JET MT050, MT100, MT200, MT300, MT500 Operating Instructions and Parts Manual

JET

Operating Instructions and Parts Manual

MT Series 2-speed Electric Trolley

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1.0 IMPORTANT SAFETY INSTRUCTIONS

 Read and understand this entire manual

before attempting assembly or operation. You should also be thoroughly familiar with all

information in the owner’s manual that

accompanied your hoist.

 Read and understand the warnings posted on

the machine and in this manual. Failure to comply with all of these warnings may cause serious injury.

 Replace the warning labels if they become

obscured or removed.

 This trolley is designed and intended for use

by properly trained and experienced personnel only. If you are not familiar with the proper and safe operation of a trolley, do not use until proper training and knowledge have been obtained.

 Do not use this trolley for other than its

intended use. If used for other purposes, JET disclaims any real or implied warranty and holds itself harmless from any injury that may result from that use.

 Do not install this trolley where explosive

hazards may exist.

 Beam must be properly installed and rated for

anticipated loads. Do not install trolley on beams of unknown capacity.

 Do not install trolley on damaged or deformed

beams.

 JET trolleys are designed to be used with

hoists of the same rated capacity. Never use a hoist with a capacity greater than the capacity of the trolley.

 Never subject trolley to a side pull or load.

Load must be centered directly under the hoist/trolley assembly.

 Make sure load is stable and secure before

moving.

 Never lift load higher than is necessary to

safely move it.

 Do not use to lift people, or loads over people.

Warn others in the vicinity when lifting or transporting a load. Avoid swinging load and hook.

 Do not use in wet, damp or poorly lit locations.

This trolley is not rated for outdoor use.

 Do not exceed the rated capacity of the trolley.  Maintain firm footing when operating the trolley.  The exposed end of the beam or rail must

have a stop installed to contact the frame sides of the trolley, to prevent the trolley from sliding off the beam/rail.

 Always inspect the trolley for damage prior to

use. If the trolley is damaged, do not use until it has been repaired or replaced.

 Leave all internal maintenance to a qualified

JET service center.

 Do not operate this trolley while tired or under

the influence of drugs, alcohol or any medication.

 Thoroughly familiarize yourself with all

instructions that accompanied the hoist you will be using with this trolley.

 Anticipate stopping points and allow the trolley

to come to a smooth stop. Avoid sudden stops or reversals.

Familiarize yourself with the following safety notices used in this manual:

This means that if precautions are not heeded, it may result in minor injury and/or possible machine damage.

This means that if precautions are not heeded, it may result in serious injury or possibly even death.

- - SAVE THESE INSTRUCTIONS - -

WARNING: This product can expose you to chemicals including lead and cadmium which are known to the State of California to cause cancer and birth defects or other reproductive harm, and phthalates which are known to the State of California to cause birth defects or other reproductive harm. For more information go to http://www.p65warnings. ca.gov.

2.0 Table of Contents

1.0 IMPORTANT SAFETY INSTRUCTIONS ....................................................................................................... 2

2.0 Table of Contents ........................................................................................................................................... 3

3.0 Introduction .................................................................................................................................................... 4

4.0 MT Trolley Specifications ............................................................................................................................... 5

4.1 MT trolley with TS series hoist – dimensions ............................................................................................. 6

5.0 Unpacking ...................................................................................................................................................... 7

5.1 Contents of Shipping Container ................................................................................................................. 7

6.0 Installation & Assembly .................................................................................................................................. 7

6.1 Mount trolley to beam ................................................................................................................................. 7

6.2 Mount hoist to trolley .................................................................................................................................. 7

7.0 Electrical connections .................................................................................................................................... 9

7.1 GROUNDING INSTRUCTIONS ................................................................................................................. 9

7.2 Extension Cords ......................................................................................................................................... 9

7.3 Inspecting trolley motion ............................................................................................................................. 9

