Quantum QIMT Series Instruction Manual

Form MHD56125
INTERNATIONAL
PARTS, INSTALLATION AND MAINTENANCE MANUAL
for
QUANTUM ‘QIMT’ Series
Electric Trolleys
(Dwg. MHP0859)
Form MHD56125
Edition1
September 1998
71335962
©
1998 Ingersoll-Rand Company
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important safety, installation, and maintenance information.
Make this manual available to all persons responsible for the operation,
installation and maintenance of these products.
WARNING
Do not use this trolley for lifting, supporting, or transporting people or lifting or
supporting loads over people.
Always operate, inspect and maintain this trolley in accordance with American National
Standards Institute Safety Code (ASME B30.16) and any other applicable safety codes
and regulations.
Refer all communications to the nearest Ingersoll-Rand Material Handling Office or
Distributor.
Unlessotherwise noted, tons in this
manual are metric tons (2,200 lb)

TABLE OF CONTENTS
Safety Information
Danger, Warning, Caution and Notice............................................................................................................................................................ 3
Safety Summary ..............................................................................................................................................................................................3
Safe Operating Instructions .........................................................................................................................................................................4
Warning Labels .............................................................................................................................................................................................4
Specifications .................................................................................................................................................................................................5
Description of Trolley Operation ....................................................................................................................................................................5
Model Code Explanation ................................................................................................................................................................................5
Performance.....................................................................................................................................................................................................6
Installation
Trolley and Hoist Installation .........................................................................................................................................................................8
Power Connection ...........................................................................................................................................................................................9
Trolley Brake Kit Installation .......................................................................................................................................................................10
Wiring Diagrams...................................................................................................................................................................................12 - 18
Operation ..................................................................................................................................................................................................... 19
Inspection
Records and Reports ..................................................................................................................................................................................... 20
Frequent Inspection .......................................................................................................................................................................................20
Periodic Inspection ........................................................................................................................................................................................20
Inspection and Maintenance Report ..............................................................................................................................................................21
Lubrication ..................................................................................................................................................................................................22
Troubleshooting ..........................................................................................................................................................................................23
Maintenance
Maintenance Intervals ................................................................................................................................................................................... 24
General Maintenance Instructions ................................................................................................................................................................24
Brake Adjustment Procedure.........................................................................................................................................................................25
Disassembly and Assembly ....................................................................................................................................................................25 - 28
Cleaning, Inspection and Repair....................................................................................................................................................................26
Parts Ordering Information .......................................................................................................................................................................29
Trolley Assembly Parts Drawing ..................................................................................................................................................................30
Trolley Assembly Parts List ...................................................................................................................................................................31 - 33
Trolley Brake Assembly Parts Drawing (Optional Feature) ........................................................................................................................ 34
Trolley Brake Assembly Parts List (Optional Feature) ............................................................................................................................... 35
Control Pendant Assembly Parts Drawing ................................................................................................................................................... 36
Control Pendant Assembly Parts List ............................................................................................................................................................37
Label Assembly Drawing And Parts List ..................................................................................................................................................... 38
Special Tools And Accessories .....................................................................................................................................................................38
Warranty ......................................................................................................................................................................................................39

