JET 1-Ton Manual Trolley (Model 1-HDT) Instruction Manual

1. Introduction

This manual provides essential information for the safe and effective use of the JET 1-Ton Manual Trolley, Model 1-HDT. This trolley is designed for material handling applications, offering low maintenance and reliable performance on wide-flange H-beams, standard I-beams, or curved tracks. It complies with OSHA regulations and ANSI/ASME standards B30.11 and B30.17.

The JET 1-Ton Manual Trolley has a capacity of 2200 pounds (1 ton) and features hardened wheels with double-sealed, permanently lubricated bearings for smooth movement. Spacer washers are included for precise adjustment to various beam flange widths.

Figure 1: JET 1-Ton Manual Trolley (Model 1-HDT)

2. Safety Information

Read and understand all safety warnings and instructions before operating this equipment. Failure to follow these instructions may result in serious injury or property damage.

• Capacity: Never exceed the rated capacity of 1 ton (2200 lbs). Overloading can cause equipment failure and severe injury.
• Inspection: Before each use, inspect the trolley for any signs of damage, wear, or loose components. Do not use if damaged.
• Beam Compatibility: Ensure the trolley is correctly installed on a beam that is structurally sound and rated to support the intended load.
• Load Stability: Always ensure the load is balanced and securely attached to the lifting device connected to the trolley. Avoid sudden movements.
• Personnel: Keep hands, feet, and body clear of moving parts and suspended loads. Do not stand under a suspended load.
• Environment: Operate the trolley in a well-lit, clear area, free from obstructions.
• Maintenance: Only qualified personnel should perform maintenance and repairs. Use only genuine JET replacement parts.

3. Product Features

The JET 1-Ton Manual Trolley is engineered for durability and smooth operation. Key features include:

• Hardened Steel Wheels: Designed for longevity and smooth rolling on various beam types.
• Double-Sealed Lubricated Ball Bearings: Provide maintenance-free operation and reduce rolling resistance.
• Built-in Bumper Guards: Integrated into the side plates to enhance safety and protect the trolley from impacts, extending its service life.
• Welded All-Steel Frame: Ensures maximum durability and structural integrity.
• Powder Coat Finish: Provides protection against corrosion and wear.
• Adjustable Design: Easily adapts to wide-flange H-beams, standard I-beams, or curved tracks using included spacer washers.
• Load Tested: Each unit is load tested to 125% of its rated capacity to ensure safety and reliability.

Figure 2: Key Features of the Manual Trolley

4. Setup and Installation

Proper installation is crucial for safe and efficient operation. Follow these steps to install the JET Manual Trolley:

1. Beam Selection: Ensure the overhead beam is capable of supporting the trolley and the maximum intended load. Refer to the beam manufacturer's specifications.
2. Trolley Disassembly: Disassemble the trolley by removing the cotter pin and castle nut from one end of the cross shaft. Carefully slide off the side plate and wheel assembly.
3. Beam Flange Measurement: Measure the width of the beam flange where the trolley will be installed.
4. Spacer Washer Adjustment: Select the appropriate number of spacer washers to achieve a snug fit on the beam flange. The goal is to minimize lateral movement while allowing free rolling. Place the washers on the cross shaft, between the wheel assemblies and the side plates.
5. Reassembly on Beam: Position the trolley on the beam. Reattach the removed side plate and wheel assembly. Secure the castle nut and cotter pin. Ensure the cotter pin is fully spread to prevent the nut from loosening.
6. Test Movement: Before attaching any load, push the trolley along the beam to ensure it rolls smoothly without binding or excessive play.
7. Attach Hoist: Connect your lifting device (e.g., chain hoist) to the trolley's load bar. Ensure all connections are secure and rated for the load.

Figure 3: Trolley Installed on an I-Beam with Hoist

5. Operation

Operating the JET Manual Trolley is straightforward, but always prioritize safety.

1. Pre-Operation Check: Before each use, perform a visual inspection of the trolley, beam, and lifting device. Check for any damage, obstructions, or loose parts.
2. Load Attachment: Securely attach the load to the lifting device's hook. Ensure the load is balanced to prevent swinging.
3. Lifting: Use the attached hoist to lift the load clear of the ground or any obstructions.
4. Movement: To move the load horizontally, apply steady, even force to the load or the lifting device. Avoid sudden jerking motions. The trolley is designed for manual pushing/pulling.
5. Positioning: Guide the load to its desired location. Ensure the path is clear.
6. Lowering: Once positioned, carefully lower the load using the lifting device. Ensure the landing area is clear and stable.
7. Post-Operation: After use, ensure the trolley is left in a safe, clear position.

6. Maintenance

Regular maintenance ensures the longevity and safe operation of your JET Manual Trolley.

• Cleaning: Keep the trolley and beam surfaces clean and free of debris, grease, or other contaminants that could impede smooth movement.
• Lubrication: The wheel bearings are permanently lubricated and sealed, requiring no additional lubrication. However, periodically check for any signs of bearing wear or damage.
• Fasteners: Periodically check all nuts, bolts, and cotter pins for tightness and security. Tighten any loose fasteners.
• Wheel Inspection: Inspect the wheels for wear, cracks, or flat spots. Worn wheels should be replaced immediately.
• Frame Integrity: Inspect the steel frame and side plates for any signs of bending, cracks, or deformation.
• Storage: When not in use, store the trolley in a clean, dry environment to prevent corrosion.

7. Troubleshooting

This section addresses common issues that may arise during the use of the manual trolley.

8. Specifications

Detailed specifications for the JET HDT Series Manual Trolleys, including the 1-Ton model (1-HDT).

Figure 4: Technical Drawing and Specifications Table

9. Warranty and Support

The JET 1-Ton Manual Trolley (Model 1-HDT) comes with a 2-Year Warranty from the date of purchase, covering defects in materials and workmanship under normal use and service. For warranty claims or technical support, please contact JET customer service.

Figure 5: 2-Year Warranty

For further assistance, please refer to the official JET website or contact their authorized service centers.