8.0 User-maintenance ........................................................................................................................................ 10

8.1 Brake inspection ....................................................................................................................................... 10

8.2 Lubrication ................................................................................................................................................ 10

8.3 Additional servicing .................................................................................................................................. 10

9.0 Pendant controllers for Trolley with TS Hoist ............................................................................................... 10

10.0 Troubleshooting MT Series Trolleys .......................................................................................................... 11

11.0 Replacement Parts ..................................................................................................................................... 12

11.1.1 MT050 and MT100 Trolley Frame – Exploded View ........................................................................... 13

11.1.2 MT050 and MT100 Trolley Frame – Parts List .................................................................................... 14

11.2.1 MT050 and MT100 Trolley Motor – Exploded View ............................................................................ 15

11.2.2 MT050 and MT100 Trolley Motor – Parts List ..................................................................................... 16

11.3.1 MT050 and MT100 Trolley Electricals – Exploded View ..................................................................... 17

11.3.2 MT050 and MT100 Trolley Electricals – Parts List .............................................................................. 17

11.4.1 MT200 Trolley Frame – Exploded View .............................................................................................. 18

11.4.2 MT200 Trolley Frame – Parts List ....................................................................................................... 19

11.5.1 MT200 Trolley Motor – Exploded View ............................................................................................... 20

11.5.2 MT200 Trolley Motor – Parts List ........................................................................................................ 21

11.6.1 MT200 Trolley Electricals – Exploded View ........................................................................................ 22

11.6.2 MT200 Trolley Electricals – Parts List ................................................................................................. 22

11.7.1 MT300 and MT500 Trolley Frame – Exploded View ........................................................................... 23

11.7.2 MT300 and MT500 Trolley Frame – Parts List .................................................................................... 24

11.8.1 MT300 and MT500 Trolley Motor – Exploded View ............................................................................ 25

11.8.2 MT300 and MT500 Trolley Motor – Parts List ..................................................................................... 26

11.9.1 MT300 and MT500 Trolley Electricals – Exploded View ..................................................................... 27

11.9.2 MT300 and MT500 Trolley Electricals – Parts List .............................................................................. 27

12.0 Electrical connections ................................................................................................................................ 28

12.1 MT Trolley wiring .................................................................................................................................... 28

13.0 Warranty and Service ................................................................................................................................. 29

3.0 Introduction

This manual is provided by JET covering the safe operation and maintenance procedures for a JET MT Series Electric Trolley. This manual contains instructions on installation, safety precautions, general operating procedures, maintenance instructions and parts breakdown.

The JET MT trolley ranges from 1/2 ton to 5 ton and is designed to pair with a TS series JET hoist. The trolley is made of thick steel elements, including side plates, wheel axles, suspension bolts, and center load plate. Wheels are hot-forged steel, and hardened steel comprises the gears and pinion, which is driven by a planetary gear reducer. Extensions are available to accommodate the width of most beam flanges.

This machine has been designed and constructed to provide consistent, long-term operation if used in accordance with instructions set forth in this manual. If there are any questions or comments, please contact either your local supplier or JET. JET can also be reached at our web site: www.jettools.com.

Record your purchase information here for quick reference:

Model No.:

Stock No.:

Serial No.:

Purchased From:

Date Purchased:

Date Installed:

Installer:

4.0 MT Trolley Specifications

The specifications in this manual were current at time of publication, but because of our policy of continuous improvement, JET reserves the right to change specifications at any time and without prior notice, without incurring obligations.

Figure 4-1: Trolley specs

MT050

MT100

MT200

MT300

MT500

Stock no.