MHD56125 - Edition 1 3
SAFETY INFORMATION
This manual provides important information for all personnel
involved with the safe installation, operation and proper
maintenance of this product. Even if you feel you are familiar
with this or similar equipment, you should read this manual
before operating the trolley.
Danger, Warning, Caution and Notice
Throughout this manual there are steps and procedures which, if
not followed, may result in an injury. The following signal words
are used to identify the level of potential hazard.
Danger is used to indicate the presence
of a hazard which will cause severe
injury, death, or substantial property
damage if the warning is ignored.
Warning is used to indicate the
presence of a hazard which can cause
severe injury, death, or substantial
property damage if the warning is
ignored.
Caution is used to indicate the presence
of a hazard which will or can cause
injury or property damage if the
warning is ignored.
Notice is used to notify people of
installation, operation, or maintenance
information which is important but not
hazard-related.
DANGER
WWAARRNNIINNGG
NNOOTTIICCEE
Safety Summary
WARNING
• Do not use this trolley or attached equipment for lifting,
supporting, or transporting people or lifting or supporting
loads over people.
• The supporting structures and load-attaching devices used
in conjunction with these trolleys must provide a liberal
safety factor. This is the customer’s responsibility. If in doubt,
consult a registered structural engineer.
• Electrical installation should be performed by licensed
electricians in accordance with the latest edition of the
National Electrical Code(ANSI/NFPA 70) and any applicable
local, state and national electrical codes and ordinances.
NOTICE
• Lifting equipment is subject to different regulations in each
country. These regulations may not be specified in this
manual.
The National Safety Council, Accident Prevention Manual for
Industrial Operations, Eighth Edition and other recognized safety
sources make a common point: Employees who work near
suspended loads or assist in hooking on or arranging a load
should be instructed to keep out from under the load. From a
safety standpoint, one factor is paramount: conduct all lifting
operations in such a manner that if there were an equipment
failure, no personnel would be injured. This means keep out from
under a raised load and keep out of the line of force of any load.
Ingersoll-Rand Material Handling hoists and trolleys are
manufactured in accordance with the latest ASME B30.16
standards.
The Occupational Safety and Health Act of 1970 generally places
the burden of compliance with the user, not the manufacturer.
Many OSHA requirements are not concerned or connected with
the manufactured product but are, rather, associated with the final
installation. It is the owner’s and user’s responsibility to
determine the suitability of a product for any particular use. It is
recommended that all applicable industry, trade association,
federal, state and local regulations be checked. Read all operating
instructions and warnings before operation.
Rigging: It is the responsibility of the operator to exercise
caution, use common sense and be familiar with proper rigging
techniques. Refer to ASME B30.9 for rigging information,
American National Standards Institute, 1430 Broadway, New
York, NY 10018.
This manual has been produced by Ingersoll-Rand to provide
dealers, mechanics, operators and company personnel with the
information required to install, operate, maintain and repair the
products described herein.
It is extremely important that mechanics and operators be
familiar with the servicing procedures of these products, or like
or similar products, and are physically capable of conducting the
procedures. These personnel shall have a general working
knowledge that includes:
1. Proper and safe use and application of mechanic’s common
hand tools as well as special Ingersoll-Rand or
recommended tools.
2. Safety procedures, precautions and work habits established
by accepted industry standards.
Ingersoll-Rand cannot know of, or provide all the procedures by
which product operations or repairs may be conducted and the
hazards and/or results of each method. If operation or
maintenance procedures not specifically recommended by the
manufacturer are conducted, it must be ensured that product
safety is not endangered by the actions taken. If unsure of an
operation or maintenance procedure or step, personnel should
place the product in a safe condition and contact supervisors and/
or the factory for technical assistance.

4MHD56125 - Edition 1
SAFE OPERATING INSTRUCTIONS
The following warnings and operating instructions are intended
to avoid unsafe operating practices which might lead to injury or
property damage.
Ingersoll-Rand recognizes that most companies who use trolleys
have a safety program in force at their facility. In the event that
some conflict exists between a rule set forth in this publication
and a similar rule already set by an individual company, the more
stringent of the two should take precedence.
Safe Operating Instructions are provided to make an operator
aware of unsafe practices to avoid and are not necessarily limited
to the following list. Refer to specific sections in the manual for
additional safety information.
1. Only allow personnel trained in safety and operation of this
trolley to operate this product.
2. Only operate a trolley if you are physically fit to do so.
3. When a “DO NOT OPERATE” sign is placed on the
trolley, or controls, do not operate the trolley until the sign
has been removed by designated personnel.
4. Check that the hoist is securely attached to the trolley before
using.
5. Before each shift, check the trolley for wear and damage.
Never use a trolley that inspection indicates is worn or
damaged.
6. Never lift a load greater than the rated capacity of the
trolley. Refer to capacity labels attached to trolley.
7. Only operate a trolley when the hoist load chain is centered
over the hook. Do not “side pull” or “yard”.
8. Pay attention to the load at all times when operating the
trolley.
9. Make sure everyone is clear of the load path. Do not lift a
load over people.
10. Never use the trolley for lifting or lowering people, and
never allow anyone to stand on a suspended load.
11. Do not swing a suspended load.
12. Do not leave load suspended when trolley is not in use.
13. Never weld or cut a load suspended by the trolley.
14. Do not operate trolley if excessive noise, jamming,
overloading, or binding occurs.
15. Shut off electrical supply before performing any
maintenance.
16. Avoid collision or bumping of trolley.
17. After use, or when in a non-operational mode, the trolley
should be secured against unauthorized and unwarranted
use.
WARNING LABELS
Each trolley is shipped from the factory with the warning labels shown. If the labels are not attached to your trolley, order new labels and
install them. Refer to the parts list for the part number. Labels may be shown smaller than actual size.
WARNING
Handling people with
this equipment.
Can cause severe
injury or death.
Do not use for lifting,
lowering or transporting
people. 04306445

