FS Industries ENGINEERED STEEL PRODUCTS
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RAILSTAR MOTOR DRIVEN TROLLEY

railstar motor driven trolley Fits wide range of beam sizes for maximum
    versatility
For use with hook suspended single speed hoists
   that are equipped with reversing contactor
Steel plate side frames
Steel spur gearing for optimum strength and
    smooth operation
Durable hardened cast iron trackwheels that
    operate on standard S-beams or flat flanged
    beams
Lifetime lubricated double row ball bearings for
    high efficiency, low maintenance
Cast iron control enclosure
Four-button control station included for operating
    single speed hoist proportioned to 20 ft. lift
Trolley guards standard
115 volt control circuit
One-year warranty
Imported
trolley
CLEARANCE DIMENSIONS (IN.)
Dimension Rated capacity* (tons)
1/8-2 3
Min. radius curve 52 71
Beam range S6x12.5-S18x54.7 S8x18.4-S24x79.9
A 12 3/4 14 1/8
B 6 3/8 6 3/4
C** 4 13/16 5 1/4
D 3 9/16 3 15/16
E 2 9/16 2 15/16
F** 4 3/4 5 3/16
G** 6 6 5/16
H** 17 ft. 17 ft.
J 7 1/2 9 5/16
K 4 1/8 4 11/16
SINGLE PHASE L 12 3/4 15 3/16
THREE PHASE L 11 7/16 13 7/8
M** 1 1/2 2 15/16
N** 3/8 3/4
P** 1 7/16 1 9/16
Q** 5 1/8 5 7/8
R 1/2 3/4
S 1 1/16 1 1/16
T** 8 7/8 9 9/16
**Dimensions given are for minimum S-beam and will vary with larger beams.

SPECIFICATIONS
Rated
Cap.*
(tons)
Product
Code
Operating voltage Phase Travel Speed Motor
H.P.
Min.
beam
size
Max.
beam
size
Shipping
weight
(lbs.)
50 hertz
(F.P.M.)
60 hertz
(F.P.M.)
50 hertz 60 hertz
1/8-2 0300 220/380-415 220-240/440-480 3 65 78 1/3 S6x12.5 S18x54.7 108
1/8-2 0301 n/a 110-120 1 n/a 78 1/3 S6x12.5 S18x54.7 113
3 0302 220/380-415 220-240/440-480 3 65 78 3/4 S8x18.4 S24x79.9 185
3 0303 n/a 110-120 1 n/a 78 3/4 S8x18.4 S24x79.9 190
Note: Three phase units are reconnectable for high and low range voltage

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PRICING FOR RAILSTAR MOTOR DRIVEN TROLLEY
Product
Code
Rated Cap.*
(tons)
Travel
speed (FPM)
Std. Beam
height (in.)
Std. Flange
width (in.)
Price
1/8-2 78 6-18 3 3/8 - 6 $2,436
1/8-2 78 6-18 3 3/8 - 6 $2,436
3 78 8-24 4-7 $2,882
3 78 8-24 4-7 $2,882
Universal hook plate and 4 button single speed control station included.
Standard P.B. drop is 16 ft. Standard Power Cord length is 4 ft. imported.

INSTALLATION
UNPACKING INFORMATION
After removing the trolley from the shipping carton,
carefully inspect the external condition of the cords,
control box, gear reducer and motor for damage that
may have occurred during shipment and handling. Check
to make sure all parts (trolley side frame assembly with
control box, trolley side frame with gear reducer and
motor, hook plate, suspension bolts, spacer washer,
spacer tubes, lockwashers and nuts) are furnished. Also,
before attempting to install the trolley, make sure that
the power supply indicated on the nameplate is the same
as the power supply on which the unit is to operate. If
there is damage, refer to packing slip envelope for
claim procedure.
Due to the variations in beam flange widths, it is
suggested that the beam flange width be measured to
determine the exact distribution of spacer washers. The
distance between trackwheel flanges (dimension "X")
should be 1/8 to 3/16 inch (3.2 to 4.8 mm) greater than
the beam flange width for straight runway beams, and
3/16 to 1/4 inch (4.8 to 6.3 mm) greater than the beam
flange width if runway system includes sharp curves. The
use of other than our supplied washers may result in
trackwheel to beam flange variations and thus Table 2
will not apply.
INSTALLATION
The hoist, trolley and hook suspension for suspending
the hoist from the trolley may be packed separately. If
necessary, assemble the hook suspension to the hoist
according to the instruction furnished with the suspension
and/or the instruction in the manual furnished with the
hoist.
The Railstar Motor Driven Trolley is designed for operation at ambient temperatures of 0° to 100°F (-17 to 38°C).
Now install the trolley on the beam by sliding one side
frame out far enough to allow the trackwheels to clear
the beam flange Lift the trolley up so that the trackwheels
are riding on the beam. Draw the side frames together
and tighten the nuts snugly to compress the lockwashers.
Suspend the hoist from the trolley hook plate so that the
hoist power and control cords are son the control box
side of the trolley. Verify distance between trackwheel
flanges (dimension "X") as noted above.
