UNIT 4.

6 TRAVELLING TROLLEYS

Contents

1. Types of trolley used with power hoists

2. Runway systems
2.1 Light duty runway systems

3. Trolleys
3.1 Types of wheel
3.2 Rigid or articulated

4. Examination of runway beam and trolley

5. Types of defect found in “in service” inspection and action that should
be taken in the event of a defect
5.1 The erection of the trolley
5.2 Testing of trolleys
5.3 Operation
5.4 Training
5.5 Marking

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Introduction

In conjunction with this unit reference should be made to Section 7 of the LEEA
COPSULE (Code of Practice for the Safe Use of Lifting Equipment) and
manufacturers’ manuals.

This unit covers the types of travelling trolley used with power hoists. We shall then
consider their construction, examination and requirements for safe use.

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1. Types of trolley used with power hoists

There are basically three types of trolley used with power hoists:

(i) Hand Pushed Trolley Fig.1

(ii) Hand Geared Trolley Fig.2
(iii) Electric Traverse Trolley Fig.3

The illustrations are of trolleys used with Morris and Konecranes but the general
construction is the same for other manufacturers.

Figure 1
Hand pushed trolley

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 Figure 2
Hand geared trolley

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 Figure 3
Electric traverse trolley

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2. Runway systems

Most modern runway systems utilise the universal beam section (BS4: 1980). On
older installations the runway may be of the old rolled steel joist section, (See Fig.4).

Universal Beam (UB) Rolled Steel Joist (RSJ)

Figure 4
RSJ and UB Sections showing the basic differences

It is important when examining a runway beam system to check that trolley runners
are compatible with the flange taper, especially if the equipment is old or has been
resited. A taper roller suitable for an RSJ profile will only run on the edges of the
flange of a UB causing rapid wear to both the wheel and the flange. This can lead to
possible overloading and distortion of the flange as well as to the trolley side plates
and wheel axles.

The modern trolley runner has a radius end profile, although small, allowing it to sit
correctly on either type of flange (usually ¾ width).

Most trolleys are built with adjustments for different flange widths, the most common
method using spacer bars and a series of washers. Maximum total clearance
between runner flanges and beam flange should be 2-3mm. It is important that the
trolley is correctly set for the beam.

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2.1 Light duty runway systems
For light duty installations tracks have been developed using a form rolled section.
These sections are also often incorporated into light duty swing jib cranes.

Demag KBK section Konecranes XM & AL Sections

Figure 5
Typical form rolled runway sections

3. Trolleys

Trolleys are supplied with either a load bar (See figure 7) or suspension plate for
‘hook in' arrangements. Alternatively, the trolley is built in as part of the permanent
structure of the hoist unit. (See figures 1-3)

Most electric traverse trolleys are of the four-runner type driving on two runners on
the same side. Long boomed hoists tend to use two four wheeled trolleys. Where
headroom is a problem the hoist may be mounted on one side of the runway beam
with a counter balance on the other, (See Fig. 6).

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 c_holiad2a

Figure 6
Trolley/Hoist arrangement used in low headroom situation

When the B-dimension increases, the fleet angle of the ropes, with the hook in the
up most position, changes accordingly. To avoid overloading the ropes, overload
device, return sheaves and other structures, the minimum C-dimension may not be
smaller than recommended by the hoist manufacturer.
In this arrangement the ropes fall at an angle. When using such a hoist it is very
important that the overwind limit is correctly set. This is because, as the bottom block
approaches near to the trolley, the angle between the rope falls from the drum and
compensating sheave increases. This increases the load in each rope, which may
eventually exceed the breaking strength of the rope.

The same limitation would be true of any multi-fall hoist where the rope or chain falls
at an angle to meet the bottom block.

3.1 Types of wheel

Most of the modern trolleys are fitted with wheels having a tread profile that is
suitable to run on any standard rolled steel section flange. Older trolleys and those
for certain applications may have wheels with tread profiles to suit a specific steel
section flange, such as RSJ. The more common trolleys have wheels with a plain-
bushed bearing. For special applications and for higher loads anti-friction (ball or
roller) bearings are available.