MHD56125 - Edition 1 5
SPECIFICATIONS
Description of Trolley Operation
Quantum ‘QIMT’ series electric trolleys are available in
capacities ranging from 1 to 5 metric tons (2200 to 11,000 lb) and
are designed to support hoists. Quantum ‘QIMT’ series electric
trolleys are manufactured in accordance with the latest technical
developments along with known technical safety regulations and
specifications, and are tested for safety by the manufacturer. All 3
phase Quantum trolleys carry an H4 class trolley duty service
rating.
Trolleys are fitted with a 42 volt low voltage control system
which is electrically interlocked. An optional 110 volt control
system is available.
Quantum ‘QIMT’ electric trolleys are driven by cylindrical,
squirrel cage motors. The two-stage enclosed spur gearing is
designed to provide smooth, controlled travel. The gears are
hardened, self-adjusting and continuously lubricated. The helical
design of the gearing ensures running noise is kept to a
minimum. The output from the gearing section powers the trolley
wheels.
An optional multi disc brake can be added to the trolley. The
brake magnet is opened and closed by means of the disc system’s
torque arm. In a deenergized mode, the compression spring
produces the braking torque, restricting trolley movement.
Quantum ‘QIMT’ series electric trolleys are equipped with a
control pendant for the following functions:
Up-Down / Single or dual speed (hoist operation)
Emergency stop (red button)
Left / right travel
Trolley Motor Rating:
Normal speed:
60% / 240 switchings per hour
Slow speed:
20% / 240 switchings per hour
Model Code Explanation
Example: QIMT50NS15A3B QIMT 50 NS 15 A 3 B
Series
Frame Size
Speed
Pendant Control Length
Flange Width
Voltage
Options
Series Frame Size
QUANTUM Motorized Trolley (QIMT) 50 = 1 ton (1,000 kg max) for QI25 and QI50 Hoists
150 = 2 ton (2,000 kg max) for QI100 Hoists
300 = 5 ton (5,000 kg max) for QI200, QI300 and QI500 Hoists
Speed Pendant Control Length (Length in feet (ft.))
NS = Normal Speed 48 fpm (14.6 mpm)
ND = Normal/Dual Speed 48/16 fpm (14.6/4.9 mpm)
HS = High Speed 96 fpm (29.3 mpm)
HD = High/Dual Speed 96/24 fpm (29.3/7.3 mpm)
xx = Specify
Flange Width Voltage
A = Refer to Trolley Beam Installation Table
B = Refer to Trolley Beam Installation Table
C = Refer to Trolley Beam Installation Table
D = Refer to Trolley Beam Installation Table
3 = 230/3/60*
4 = 460/3/60*
5 = 575/3/60
6 = 380/3/50
Options
B = Trolley Brake
K = 110 volt Control
F = F “xx”, Specify power cord length in feet (Std. is 3 ft.)
Notes:
* = Single speed 230/460 volt motors are connectable for either voltage. Speed at 380v is 20% less than listed. Amps rated at 60 Hz
except 380v is at 50 Hz. For special applications please consult the factory.

6MHD56125 - Edition 1
Table 1 Trolley Performance
Table 2 Trolley Weight
Trolley
Model
Maximum
Hoist
Capacity
(Model)
Travel Speed Trolley Motor Trolley Amperage (3 Phase / 60 Hz)
fpm mpm HP kW 230/
460V 230V 380V 460V 575V
QIMT50 (NS)
1000 kg
(QI25/
QI50)
48 14.6 0.19 0.145 0.86/
0.43 --- 0.35
QIMT50 (ND) 48/
16 15.6/
4.9 0.15/ 0.05 0.11/ 0.04 --- 0.64/ 0.50 0.32/ 0.25 0.26/ 0.20
QIMT50 (HS) 96 29.3 0.29 0.22 1.00/
0.5 --- 0.40
QIMT50 (HD) 96/
24 29.3/
7.3 0.29/ 0.07 0.22/ 0.055 --- 0.64/ 0.50 0.35/ 0.25 0.28/ 0.20
QIMT150 (NS)
2,000 kg
(QI100)
48 14.6 0.19 0.145 0.86/
0.43 --- 0.35
QIMT150 (ND) 48/
16 15.6/
4.9 0.15/ 0.05 0.11/ 0.04 --- 0.64/ 0.50 0.32/ 0.25 0.26/ 0.20
QIMT150 (HS) 96 29.3 0.29 0.22 1.00/
0.50 --- 0.40
QIMT150 (HD) 96/
48 29.3/
7.3 0.29/ 0.07 0.22/ 0.055 --- 0.64/ 0.50 0.35/ 0.25 0.28/ 0.20
QIMT300 (NS)
5000 kg
(QI200/
QI300/
QI500)
48 14.6 0.4 0.30 1.20/
0.60 --- 0.48
QIMT300 (ND) 48/
16 15.6/
4.9 0.4/ 0.09 0.30/ 0.072 -- 1.20/ 1.10 0.60/ 0.55 0.48/ 0.44
QIMT300 (HS) 96 29.3 0.48 0.36 1.40/
0.70 --- 0.56
QIMT300 (HD) 96/
24 29.3/
7.3 0.48/ 0.12 0.36/ 0.09 --- 1.40/ 1.20 0.70/ 0.60 0.56/ 0.48
Trolley
Model
Weight
without
Brake with Brake
lbs kg lbs kg
QIMT50 (NS) 55 25.0 61 27.5
QIMT50 (ND) 57 26.0 71 32
QIMT50 (HS) 55 25.0 61 27.5
QIMT50 (HD) 57 26.0 71 32
QIMT150 (NS) 67 30.5 71 32
QIMT150 (ND) 69 31.5 73 33
QIMT150 (HS) 67 30.5 71 32
QIMT150 (HD) 69 31.5 73 33
QIMT300 (NS) 108 49 112 51
QIMT300 (ND) 101 46 105 48
QIMT300 (HS) 108 49 112 51
QIMT300 (HD) 110 50 114 52