The stops must be positioned so as to not exert impact
force on the hoist frame or trolley wheels. They must
contact the ends of the trolley side frames.
TROLLEY TO BEAM
It is recommended that the trolley be mounted on the beam
prior to suspending the hoist from the trolley. Before
attempting to mount the trolley on the beam, measure the
actual width of the beam flange on which the trolley is to
operate. Using this measurement determine the
arrangement of the spacer washers using Figure 1 and
Table 2. Chart A of Table 2 shows the washer
arrangement for the 1/8-2 ton (250-2000 kg.) trolley,
while Chart B provides data for the 3 ton (3000 kg.)
trolley. Loosely assemble the side frames, hook plate,
spacer washers, spacer tubes, lockwashers and nuts
on the suspension bolts as shown in Figure 1.
motor driven trolley
TABLE 1
CHART A: 1/8 THRU 2 TON RAILSTAR TROLLEY
WASHER SPACING
FLANGE WIDTH NUMBER OF SPACER WASHERS
IN. MM A B C D
31/4 82.5 22 0 0 0
33/8 85.7 21 1 0 0
35/8 92.1 19 2 1 0
4 101.6 16 3 3 0
41/8 104.8 15 4 3 0
45/8 117.5 11 6 5 0
5 127 8 7 7 0
51/8 130.2 7 8 7 0
51/4 133.3 6 8 8 0
51/2 139.7 4 9 9 0
55/8 142.9 3 10 9 0
6 152.4 0 11 11 0
Electrical Connections
The trolley electrical connections must be completed as
shown in Figure 2 (see below). The hoist and trolley must
be supplied with adequate electrical power in order to
operate properly. For proper operation, the voltage,
(measured at the trolley terminal board with the hoist
operating in the up direction with full load) must be
as indicated in the table below.
TABLE 2
NOMINAL
CURRENT
MIN. RUNNING
VOLTAGE
MIN. STARTING
VOLTAGE
115-1-60 104 98
230-3-60 198 198
460-3-60 396 396
220-3-50 198 198
380-3-50 352 352
415-3-50 374 374
CHART B: 3 TON (3000 Kg)
FLANGE WIDTH  
NUMBER OF SPACER WASHERS
IN. MM A B C D
4 101.6 24 0 0 0
41/8 104.8 23 1 0 0
45/8 117.5 19 3 2 0
5 127 16 4 4 0
51/8 130.2 15 5 4 0
51/4 133.3 14 5 5 0
51/2 139.7 12 6 6 0
55/8 142.9 11 7 6 0
6 152.4 8 8 8 0
61/4 158.7 6 9 9 0
63/8 161.9 5 10 9 0
7 177.8 0 12 12 0
Signs of inadequate electrical power (Low Voltage) are:
Noisy hoist or trolley operations due to brake and/or
    contactor chattering.
Dimming of lights or slowing of motors connected
    to the same circuit.
Heating of the hoist and/or trolley motors and other
    internal components as well as heating of the wires
    and connectors in the circuit feeding the unit.
Failure of the hoist to lift the load due to motor stalling.
Blowing of fuses or tripping of circuit breakers.
To avoid these low voltage problems, the trolley must
be connected to an electrical power supply system that
complies with the National Electrical Code and
applicable local codes. This system must also be rated
for a minimum of 20 amps and it must have #14 AWG
or larger wiring, a disconnecting means, overcurrent
protection (slow blow fuses or inverse-time type circuit
breakers) and provisions for grounding.
TYPICAL POWER SUPPLY SYSTEM
If grounding is to be through the metal to metal contact
between trackwheels and the operating flange of the
beam, make sure that:
1. No paint or other insulating material is applied to the
    operating flange of the beam.
2. No paint or other insulating material is applied to the
    trackwheel treads.
Remember, operation with low voltage can void our
repair/replacement policy. When in doubt about any
of the electrical requirements, consult a qualified
electrician. Always disconnect the power from the
power supply system and lockout/tagout disconnecting
means before servicing the trolley or hoist.
3. The trolley beam is permanently grounded to the
    building ground system.
4. The hoist power cord, trolley power cord, hoist control
    cord, and the trolley control cord are grounded to the
    control box (see figures 3 and 4 below).
LENGTH OF
EXTENSION
CORD
SINGLE PHASE THREE PHASE
MINIMUM
WIRE SIZE
MINIMUM
WIRE SIZE
UP TO 50 FEET (15.2 M) #14AWG #16AWG
80 FEET (24.4 M) #12 AWG #16AWG
120 FEET (36.6 M) #10 AWG #14 AWG
Low voltage can also be caused by using an undersize extension cord to supply power to the trolley. The following chart should be used to determine the size wires in the extension cord in order to minimize the voltage drop between the power source and the trolley control box.