140183

140185

140187

140189

140190

Capacity

1/2 ton (500 kg)

1 ton (1000 kg)

2 ton (2000 kg)

3 ton (3000 kg)

5 ton (5000 kg)

Travel speed

FPM

(MPM)

79 / 20 fpm

(24 / 6 mpm)

79 / 20 fpm

(24 / 6 mpm)

79 / 20 fpm

(24 / 6 mpm)

79 / 20 fpm

(24 / 6 mpm)

79 / 20 fpm

(24 / 6 mpm)

Minimum radius of curve

4.25 ft. (1.3m)

5.5 ft. (1.7m)

6.5 ft. (2.0m)

Net weight

100 lbs. (45 kg)

110 lbs. (50 kg)

143 lbs. (65 kg)

Shipping weight

50 kg (110 lbs.)

129.8 lbs. (59 kg)

242 lbs. (110 kg)

Motor

Horsepower High Spd

0.16

0.24

0.5

0.8

Low Spd

0.04

0.05

0.12

0.2

Cycle

60 Hz

Phase

3 phase

Voltage

230V

Current Draw

(amperage)

High Spd

0.8

1.2

2.2

3.8

Low Spd

0.6

0.9

1.7

2.2

Dimensions (Figure 5-1)

15in (382mm)

15.4in (392mm)

17.4in (442mm)

4.9in (124.5mm)

4.92in (125mm)

5.3in (135mm)

12.8in (324mm)

14in (357mm)

15.6in (395mm)

7in (180mm)

7.2in (183mm)

7.2in (185mm)

2.95~4.9in

(75~125mm)

2.95~4.9in

(75~125mm)

3.93~5.9in

(100~150mm)

4.9~6.9in

(125~175mm)

4.9~6.9in

(125~175mm)

8.5in (217mm)

8.7in (221mm)

11.2in (285mm)

4.9in (125.5mm)

6.3in (159mm)

7.3in (185mm)

3.8in (95.5mm)

4.7in (120mm)

2.1in (52.5mm)

2in (51.5mm)

2.4in (60mm)

2.8in (70mm)

7/8”-9UNC

(Ø 22.2mm)

1”-8UNC

(Ø 25.4mm)

1-1/4”-7UNC (Ø 31.75mm)

1-1/2”-6UNC

(Ø 38.1mm)

1-3/4”-5UNC

(Ø 44.5mm

7.9in (200mm)

9in (230mm)

9.8in (250mm)

1.6in (41mm)

1.4in (36mm)

2.3in (57.5mm)

Table 1

* The trolley can be extended for greater “E” widths than what are shown in the chart. See the optional extension kits listed in the appropriate parts list for each machine.

4.1 MT trolley with TS series hoist – dimensions

MT Trolleys are designed to pair with the TS hoists.

Figure 4-2

TS050

TS100

TS200

TS300

TS500

Trolley

model

no.

MT050

MT100

MT200

MT300

MT500

stock no.

140183

140185

140187

140189

140190

15-3/16" (385mm)

15-9/16" (395mm)

17-1/2" (445mm)

4-15/16" (126mm)

6-1/4" (159mm)

7-5/16" (185mm)

12-13/16" (325mm)

14-3/16" (360mm)

15-3/4" (400mm)

7-1/16" (180mm)

7-5/16" (185mm)

7-11/16" (195mm)

2-15/16" ~ 4-15/16"

3-15/16" ~ 5-7/8"

4-15/16" ~ 6-7/8"

(75~125mm)

(100~150mm)

(125~175mm)

19-11/16" (500mm)

21-1/16" (535mm)

38-3/16" (970mm)

-----

39-3/8" (1000mm)

41-5/16" (1050mm)

Table 2

* The trolley can be extended for greater “E” widths than what are shown in the chart. See the optional extension kits which are listed in the appropriate parts list for each machine.

Read and understand the entire contents of this manual before attempting assembly or operation. Failure to comply may cause serious injury.

5.0 Unpacking

Open shipping container and check for shipping damage. Report any damage immediately to your distributor and shipping agent. Do not discard any shipping material until the Trolley is assembled and running properly.