MHD56125 - Edition 1 7
Table 3 Trolley Beam Installation
* Standard
** Refer to drawing MHP0812
Hanger Shaft Dimensions
(Dwg. MHP0812)
Trolley
Model Hoist
Suspension
Type
Beam
Flange
Type
Beam Flange
Width Minimum BeamCurve
Radius
Hanger Shaft Dimensions**
a b (dia) f (dia) l
in mm ft minmm in mm in mm in mm
QIMT50 Hook or
Eyebolt A* 2.0 - 3.9 50 - 99
3.94 1.20
1.22 31
0.63 16
1.10 28 7.20 183
B 4.0 - 5.9 100 - 149 3.19 81 9.17 233
C 6.0 - 7.8 150 - 199 5.16 131 1.18 30 11.14 283
D 7.9 - 9.4 200 - 240 7.13 181 12.52 318
QIMT150 Eyebolt A* 3.0 - 5.5 76 - 139
4.92 1.50
1.57 40
0.94 24
1.38 35 9.06 230
B 5.6 - 7.8 140 - 199 4.17 106 1.57 40 11.42 290
C 7.9 - 10.2 200 - 259 6.54 166 1.65 42 13.78 350
D 10.3 - 12.6 260 - 320 8.90 226 1.77 45 16.14 410
QIMT300 Eyebolt
Hangar
Bracket
A 2.2 - 4.7 56 - 119
5.91 1.80
1.57 40 1.38 35 9.06 230
B* 4.8 - 7.0 120 - 179 4.17 106 1.57 40 11.42 290
C 7.1 - 9.4 180 - 239 6.54 166 1.65 42 13.78 350
D 9.5 - 11.8 240 - 300 8.90 226 1.77 45 16.14 410

8MHD56125 - Edition 1
INSTALLATION
Prior to installing the trolley, carefully inspect components for
possible shipping damage.
Trolleys are supplied fully lubricated from the factory.
• Owners and users are advised to examine specific, local or
other regulations, including American National Standards
Institute and/or OSHA Regulations which may apply to a
particular type of use of this product before installing or
putting trolley to use.
• A falling load can cause injury or death. Before installing
hoist and/or trolley, read “SAFETY INFORMATION”.
Trolley and Hoist Installation
WARNING
• The hoist or hoist/trolley combination selected can weigh as
much as 311 lbs. (141 kg). If parts of the trolley or hoist are
dropped, they could cause injury or damage property.
Adequately support the hoist and trolley when lifting into
place on the beam.
• To avoid an unbalanced load which may damage the trolley,
the hoist must be centered under the trolley.
• Verify trolley carrying capacity. Refer to trolley
information in “SPECIFICATIONS” section. Trolley must
provide an adequate safety factor to handle the rated load
plus the weight of the hoist and attachments.
Installing Over the End of the Beam
Pre-adjust trolley width for the beam flange measurement. Refer
to “Installing the Trolley from Underneath the Beam”.Remove
the rail stop and slide trolley on end of the beam. Reinstall rail
stop. If this procedure cannot be used due to insufficient space or
fixed limit stops, the trolley must be installed from underneath
the beam.
Installing the Trolley from Underneath the Beam
For manual trolleys refer to PT Series Parts, Operation and
Maintenance manual form number MHD56102 for complete
trolley installation information.
For powered trolleys, the hanger shaft is to be mounted from the
inside to the outside. Refer to Dwg. MHP0794 on page 9. When
doing so, observe that the number of spacers (63) is equally
distributed on both sides. For hanger shafts with narrow flange
widths, two spacers (65) are to be used.
NOTICE
• A clearance of approximately 0.039 in (1 mm) should be left
between the wheel flanges and the beam flange. At least one
spacer (63) must always be placed between the nut (48) and
the side plate. The two locknuts (47) must be firmly
tightened.
(Dwg. MHP0824)
Model
QIMT50 QIMT150 QIMT300
500 kg 1500 kg 5000 kg
ft lb Nm ft lb Nm ft lb Nm
66-77 90-105 200-295 270-400 247-284 335-385

