TRUCONNECT Remote Service for overhead cranes


Demag logo   Konecranes is the original service provider for both Konecranes and Demag equipment.


Condition, usage and operating data for efficient maintenance planning

TRUCONNECT user guide

TRUCONNECT is a suite of remote service products and applications to support maintenance operations and drive improvements in safety and productivity. 

TRUCONNECT Remote Monitoring is an essential product for incorporating predictive maintenance elements as part of a Konecranes CARE Preventive/Predictive Maintenance program. Remote Monitoring provides valuable usage and operating data that can be used along with inspection and maintenance information for a comprehensive view of equipment maintenance needs and performance. 

Analyzing and identifying anomalies, patterns and trends in TRUCONNECT data helps us make informed, component-specific predictions, and prioritize recommendations and actions. 


TRUCONNECT Remote Monitoring

TRUCONNECT SummaryTRUCONNECT Remote Monitoring collects condition, usage and operating data from control systems and sensors on a crane and provides alerts of certain anomalies. Remote Monitoring data is used in maintenance planning and in predicting possible component or equipment failure.

Collected data varies depending on the make and model of your crane, but typically covers condition and expected service life of critical components, running time, lifted loads, motor starts, work cycles and emergency stops. Additional TRUCONNECT options allow certain cranes to be equipped with hoisting brake and/or inverter monitoring.

TRUCONNECT data is accessible on the yourKONECRANES customer portal and includes:

  • Safety-related occurrences, such as brake service life, over-temperatures, attempted overloads and emergency stops
  • Pareto analysis of critical alerts and faults
  • Operating statistics, such as load spectrum, monitoring of hoist jogging, overloads, emergency stops, work cycles and running hours
  • Estimates of remaining Design Working Period (DWP) of selected components, such as the hoist, hoist brake, contactors and trolley (SMARTON)

TRUCONNECT Remote Monitoring with alerts based on the equipment/application is required in order to effectively implement predictive maintenance. Remote Monitoring data combined with inspection and maintenance data provided by the maintenance program gives a comprehensive view of equipment maintenance needs and performance.

Safety alerts are delivered automatically by email or text message to notify designated contact personnel of selected safety risk events.

Get connected to your entire fleet

Add TRUCONNECT to an existing crane with a retrofit

TRUCONNECT Remote Monitoring hardware can be retrofitted on existing cranes including Konecranes equipment, non-Konecranes brand hoists and Demag hoists and cranes equipped with SafeControl. These retrofits can help give you a comprehensive fleet view of all your assets.

​In addition to a condition monitoring unit and modem, component-specific sensors for the brake and rope can be retrofitted to provide more specific insights on the condition of these critical load-bearing components.​



TRUCONNECT Brake Monitoring

TRUCONNECT Brake MonitoringThe hoist brake is one of the most critical wearing components in a crane. The brake is looked at during inspections, but with heavily used cranes, the service lifetime of brake wearing parts may end sooner than expected. Additional inspections also require crane shutdown and provide only a snapshot of the current condition of the brake.

TRUCONNECT Brake Monitoring uses a condition monitoring device to collect the status of brake air gap, mechanical and electrical faults from the electromagnetic disc brakes. The service provides visibility into current brake condition, estimates remaining service life and indicates brake faults. Brake Monitoring information is used in predictive maintenance and can also be used for brake maintenance planning.

Brake Monitoring is delivered with new PLC controlled Konecranes SMARTON and UNITON (hoist brake) and RTG cranes (traveling/traversing machinery brakes). Retrofits are also available for most Konecranes hoist models.



TRUCONNECT Wire Rope Monitoring

Wire Rope Monitoring on yourKONECRANESThe wire rope is one of the fastest wearing load-bearing component on a crane. During a typical inspection of a wire rope, only the outer wires and strands can be visually inspected. Magnetic NDT measurements can be performed to analyze the condition of the internal wires, but this requires crane shutdown and a specialist to perform the inspection.

TRUCONNECT Wire Rope Monitoring provides a continuous view of rope condition through the use of sensors installed on the wire rope. It reveals both visible exterior defects as well as internal defects that are not detectable with a visual inspection.

An indication of defects on different parts of the rope helps you identify which parts of the wire rope have started to wear out and may need further attention.

Wire rope replacement limits are based on the ISO4309:2017 Standard (Annex C) and extensive test data and other statistical data from Konecranes.

Trend displays give you an aggregated view of rope condition over time. This information helps estimate the remaining wire rope lifetime and can aid in maintenance planning.



TRUCONNECT Remote Support

TRUCONNECT Remote Support provides 24/7 access to a global network of crane experts and specialists, offering problem solving and troubleshooting to help reduce unplanned downtime. In controlled circumstances, two-way communication with the machines and their operators can be established in order to expedite corrective action. Remote Support is ideally suited for extremely remote locations.



Data security

Konecranes digital services have been awarded ISO/IEC 27001:2013 certification for information security management. The ISO/IEC 27001 certificate demonstrates a commitment to proactively manage the information security of Konecranes digital services and ensure compliance with legal and customer requirements. The certification applies to the development and delivery of the customer portal, CheckApp for Daily Inspections and the Slings and Accessories Inspection app and the TRUCONNECT suite of remote service products.