JRClancy PowerLift User manual

Important User Information � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
General �����������������������������������������2
Manufacturer �������������������������������������2
Product Use Requirements ��������������������������2
Warranty ����������������������������������������2
Safety Precautions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
Important Safety Information�������������������������3
Maintenance Schedule � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Replacement Parts � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Recommended Tools� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Inspection and Maintenance Procedures � � � � � � � � � � � � � � � � � � � 5
Machine Covers ����������������������������������5
Beam Clamps and Machinery Frame ������������������6
Blocks and Wire Rope� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Guide Rollers� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 11
Cable Drum (Inspection Procedure) �������������������13
Motor and Gear Reducer ���������������������������14
Secondary Load Brake �����������������������������16
Output Shaft Flange Bearing� � � � � � � � � � � � � � � � � � � � � � � � � 18
Drive Shaft Bearing ��������������������������������18
Controls Enclosure ��������������������������������18
Circuit Protection and Controls Electronics��������������19
Limit Switch Settings �������������������������������20
Warning Signs and Operational Instructions�������������23
Decommissioning and Disposal � � � � � � � � � � � � � � � � � � � � � � � � � � 23
Hoist Maintenance and Inspection Log� � � � � � � � � � � � � � � � � � � � � 24
Contents
Maintenance Manual
PowerLift®and PowerLite™Hoists
©Wenger Corporation 2023 Printed in USA 2023-12 Part #003-1005-04
Wenger Corporation - Syracuse Operations, 7041 Interstate Island Road, Syracuse, New York 13209
Questions? Call�����USA: [phone] • Worldwide: [phone] • jrclancy�com
Note: Please read and understand these instructions before starting any procedures�
Note: If you need additional information, contact Wenger Corporation using the information below�
Visit the Hoists web page at jrclancy.com for more information.

2
Important User Information
General
Copyright © 2023 by Wenger Corporation
All rights reserved� No part of the contents of this manual may be reproduced, copied, or transmitted in any form
or by any means including graphic, electronic, or mechanical methods or photocopying, recording, or information
storage and retrieval systems without the written permission of the publisher, unless it is for the purchaser's
personal use�
Printed and bound in the United States of America�
The information in this manual is subject to change without notice and does not represent a commitment on the
part of Wenger Corporation� Wenger Corporation does not assume any responsibility for any errors that may
appear in these instructions�
In no event will Wenger Corporation be liable for technical or editorial omissions made herein, nor for direct,
indirect, special, incidental, or consequential damages resulting from the use or defect of these instructions�
The manufacturer reserves the right to change this product at any time�
The information in this document is not intended to cover all possible conditions and situations that might occur�
The end user must exercise caution and common sense when assembling or installing Wenger Corporation
products� If any questions or problems arise, call Wenger Corporation - Syracuse Operations at [phone]
or [phone] worldwide�
Manufacturer
The PowerLift®and PowerLite™ Hoists are manufactured by:
Wenger Corporation - Syracuse Operations
7041 Interstate Island Road
Syracuse, NY 13209
[phone] • [phone]
jrclancy�com
Product Use Requirements
• Installation of this equipment must comply with local building codes�
• Equipment must be installed according to manufacturer's installation drawings� Individual component
information is listed in the bill of materials of these drawings�
• PowerLiftandPowerLiteHoistsmustbeinspectedbyqualiedpersonneleveryyear,ormorefrequently
depending on patterns of use as well as local, state, and federal laws� They also feature circuit breakers
located within the controls enclosure or on the wiring raceways� Do not install these machines in locations
that prohibit access to the machinery or controls or prevents removal of any machine covers�
• PowerLift and PowerLite Hoists are designed for indoor use only in buildings with temperatures between
50º and 100º F (10º- 38º C)�
• Do not expose machines to rain, extreme humidity or condensing moisture
• TherecommendedworkingloadanddutycycleofeachmachineismarkedontheIdenticationLabel
on the controls enclosure machine� Do not exceed�
• The hoist machinery must be protected from oil, dust and other contaminants�
• PowerLift and PowerLite Hoists machines are approximately 168" (4267 mm) long, 11" (279 mm) wide
and 30" (762 mm) tall� Units weigh 800 lb (363 kg) or less�
Warranty
Warranty information is available at jrclancy�com�

3
Safety Precautions
Throughoutthisdocumentyoumayndcautionsandwarningswhicharedenedasfollows:
• DANGER: Failure to follow the instruction will result in death, or serious injury, or damage to property�
• WARNING: Failure to follow the instruction could result in death, or serious injury, or damage to property�
• CAUTION: Failure to follow the instruction could result in minor injury or damage to property�
• NOTICE: Indicates information that is considered important but not hazard related�
Important Safety Information
• Read all of these safety instructions before using the equipment�
• Theproceduresinthismanualareforusebyqualiedpersonnelonly.Ifyouarenotqualied,contactthe
companythatinstalledyoursystemortheJ.R.Clancyfactorytondthenearestserviceprovider.
• Read this manual carefully before installing or using this product�
Failure to do so can result in injury or death�
• AnIdenticationLabelisattachedtocontrolsenclosureoneachunitandcontainsimportantmodelnumber,
speed, and capacity information that is necessary for proper maintenance and use�
• All users must be aware of maintenance requirements and warned of the associated hazards� Keep a copy of this
manual available along with all other product documentation for future reference�
Electrocution Hazard.
• Remove power source before opening electrical
panels.
• Electrical equipment must be installed by qualied
electricians.
!DANGER
Moving parts can cut or crush.
• Keep body parts away from machinery in motion.
• Remove power source before working on machinery.
• Machines with moving parts within 106" (2.7 m)
vertically from the oor and less than 60" (1.5 m)
horizontally from a safety barrier must be tted with
machine covers. Guards must be in place during use.
!WARNING
A competent person must be present and available
whenever any operation or maintenance procedures
are performed on any system.
!WARNING A"competentperson"isdenedasonewhoiscapable
of identifying existing and predictable hazards in the
surroundings or working conditions, which are unsanitary,
hazardous, or dangerous to employees, and who has
authorization to take prompt corrective measures to eliminate
them�
• Make sure anyone installing or using the equipment has read and understands these instructions.
• Failure to comply with the Dangers, Warnings, Cautions and Notices in this document can result in damage
to property or serious injury.
• Always observe and comply with the Dangers, Warnings, Cautions and Notices posted on the system equipment.
!WARNING
!WARNING
Improper installation or maintenance can cause the load to fall.
• Hoisting machines impose signicant loads on the structure to which they are attached. You are responsible for
verifying that an engineer or other qualied person has determined that this structure can withstand the loads.
• Equipment must be installed and maintained by qualied personnel.
• Annual inspection and maintenance of this product is required. Some applications may require more frequent
inspection and service.
• Do not substitute or modify components provided with this equipment.
• Do not exceed the recommended working load of the hoist. It varies by model and is marked on the Identication
Label on the hoist.
• Do not exceed 500 lb [228 kg] on any one wire rope.
• Do not lift or support people or animals.
• Hoists can weigh up to 800 lb [363 kg] each, plus the weight of any packaging. You must use proper lifting and
handling equipment and safe work practices if they are to be moved.

4
Maintenance Schedule
Replacement Parts
Annual inspection and operator training is required�
Certain applications may demand more frequent inspections and maintenance� It is the responsibility of the user
to monitor the machinery and adjust the maintenance schedule accordingly� Be aware of government regulations
concerning the inspection of hoisting equipment�
Lubricantsandothercomponentsthatcanbeprocuredlocallyarefullyspeciedintheappropriatesectionof
thismanual.Useonlythespeciedtypeandgradeofmaterials.ContactyourlocalJ.R.Clancydealertoobtain
any parts not listed in this document�
Recommended Tools
The following tools and materials may be used in this manual and during annual inspections and regular
maintenance� This list is not exhaustive, but can be used as a starting point for selecting the proper tools�
• Appropriate personal protective equipment
• 5/16" hex nut driver
• 9/16", 3/4" open-ended box wrenches
• 3/4", 17 mm socket wrenches
• Torque wrench
• Wire rope termination tools, as necessary
• Castrol Pyroplex Red NLGI #2 High Temperature Grease
• Portable grease pump