MHD56125 - Edition 1 9
• Total clearance between wheel flanges (53 and 54) and
beam flange must not exceed 0.078 in. (2 mm). At least one
spacer (63) must always be placed between the side plate and
the nut (48). Torque nut (48) in accordance with Table 4.
Install locknut (47) hand tight, then tighten with a wrench an
additional 1/4 or 1/2 of a rotation.
• Replace locknut (47) with a new one after each use. Do not
reuse locknuts.
The counterweight (62) is bolted to the side plate which has the
plain wheels (54). The gear assembly (102) with the relay box
(18) is attached to the side plate which has the geared wheels
(53). A brake assembly (101) can be retrofitted to all motorized
trolleys.
1. The safe working load (SWL) of the trolley should be
checked first. Refer to trolley capacity information in
“SPECIFICATIONS” section.
2. Spacers (63) are to be placed on the inside of the two side
plates, to suit the beam flange width. There should be an
equal number of spacers (63) on each side of the hanger
shaft. Remaining spacers should be equally placed on the
hanger shaft on the outside of side plates.
3. Bolt the counterweight (62) to the outside of the side plate.
4. The voltage should be checked.
5. For the electrical connections: refer to wiring diagrams.
6. Verify beam/rail stops are securely installed.
Electrical Equipment
WARNING
• Electrical installation should be performed by licensed
electricians in accordance with the latest edition of the
National Electrical Code (ANAI/NFPA 70) and any
applicable local, state and national electrical codes and
ordinances.
• Never install two wires into the same terminal port.
For QIMT50 and QIMT150 trolleys, the supply cable should be
AWG-14 and for QIMT300 trolleys AWG-12. The electrical
supply must have branch circuit protection in accordance with
National Electrical Codes. The supply cable wires must be
connected to terminals L1, L2, L3 and PE yellow/green (ground-
earth) in the trolley control assembly.
The control voltage is 42 volts (optional 110 volts) which is
produced by a built-in transformer. The brake assembly, if
equipped, is connected in parallel with the motor (refer to wiring
drawings).
Power Connection
Power Supply conductors must be sized in accordance with NEC
310-15(b) specifications.
Pendant Connection
For four button control pendants, feed pendant cable through
wire connector and into the relay box. Separate and connect
wires 1, 2, 3, 4, 41, 42, 43 and 50 (8 wires) to similarly marked
ports on the lower side of the terminal strip.
• Before connection of the electric chain hoist and/or trolley,
check to ensure that the voltage specified on the nameplate
matches the supply voltage.
After installation, the trolley should be connected by a licensed
electrician who is knowledgeable with NEC article 430 and local
regulations. Ensure that the voltage and frequency of the
electrical supply correspond with the data stamped on the trolley
nameplate before connecting the trolley.
In addition, the following points are of primary importance when
installing and connecting the trolley:
Restricted Ventilation will cause a trolley motor to operate at a
higher than desired temperature. Dirt, dust, chemicals, snow, oil,
etc. all can cause a problem. Avoid installing trolleys where air
flow will be restricted or excessive ambient temperatures may be
encountered.
Voltage Unbalance can cause excess temperature rise resulting
in premature trolley motor failure. Periodically check voltage.
Electrical Connections, if not tight and secure, will be a
continuous cause of trouble. During installation the electrician
must make sure that all electrical connections including the
ground connection are secure. Make sure all junction boxes and
switch enclosures are adequately sealed and protected for the
environmental conditions to be encountered.
To connect the trolley to the power supply, remove the electrical
cover plate which is located nearest the power supply and
pendant cable ports. Do not remove gear end cover. Connect the
power supply cable.
(Dwg. MHP0794)

