolt
Adjusting
ring
Support bolt
Adjusting
ring
Lining plate
End carriage Scale
16 Swiss Lifting Solutions

17Swiss Lifting Solutions

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We,
GIS AG, Swiss Lifting Solutions, Luzernerstrasse 50, CH-6247 Schötz
hereby declare that the partly completed machinery
GIS crane components, model series GKU
with a load capacity of up to 5000 kg
developed for transporting loads and intended to be integrated into a machine, meets the essential requirements of the
following EC directive, insofar as applicable to the scope of the delivery:
EC Machinery Directive 2006/42/EC
We also declare that the technical documentation has been compiled in accordance with Annex VII, Part B of Directive
2006/42/EC. We undertake to submit the specific documents relating to the crane components to national authorities on
receipt of a reasonable request. The information will be supplied by electronic means.
Harmonised standards applied:
EN ISO 12100 Safety of machines; General design guidelines; risk assessment and risk reduction
Standards and technical specifications applied:
EN 13001-1 Cranes; General design; Part 1: General principles and requirements
Accident prevention regulations
This declaration refers only to the crane components. Start-up is prohibited until it has been proven that the
crane into which the components are integrated corresponds with the above EC Directive.
Authorised to compile relevant technical documentation:
GIS AG, Luzernerstrasse 50, CH-6247 Schötz
Schötz, 20.01.2021 GIS AG
I. Muri E. Widmer
Director Sales Manager
Declaration for the incorporation of an incomplete machine in accordance with the EU directive 2006/42/EC, Annex II B
5.2 EC Declaration of incorporation