The following wiring diagrams show connections to be
made within trolley control box. For special units, see
wiring diagram supplied with unit. NOTE: Trolley power
cord must be replaced (if necessary), hoist power cord
must be connected to the trolley power circuit, hoist
control cord must be connected to the trolley and wired
to the trolley control cord and the control cord must be
shortened (if necessary) before the system supplying
power to the trolley is energized.
In addition, as shipped from the manufacurer, the
three phase trolleys are connected to operate on
380-415 Volts, 3 Phase, 50 Hertz or 440-480 Volts,
3 Phase, 60 Hertz. These units can be converted to
operate on 220 Volts, 3 Phase, 50 Hertz or 230 Volts,
3 Phase, 60 Hertz. To do this, reconnect the motor leads
to the motor cord and move lead #10 at the transformer
terminal board to the "220" position as shown on the
wiring diagram supplied with the trolley or wiring
diagram 03702. Be sure to re-mark, using tape or
some other suitable material, the trolley identification
plate to indicate that the unit is suitable for operation
on 220-3-50 or 230-3-60.
CONTROL STATION
The standard trolleys are supplied with a four button
control station. The hoist control buttons are the single
speed type that can be used to control a single speed
hoist that is equipped with a reversing contactor. The
trolley control buttons are also the single speed type.
To shorten the cord, measure the distance the control
station is to be raised. Remove the cover from the control
station and disconnect the wires from the various
terminals. Using wire cutters, cut the external wire rope
strain relief just above the fitting used to form the loop.
Measuring from the end of the longest wire, cutoff the
cord the distance the station is to be raised. Using the
cut-off piece of cord as an example, remove the outer
jacket and prepare the individual wires of the shortened
cord accordingly.
Unless ordered special, the control station is suspended
from the trolley control box by a cord that is approximately
16'-3" (4.95 M) long. If this is too long for your application,
the cord should be shortened so that the control station is
approximately four feet above the operating floor.
Slide the prepared cord through the grommet on top
of the control station. Clamp the cord to the top of the
control station and, using the wiring diagram supplied
with the trolley, connect the wires to the various
terminals. Now, remove the insulation from the wire
rope stain relief. Slide the clamp sleeve (from the wiring
kit) up on the wire rope and feed the rope around the
pin at the top of the station. Feed the end of the wire
rope through the other side of the clamp sleeve. Pull on
the end of the wire rope until it supports the control
station. Slide the clamp sleeve down to form a tight
loop and then squeeze the clamp sleeve using a vise
or very large pliers to secure the loop. Reattach the
cover to the control station.
TROLLEY POWER CORD
The short power cord furnished is for use with a collector
and bus system. It should be discarded if a cable is to
supply power to the trolley. Connect the "new" power
cord to the terminal board as shown in Figure 3. The box
connector must be made tight on the cable, and if
necessary, a separate strain relief should be provided to
prevent any stress on the wires of the power cord.
FIGURE 3. HOIST POWER CORDS CONNECTIONS
(other wiring is not shown for clarity)
HOIST CONTROL CORD Energize the power supply system. Depress the trolley
control button. If the movement of the trolley does not
agree with the direction arrows on the control station,
de-energize the power supply system. Remove trolley
control box cover and interchange the red and black
wires as shown in Figure 5.
The hoist control cord must be shortened and run into the
trolley control box so that the hoist can be controlled from
the four button control station suspended from the trolley.
To do this, form a loop in the hoist control cord as shown
in Figure 2. Allowing 5 to 6 inches (127.0 to 152.4 mm)
for making connections inside the control box, cut-off the
hoist control cord. The hoist control station and excess
cord can be discarded. Strip 5" to 6" (127.0 to 152.4 mm)
of the outer jacket from the cord to expose the individual
wires. Run the cord through the box connector and firmly
tighten the outer nut of the connector to secure the cord.
Strip 3;g" (9.5 mm) of insulation from the individual wires.
*Connect the brown, yellow and blue wires to the terminal
board as shown in Figure 4. Loosen one of the screws
used to attach the terminal board or transformer to the
control box. Firmly crimp a spade type terminal (from the
wiring kit) to the end of the green wire and slide the
terminal under the head of the screw. Firmly tighten screw
to insure proper ground.
Now, depress the "up" button. If the hoist hook lowers, de-energize the power supply system and interchange the red and black wires of the hoist power cord at the terminal board as shown in Figure 5.
(OTHER WIRING IS NOT SHOWN FOR CLARITY)
*Color coding of wires may vary. Refer to wiring diagram
supplied with hoist for color coding of up, down and
common wires.
THREE-PHASE UNITS
A three phase motor can rotate in either direction
depending on its connection to the power supply. There-
fore, the direction of trolley and hook travel relative to the
selected indicated direction must be checked before the
trolley is put into service. If the hoist power cord is not
properly connected to the terminal board inside the trolley
control box, serious damage could result and the hoist limit
switches are ineffective. The trolley should be checked first
and then the hoist.
Hoist Trolley, Trolleys, CM Railstar Motor Driven Trolley, Wide Range of Beam Sizes, Use with Hook Suspended Single Speed
Hoists, and Trolley Guards from your source for material handling equipment.
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