10 MHD56125 - Edition 1
The electric trolley or chain hoist trolley combination must be
connected in accordance with supplied wiring diagrams.
Remove approximately 3/8 in. (9 mm) of the electrical power
cable protective casing to expose wires.
Open the spring clamp with a narrow blade (1/8 in. (3.5 mm)
wide) screwdriver,as shown in Dwg. MHP0795 below and install
power cable end. Cable (leads) can be identified by color, or in
the case of pendant cables, by numbers taped to each cable.
Terminals are identified by letters or labels on the terminal
blocks. Manufacturer-supplied cables have bare wire ends.
(Dwg. MHP0795)
Ground (Earth) Connections
DANGER
•
• The ground (earth), green or green/yellow wire, must not
carry any power. With trolley only or trolley/hoist
combinations, the power supply is connected to the control
assembly of the trolley drive motor.
NOTICE
• The ground (earth) connection must be wired to the green/
yellow ground (earth) connection terminal. Ground (earth)
wire of the terminal power supply is connected to the yellow/
green wire (PE).
Brake Assembly (optional feature)
When adding the optional brake assembly to the trolley, the brake
drive must be installed to the motor output shaft. This procedure
requires the removal of the brake arm and discs, then reinstalling.
Connect brake wiring to terminal block in control assembly.
Refer to wiring diagrams.
The trolley brake assembly locks the main shaft of the trolley
drive motor through a disc brake assembly. This assembly is a
spring set design which locks the rotor shaft when power is not
applied to the motor. When power is applied, the springs are
compressed which allows the motor to rotate and move the load.
WARNING
• If power is disrupted to the trolley with a brake, the load
will not be able to be moved freely.
Trolley Brake Kit Installation
If the trolley brake kit is supplied separately or ordered after the
trolley has been installed follow the steps provided for
installation.
WARNING
• Never perform maintenance on a hoist or trolley while it is
supporting a load.
• Ensure that power is turned off and unit is disconnected.
Refer to Dwg. MHP1075 on page 34.
1. Remove capscrews (70 and 71) and lockwashers (16).
Carefully remove brake cover (72). There is a bag of
installation parts inside, remove bag.
2. Remove retainer (84). Push down on brake lever (82), while
pulling brake pin (83) out of lever block (80). Carefully
release pressure on brake lever (82).
3. Remove locknut (97, not available separately, part of 85) on
solenoid (85) end of brake lever (82). Remove brake lever
(82), spring (87), spring guide (88) and spring (98, not
available separately, part of 85).
4. Remove cup disc (74), brake washer (75) and brake discs
(76 and 77).
5. Remove retainer ring (29) from rotor assembly (31).
Remove four capscrews (26) and lockwashers (34) from
motor cover (27). Using a screwdriver to hold rotor
assembly (31) in position, pull motor cover off. Rotor
assembly (31) should stay in stator (28).
6. Mount brake housing (90) to stator (28) using three
capscrews (26) and lockwashers (16). The bottom capscrew
(26) and lockwasher (16) is not used due to no access.
7. Place key (93) in rotor assembly (31) and slide brake hub
(92) on to rotor shaft (31). Install retainer ring (29).
8. Insert brake discs (starting with 77 then 76, repeat until all
discs are inserted), brake washer (75) and cup disc (74).
9. Place spring (98, not available separately, part of 85) on
screw section of solenoid (85). Place spring (87) and spring
guide (88) into slot in brake housing (90).
10. Place brake lever (82) into lever block (80) and press down.
While pressing brake lever (82), slide pin (83) through lever
block (80) and brake lever (82) until pin protrudes on
opposite side. Press on retainer (84). Thread locknut (97, not
available separately, part of 85) onto threaded shaft of
solenoid (85) until 2 to 3 threads are exposed beyond
locknut (97).

MHD56125 - Edition 1 11
11. Ensure wires are connected correctly (in brake housing) for
your operation:
a. Brown wire in control cable to black wire in solenoid
(85).
b. Blue wire in control cable to brown wire in solenoid
(85) for 460v operation, red wire for 230v operation.
c. Yellow with green stripe in control cable to housing
(90). This is the ground (earth). Maintain a little slack
in wires and route around springs.
12. Check to ensure that wires are not interfering with spring
(87).
13. Insert capscrews (71) with lockwashers (16) through bottom
holes in brake cover (72). Position gasket (73) over
capscrews and place this assembly onto brake housing (90).
Make sure that control cable wires are not pinched by
capscrews. Tighten a couple of turns.
14. Insert capscrews (70) with lockwashers (16) through top
holes in cover (72), screw into housing (90) and tighten.
15. Tighten capscrews (71).
16. Loosen one screw (2) in lower right corner of relay box
cover (1), remove the other three screws (2). This should
allow cover (1) to rotate out of the way.
17. Remove smaller access plug (23) from bottom of relay box.
Separate cable connector (22) on control cable and push
control wire up through access hole.
18. Remove four screws (4) from control assembly (5) and pull
out slightly. Route control cable wires over and between
contactors and out through a hole in the control assembly
(5).
19. Connect wires to terminal strip in the following locations:
a. Brown wire in control cable to terminal 49.
b. Blue wire in control cable to terminal U1.
c. Yellow with green stripe in control cable to terminal
PE.
20. Maintain a little slack and route wires around terminal strip.
Attach cable connector (22) into relay box and tighten.
Insert four screws (4) into control assembly (5) and tighten.
21. Replace relay box cover (1) and tighten screws (2).
Trolley Brake Test
1. Turn on power to trolley and observe.
2. By hand, grab load hook and apply a side load to trolley.
Trolley should not move.
3. Using control pendant, move trolley in both directions (no
load on hook) for a short distance. Observe for erratic
movement and/or unusual noise.
4. Lift a load 5 - 10 inches (127 - 254 mm). Using trolley,
move the load a short distance in both directions. Trolley
should stop when pendant button is released.