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3.2 Rigid or Articulated
The most common forms of four-wheeled trolley have the wheels arranged on fixed
side-plates and are known as rigid trolleys. This makes them suitable for use on
straight runway beams or those with a generous radius. Articulated trolleys are also
available. These have four or more wheels and are designed so that each pair or set
of wheels is free to pivot relative to the others in plan view.

4. Examination of runway beam and trolley

When examining a hoist with trolley mounted on a runway the runway must also form
a part of the examination:

1. Check the runway has a valid test certificate.

2. Runway beam or girder should be of the proper size, adequate strength, with
an even running surface and should be packed level at suspension points. In
any 2 metres the runway should not deviate by more than 2mm and the
maximum total deviation over the whole runway should not exceed 10mm.
3. Ensure adequate stops are fitted to the runway.
4. Remove the trolley from the runway, disassemble and clean.
5. Check the markings on the trolley (i.e. SWL/WLL, distinguishing number,
maker’s name) against the test certificate.
6. Check cross bolts, side plates, assemblies and bearing stubs for deformation
7. Check bearings for evidence of wear. If debris or water is able to penetrate
the seals rapid wear and seizure can take place.
8. Check runners for free running and the outside diameters for wear.

In addition - for hand geared trolleys:

9. Check chain for wear (8% of link diameter), kinks and overstretching. If fitted
with a safety link, ensure this has not opened out
10. Check hand chain wheel for wear and deformation; ensure the guard fits
closely around the hand chain wheel
11. Check gears for evidence of wear, broken or deformed teeth. After
examination lubricate bushes and shafts with an MOS 2 grease

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Or - for electric traverse trolleys:

12. Check the motor brake for wear and loss of efficiency
13. Check the electric motor for security to side plate
14. Check the electric motor for wear in the bearings
15. Check the cables for integrity and insulation
16. Check the pinion and gears for wear, broken teeth alignment and correct
engagement

5. Types of defect found in ‘in service’ inspection and

action that should be taken in the event of a defect

This inspection should be carried out by a Responsible Person on a regular basis to

ensure that the equipment is properly maintained and in working order at all times.
The frequency of inspections should be determined according to the conditions of
service. If any of the following defects are found the trolley should be withdrawn from
service and referred to the Competent Person for thorough examination.

1. Appreciable wear of the trolley wheel treads and bearings or damage to

flanges.
2. Insecurity of the wheels and axle pins.
3. Distortion, particularly in the side plates and load bar.
4. Wear on the bearing points.
5. Cracked or defective welding.
6. Incorrectly substituted components.
7. Worn, corroded or damaged hand-chain, particularly on the bearing surface
on the inside of the links but also the outside of the links. Bear in mind
possible damage to the operatives’ hands.
8. Illegible SWL/WLL or other markings.

In making their report, the Competent Person must send a copy to the HSE (See unit
4.1)

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In addition, for trolleys in situ, if any of the following defects are found the Examiner
should recommend the following action: "That the equipment be removed from
service until the following modification work is carried out".

1. Incorrect size of trolley for the runway beam.

Action: replace with correct size of trolley.
2. Wrongly adjusted trolley.
Action: re-adjust to correct side clearance between the wheel flanges and the
toes of beam, usually 2 to 3 mm total clearance. Also ensure that the trolley is
correctly aligned centrally with the flange of the runway (See Fig.7).
3. Incorrect or wrongly fitted hoist block.
Action: remove and replace or refit as required.
4. Trolley wheels or runway contaminated with lubricant or other fluid that could
cause wheel slip.
Action: clean wheels and beam.
5. Wrongly adjusted anti-tilt device.
Action: re-adjust.
6. Distortion or appreciable wear of the runway beam on which the trolley is
fitted. End stops missing or ineffective.
Action: remove from service.