Compare the contents of your container with the following parts list to make sure all parts are intact. Missing parts, if any, should be reported to your distributor. Read the instruction manual thoroughly for assembly, maintenance and safety instructions.

5.1 Contents of Shipping Container

1 Electric Trolley 1 Owner's manual 1 Product registration card 1 Test report

6.0 Installation & Assembly

The MT Series trolley is designed to run on standard “I” beams, wide-flanged “H” beams, or curved track with a minimum radius shown in the chart in sect. 5.0.

6.1 Mount trolley to beam

The trolley is heavy; use an

assistant or a lifting device to help stabilize it while you assemble it to the beam.

Note: Mount the trolley to the beam first before mounting a hoist to it.

1. Measure the width of the beam flange on which the trolley will operate. This is important as beam flanges may vary in width. See sect.

4.1 for the beam width range for your specific trolley.

2. Determine the arrangement of spacer washers between the trolley side frames based upon the measurement. Spacers must be moved in sets of two to maintain centerline of trolley.

Distance between trackwheel flanges should be 1/8- to 2-inches (3 to 5mm) greater than the beam flange width for straight runway beams, and 3/16- to 9/32-inches (5 to 7mm) for sharply curved beams.

3. Loosely assemble side frames, position tubes, spacer washers and nuts on the stay bolts. See Figure 6-1.

4. Install the trolley on the beam by sliding one side plate out enough to allow trackwheels to clear the beam.

5. Make sure the trackwheels are riding on the beam, and draw the side plates together. Tighten the nuts securely.

Note: If the trolley sits at a slight angle, this is normal. The weight of the hoist or load will level it to horizontal.

Figure 6-1

End stops must be installed at the exposed ends of a beam. These will be contacted by the rubber bumpers on the trolley to help cushion impact.

Open-end beams must have

the proper end stops installed to prevent the trolley from running off the beam. Failure to comply may cause serious injury and/or property damage.

6.2 Mount hoist to trolley

This trolley has been designed to accommodate the JET TS-Series Hoist. They can be connected so that one pendant cord and power cord will operate both trolley and hoist. Make sure the hoist has been set to the same voltage specifications as the trolley, and matches the size and load capacity of the hoist that will be connected to it.

1. The trolley has been assembled to the beam. However, the trolley should also be stabilized by an additional support system, such as chains, until the hoist mounting system is completed. See Figure 6-2.

Figure 6-2

2. Align tabs on top of hoist (Figures 6-3,6-4) to holes on underside of trolley. Secure with the existing pins, washers and hex nuts.

The hoist should be oriented so that the electrical strain reliefs on hoist and trolley are at the same end. Make sure hoist is securely mounted.

Figure 6-3

Figure 6-4

3. Bring the trolley power cable into the hoist through the cable gland. See Figure 6-5. Connect the four wires from the trolley cable to the KM1 contactor, as described in Figure 6-5.

Figure 6-5

4. Locate the grey and orange wires in the hoist. See Figure 6-6. The grey wire will control the forward movement of the trolley. The orange wire will control the reverse movement of the trolley.

5. Bring the trolley control cable through the second gland on the same side of the hoist, and connect it as follows.

Connect #1 Red wire to port A2 of the KM3 contactor.

Connect #2 White wire to the grey wire. Connect #3 Black wire to the orange wire. Connect E grounding wire to the ground plate. Note: if you connect the #2 White wire to the

orange wire (instead of the grey), the motor movement will be reversed.

Figure 6-6

6. Trolley and hoist are now connected. Remove the chain support from atop the trolley.

7. Proceed to sect. 7.0 for electrical connections.

7.0 Electrical connections

Electrical connections must be

made by a qualified electrician in compliance with all relevant codes. This machine must be properly grounded to help prevent electrical shock and possible fatal injury.

7.1 GROUNDING INSTRUCTIONS

In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock.