12 MHD56125 - Edition 1
WIRING DIAGRAM
Single Speed, Three Phase Trolley with Emergency Stop
(Dwg. MHP0821)

MHD56125 - Edition 1 13
WIRING DIAGRAM
Dual Speed, Three Phase Trolley with Emergency Stop
(Dwg. MHP0822)

14 MHD56125 - Edition 1
WIRING DIAGRAM
Single Speed, Three Phase Trolley with Emergency Stop and Single Speed, Three Phase Hoist
(Dwg. MHP1111)

MHD56125 - Edition 1 15
WIRING DIAGRAM
Single Speed, Three Phase Trolley with Emergency Stopand Dual Speed, Three Phase Hoist
(Dwg. MHP1112)

16 MHD56125 - Edition 1
WIRING DIAGRAM
Dual Speed, Three Phase Trolley with Emergency Stop and Single Speed, Three Phase Hoist
(Dwg. MHP1113)

MHD56125 - Edition 1 17
WIRING DIAGRAM
Dual Speed, Three Phase Trolley with Emergency Stop and Dual Speed, Three Phase Hoist
(Dwg. MHP1114)

18 MHD56125 - Edition 1
WIRING DIAGRAM
Trolley Control Assembly Wiring for Single Speed Trolley with Dual Speed Hoist
(Dwg. MHP0970)
B6-30-01
K45
E12.94.4
K41
VB6-30.01
K42
Red Transformer 230V
Black Transformer
Brown Transformer 460V
FUSE
Orange Transformer Orange Transformer
X40
PE
Trolley Brake Trolley Motor
Right
Left
Trolley Controls
UP
DOWN
High Speed
Hoist Controls
Pendant
2
T1
4
T2
6
T3
22
NC
A
2
1
L1
3
L2
5
L3
21
NC
A
1
A 1
21 NC 1 U 3 L2 5 L3 1 L1 3 L2 5 L3 21 NC
A 1
2 T1 4 T2 6 T3 22 NC
A 2
A 2
22 NC 2 T1 4 T2 6 T3
L
E
1 L
E
2 L
E
3 L
A
1 L
A
2 L
A
3 U
U
1
VW49 47 50 41 42 43 12 48 3 4
Common
E. Stop Relay
High Speed
Common
Common
UP
DOWN
Hoist Motor

MHD56125 - Edition 1 19
OPERATION
The four most important aspects of trolley operation are:
1. Follow all safety instructions when operating trolley.
2. Allow only people trained in safety and operation on this
product to operate trolley.
3. Subject each trolley to a regular inspection and maintenance
program.
4. Be aware of the trolley capacity and weight of load at all
times.
Operators must be physically competent. Operators must have no
health condition which might affect their ability to act, and they
must have good hearing, vision and depth perception. The trolley
operator must be carefully instructed in his duties and must
understand the operation of the trolley, including a study of the
manufacturer's literature. The operator must thoroughly
understand proper methods of hitching loads and should have a
good attitude regarding safety. It is the operator’s responsibility
to refuse to operate the trolley under unsafe conditions.
WARNING
• The trolley is not designed or suitable for lifting, lowering
or moving persons. Never lift loads over people.
• Do not side load or “yard” a load with a powered trolley.
Motorized Trolley Operation
The motorized trolley is used to move SUSPENDED loads over
the length of the runway. The trolley motor is not a variable speed
motor it has only one speed. For loads to be positioned accurately
the trolley direction button on the pendant may be bumped
(pushed momentarily). Trolleys are available with a two speed
option. On two speed trolleys, select the high speed setting when
moving between stations.
• A swinging load can cause injury and/or damage to
property. Do not allow load to swing freely. Maintain contact
with load at all times.
Use the low speed setting when accurate load positioning is
required. A swinging load has a large amount of force while it is
swinging freely. Care should be taken to prevent the load from
swinging.
Before starting the motorized trolley, ensure that load is lifted
clear of the ground. Observe the path to be covered and warn any
personnel in the area. Do not combine hoisting and moving
operations. Either lift, lower a load or travel a load, do not do
both.
WARNING
• When using motorized trolleys lift the load only high
enough to clear the ground or any obstacles.
• Do not side load or “YARD” a load with a powered trolley.
• Do not lift or move any load over people.
Initial Operating Checks
Trolleys are tested for proper operation before leaving the
factory. Prior to placing the trolley into service the following
initial operating checks should be performed.
1. After installation of trolley, check to ensure the hoist is
centered and secure.
2. Check connections and position of all electrical supply
cords and plugs.
3. Operate trolley along the entire length of the beam.
4. Check trolley and hoist performance when raising, moving
and lowering test load(s). Hoist and trolley must operate
smoothly prior to being placed in service.
5. Check that hoist is properly installed on hanger shaft and
centered with the hook latch engaged.
Control Pendants
Standard pendants for “Quantum” series electric trolleys
provide push button control for the following functions. Refer to
Dwg. MHP0852 below:
Hoist Down / Up
Trolley Left / Right
Single or Dual speed
Emergency Stop (red button)
Ensure hoist and motorized trolley operation matches direction of
pendant buttons.
(Dwg. MHP0852)
Dual speed operation control pendant buttons have two positions.
Depressing the button to the first position produces normal speed.
Depressing the button to the full extent of its travel produces high
speed.
Emergency Stop
The emergency stop button will remain depressed after
activation. To reset twist (rotate) emergency stop button
clockwise until button releases and spring returns to its original
position. When a hoist and trolley combination is used the
emergency stop is integrated in the trolley relay box.

