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Railstar Motor Driven Trolley

• Fits wide range of beam sizes for max 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
railstar motor driven trolley
trolley
Railstar Motor Driven Trolley Dimensions (inches)
Dimension Rated Capacity*
1/8 - 2 Tons 3 Tons
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.

Railstar Motor Driven Trolley Specifications
Rated
Cap*
(tons)
Product
Code
Operating Voltage Phase Travel Speed Motor
HP
Min
Beam
Size
Max
Beam
Size
Shipping
Weight
50 hertz
(FPM)
60 hertz
(FPM)
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 lbs
1/8-2 0301 n/a 110-120 1 n/a 78 1/3 S6x12.5 S18x54.7 113 lbs
3 0302 220/380-415 220-240/440-480 3 65 78 3/4 S8x18.4 S24x79.9 185 lbs
3 0303 n/a 110-120 1 n/a 78 3/4 S8x18.4 S24x79.9 190 lbs
Note:Three phase units are reconnectable for high and low range voltage.

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Railstar Motor Driven Trolley Prices
Product Code
Capacity
Travel speed (FPM)
Standard Beam Height
Standard Flange Width
Price
1/8 - 2 tons
78
6 - 18"
3 3/8 - 6"
$2,512
1/8 - 2 tons
78
6 - 18"
3 3/8 - 6"
$2,512
3 tons
78
6 - 18"
4 - 7"
$2,972
3 tons
78
8 - 24"
4 - 7"
$2,972
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.

Railstar Motor Driven Trolley 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.
TABLE 1
motor driven trolley
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
CHART B: 3 TON (3000 Kg)
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
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" (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.
THREE-PHASE UNITS
A three phase motor can rotate in either direction
depending on its connection to the power supply.
Therefore, 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.
(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.
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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