1.5m 1.5mm
m

Total clearance equals sum of these dimensions. Ensure trolley is correctly adjusted

Figure 7
Trolley alignment

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5.1 The erection of the trolley
The erection procedure for the trolley should be in accordance with the
manufacturer’s instructions and take account of the erection and commissioning
procedures for the appliance that it is to support. The detail of this procedure will
vary depending on the type of trolley used, but in particular attention should be paid
to the following:
1. The trolley should only be used on a runway beam which complies with the
requirements of BS 2853 as far as they are applicable and has been tested
and certified as such.
2. Prior to commencing installation of trolleys that have been in storage, a check
should be made to ensure that no damage has occurred whilst in storage.
3. It is essential to ensure the structure on which the trolley is to be erected is
adequate for the load it is intended to carry. This load includes the self-weight
of the trolley and the weight of the lifting appliance it is to support, together
with any attachments (i.e. slings, shackles etc) plus an allowance on the total
to take account of the effect of dynamic loading (10% in the case manually
operated appliances and 25% in the case of powered appliances). If the
supporting structure forms part of, or is attached to part of, the building
structure, care must be taken to ensure it is suitable for the intended lifting
application. An architect or structural engineer should be consulted and
his/her written approval kept on file with the records for the lifting equipment.
4. Ensure that the trolley is of a suitable type for the particular operation.
5. Ensure that the trolley is of the right size for the runway beam to which it is to
be fitted.
6. If the trolley is adjustable, ensure that it is aligned centrally with the beam
flange and that the side clearances are in accordance with the manufacturer's
recommendations. These are usually of the order of 2 to 3mm total
clearance.
7. If the trolley is dismantled in order to fit it to the runway ensure that it is
reassembled correctly.
8. If the runway end stops are removed in order to fit the trolley ensure that they
are refitted securely and correctly.
9. If an anti-tilt device is fitted, ensure that it is correctly adjusted and that there

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 is no obstruction to its operation on the underside of the runway flange.
10. Ensure that all fixing bolts and nuts are tight.
11. If the trolley is to be used with an electrically operated lifting appliance then
the trolley and runway must NOT be used as the earth return. A separate
earth conductor MUST be used.

Any electrically operated appliance should be installed in accordance with IEE

Regulations (currently the 17th edition).

5.2 Testing of trolleys

Manual lifting machines are tested with an overload of SWL +50%. Lifting machines
power are tested to SWL +25%.

If a trolley is of the detachable or hook in type it should therefore be tested to

SWL/WLL +50%.

If a trolley is built in a hoist unit as a part of the appliance, the trolley would be tested
with the hoist. If it were power operated the proof on test load would be SWL/WLL
+25%.

5.3 Operation

1. The trolley must not be used to suspend a total load that is in excess of the
SWL/WLL marked on the trolley.
2. Care should be taken to ensure that the trolley is not subjected to shock
loading. For example: vertically by misuse of the lifting appliance, or
horizontally by running into the end stops of the runway.
3. It is essential to note that trolleys are suitable for in line use only. Either the
load or the trolley must be moved to the correct position before use to achieve
this.
4. When two or more trolleys are used for one lift care should be taken to ensure
that no one trolley will be subjected to a load greater than its own marked
SWL/WLL.

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5. Trolleys should not be left in a position where they are liable to be subjected
to extremes of temperature.
6. At no time should the operative permit either themselves or other personnel to
be beneath or climb on the suspended load.

5.4 Training

Although the tester and examiner is not called upon to train operatives, they must be
aware of the training requirements. This allows them to advise the owner/user of any
bad practices they become aware of whilst on site.

Operatives should be instructed in the specific use for which the trolley is intended.

Operatives whose job it is to erect trolleys should be trained in the correct method of
assembly and fitting of the trolley. They should also be made aware of which part of
the structures available are suitable for use as runways and what they are capable of
supporting.

5.5 Marking

The following information should be permanently and legibly marked on a suitable

part of the trolley:

1. Distinguishing mark. This should be unique to the trolley and identify it with
the Test Certificate.
2. SWL/WLL.
3. An indication that it is suitable for power operated lifting appliances.
4. The width of the runway beam for which the trolley is designed or, in the case
of an adjustable trolley, the range of widths.

The marking should be by means of a suitable metal tab permanently attached, or by

stamping (provided that no mechanical property of the trolley is impaired).

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