20 MHD56125 - Edition 1
INSPECTION
Inspection information is based in part on American National
Standards Institute Safety Codes (ASME B30.16).
WARNING
• All new, altered or modified equipment should be inspected
and tested by personnel instructed in safety, operation and
maintenance of this equipment to ensure safe operation at
rated specifications before placing equipment in service.
• Never use trolley that inspection indicates is damaged.
Frequent and periodic inspections should be performed on
equipment in regular service. Frequent inspections are visual
examinations performed by operators or service personnel and
include observations made during routine equipment operation.
Periodic inspections are thorough inspections conducted by
personnel trained in the safety, operation and maintenance of this
equipment. ASME B30.16 states inspection intervals depend
upon the nature of the critical components of the equipment and
the severity of usage.
The inspection intervals recommended in this manual are based
on intermittent operation of the trolley eight hours each day, five
days per week, in an environment relatively free of dust,
moisture, and corrosive fumes. If the trolley is operated almost
continuously or more than the eight hours each day, more
frequent inspections will be required.
Careful inspection on a regular basis will reveal potentially
dangerous conditions while still in the early stages, allowing
corrective action to be taken before the condition becomes
dangerous.
Deficiencies revealed through inspection, or noted during
operation, must be reported to designated personnel instructed in
safety, operation and maintenance of this equipment. A
determination as to whether a condition constitutes a safety
hazard must be decided, and the correction of noted safety
hazards accomplished and documented by written report before
placing the equipment in service.
Records and Reports
Inspection records, listing all points requiring periodic inspection
should be maintained for all load bearing equipment. Written
reports, based on severity of service, should be made on the
condition of critical parts as a method of documenting periodic
inspections. These reports should be dated, signed by the person
who performed the inspection, and kept on file where they are
readily available for authorized review.
Frequent Inspection
For trolleys in continuous service, frequent inspection should be
made by operators at the beginning of each shift. In addition,
visual inspections should be conducted during regular operation
for indications of damage or evidence of malfunction.
1. OPERATION. Check for visual signs or abnormal noises
(grinding etc.) which could indicate a potential problem. Do
not operate the trolley until all problems have been
corrected.
2. CONTROLS. During operation of trolley, verify response to
pendant is quick and smooth. Ensure that the Up/Down and
Left/Right controls return to neutral when released. If trolley
responds slowly or movement is unsatisfactory, do not
operate trolley until all problems have been corrected.
3. ELECTRICAL SYSTEM. Visually inspect all connections
and components for indication of damage or loose
connections. Shut off and disconnect power prior to
removing inspection covers, repairing any damage or
tightening connections.
4. SUSPENSION PARTS. All statically loaded parts are
known as suspension parts. Refer to Nut Torque Table 4 in
“INSTALLATION” section.
Periodic Inspection
Frequency of periodic inspection depends on the severity of
usage: NORMAL HEAVY SEVERE
yearly semiannually quarterly
Disassembly may be required for HEAVY or SEVERE usage.
Keep accumulative written records of periodic inspections to
provide a basis for continuing evaluation.
Inspect all the items in “Frequent Inspection”. Also inspect the
following:
1. FASTENERS. Check all rivets, split pins, capscrews and
nuts. Replace if missing or tighten if loose.
2. ALL COMPONENTS. Inspect for wear, damage, distortion,
deformation and cleanliness. If external evidence indicates
the need, disassemble. Check shafts, wheels, side plates,
bearings, and covers. Replace worn or damaged parts.
Clean, lubricate and reassemble.
3. SUPPORTING STRUCTURE. Check for distortion, wear
and continued ability to support load. A visual inspection of
connecting bolts should be done periodically depending on
frequency of use.
4. TROLLEY. Check that the trolley wheels track the beam
properly. Refer to “INSTALLATION” section. Check that
wheels are not excessively worn and inspect side plates for
spreading due to bending. Ensure trolley wheels and beam
are clean. Remove any oil, grease or buildup to avoid
slipping and ensure unobstructed trolley operation. Do not
operate the trolley until problems have been determined and
corrected.
5. LABELS AND TAGS. Check for presence and legibility.
Replace if necessary. Refer to “WARNING LABELS” and
“PARTS LIST” sections for label requirements.
Trolleys Not in Regular Use
1. A trolley which has been idle for a period of one month or
more, but less than one year, should be given an inspection
conforming with the requirements of “Frequent Inspection”
prior to being placed into service.
2. A trolley which has been idle for a period of more than one
year should be given an inspection conforming with the
requirements of “Periodic Inspection” prior to being placed
into service.
3. Standby trolleys should be inspected at least semiannually
in accordance with the requirements of “Frequent
Inspection”. In abnormal operating conditions trolleys
should be inspected at shorter intervals.