The trolley power cord must be correctly wired into the hoist, and the hoist power cord must be fitted with an appropriate UL/CSA listed plug, or can be “hard-wired” directly to a control panel. If hardwired, make sure a disconnect is available for the operator.

If a plug is installed, it must have an equipmentgrounding conductor and a grounding prong. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances. Do not modify the plug.

Improper connection of the equipment-grounding conductor can result in a risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment-grounding connector. If repair or replacement of the electric cord or plug is necessary, do not connect the equipmentgrounding conductor to a live terminal.

Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded.

Repair or replace damaged or worn cord immediately.

7.2 Extension Cords

If an extension cord is necessary, make sure the cord rating is suitable for the amperage listed on

the trolley’s motor plate. An undersize cord will

cause a drop in line voltage resulting in loss of power and overheating.

The chart in Table 3 shows the correct size cord to use based on cord length and motor plate amp rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

Recommended Gauges (AWG) of Extension Cords

Amps

Extension Cord Length *

feet

100 feet

150 feet

200 feet

< 5

5 to 8

8 to 12

12 to 15

15 to 20

21 to 30

*based on limiting the line voltage drop to 5V at 150% of the rated amperes.

NR: Not Recommended.

Table 3

7.3 Inspecting trolley motion

1. Before closing the circuit breaker and testing the trolley, check that wiring has been complete. If the trolley cannot be observed when the circuit breaker is closed, station an observer within sight of the trolley to report any movement when power is applied to the trolley. Be prepared to disconnect power if trolley motor starts when the power is applied. The trolley must remain motionless when power is applied. Find and correct any problems before continuing.

2. After all assembly and wiring is complete, operate trolley forward and back a short distance, then do likewise for the entire length of the beam. Confirm that all adjustments and operations are satisfactory.

8.0 User-maintenance

The trolley should be inspected on a routine basis, with particular attention to these:

 Tightness of all fasteners  Cables/leads for broken wires, corroded or

loose terminals, damaged insulation.

 Contactors and pendant controls for loose or

corroded terminals.

 Trackwheels for worn tread, flanges, or

bearings.

 Trackwheel gears and pinion for wear.

8.1 Brake inspection

The motor brake should be inspected periodically for wear of brake lining and disc. If either is worn so that the brake cannot perform efficiently, they should be replaced.

The gap between brake lining and disc can be adjusted by the bolt shown in Figure 8-1.

Loosen nut and fully tighten adjustment bolt. Then loosen the bolt two rotations. Retighten nut against motor housing to secure setting.

Figure 8-1

8.2 Lubrication

Monthly lubricate the track wheel gear and pinion with grease.

Change out the motor gearbox grease after 100 hours of operation, then every 6 months or 2500 hours of normal service. Use a No. 3 grease, such as Mobil Cup Grease 3 or equivalent.

8.3 Additional servicing

Any other servicing should be performed by an authorized service representative.

9.0 Pendant controllers for Trolley with TS Hoist

Part no.

Description

104196

WIRED PENDANT, 4-BTN, TS+MT, for 10FT Hoist

104197

WIRED PENDANT, 4-BTN, TS+MT, for 15FT Hoist

104198

WIRED PENDANT, 4-BTN, TS+MT, for 20FT Hoist

Table 4

+ 22 hidden pages

JET MT050, MT100, MT200, MT300, MT500 Operating Instructions and Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

MT Series 2-speed Electric Trolley

1.0 IMPORTANT SAFETY INSTRUCTIONS

2.0 Table of Contents

3.0 Introduction

4.0 MT Trolley Specifications

4.1 MT trolley with TS series hoist – dimensions

5.0 Unpacking

6.0 Installation & Assembly

6.1 Mount trolley to beam

6.2 Mount hoist to trolley

7.0 Electrical connections

7.1 GROUNDING INSTRUCTIONS

7.2 Extension Cords

7.3 Inspecting trolley motion

8.0 User-maintenance

9.0 Pendant controllers for Trolley with TS Hoist