5
Inspection and Maintenance Procedures
Machine Covers
1. Machinesthathavemovingpartswithinreachofpeoplemustbettedwithcovers,seetherequirements
in the Safety Information section of this manual� Install or replace covers if required� Contact J�R� Clancy if
covers cannot be located on site�
2� Make sure that all fasteners are in place on the covers�
3� Loosely install these ten screws into the aluminum frame�
4� Slide this cover over the screws until it is approximately 1/8" from the face of the bracket�
5. Tightenthesixfastenersontherstcoversegment.
6. Slidethiscoveroverthescrews,overlappingtherstcoversegment.
7� Install this screw last, then tighten all of the other screws�
Machine Covers and Proper Sequence for Installation
1/2" stando󰀨
(do not remove)
Step 6
Step 3
Step 7
Step 4
Step 3
Step 5

6
Inspection and Maintenance Procedures (continued)
Beam Clamps and Machinery Frame
1� Make sure that two roll pins are in place on each end of the main beam�
2. Standardclampsareforbeamangesupto11"(279mm)wideand1"(25mm)thick.Flangesmustbe
atleast4"(102mm)wideand1/4"(6mm)thick.Conrmthattheclampsareappropriateforthestructure
supporting the hoist�
3� Make sure the clamp rods are tightened�
Note that some bending of the threaded rod will be observed� This is normal�
4� Make sure the thrust plate is in place at each end of the beam with two nuts and/or jam nuts on each end,
as seen below�
5� Check to make sure there is no loose hardware or materials set on top of the main beam�
Thrust
Plate
Hoist Mounting Clamp
Clamp Rod
Driver
Threaded
Rod
Jam
Nut
Fixed
Nut
Nut
Beam
Clamp
Nut
Supporting
Structure

7
Keep body parts away from
the machinery in motion.
!WARNING
Inspection and Maintenance Procedures (continued)
Blocks and Wire Rope
1. Checktheeetangleonallsheavesandadjusttokeepwithin1.5degrees.Thisisequivalentto3"(76mm)
deviation in 10' (3048 mm)�
2� Check the machine mounted loft blocks, if provided� Only one line is allowed to wrap more than 20 degrees
around these sheaves� On the multi-line block that groove must be the fourth groove as marked on the
block�
3� Remove the covers from the machine and observe the machine while running� Listen for the sound of
cables that might be rubbing against the machine or other cables� Adjust blocks if necessary to eliminate
any rubbing�
4� The nuts securing the machine-mounted blocks (if provided) to the hoist frame should be tightened to
18 ft-lb (24�4 Nm)�
These lines pass over but do not
turn around the sheave
The label indicates that only the fourth
groove can be used to turn the line
Only this one line turns over
the sheave
Detail of the Multi-Line Beam Mounted Loft Block
Tighten to
18 ft-lb (24.4 Nm)

8
Inspection and Maintenance Procedures (continued)
Blocks and Wire Rope (continued)
5. Observethemachinewhilestationary.Inspecttheeetangleofthecablewithrespecttothedrumgrooves
as seen below� Adjust the head block only if required using the following procedure�
Inspecting the Fleet Angle at the Drum
Head Block Constraints and Adjustment Nuts
Cable Climbs Out Of
Drum Groove
Cable is Parallel
With Drum Grooves
Cable Rubs Against
Wraps On Drum
Incorrect:
Head Block Too Far Back
Correct Incorrect:
Head Block Too Far Forward
Adjusting
Nut
Locking Nut
(tighten to 10 ft-lbs)
Head Block
Axial Constraint
Head Block
Transverse Constraints
a� Loosen but do not remove the locking nut on the axial head block constraint� The hoist does not need
to be unloaded as long as nuts remain fully engaged with the threaded fastener�
Improper adjustment of the constraintment bolt can result in failure.
Nut must remain fully threaded on the bolt at all times.
!WARNING
Procedure continued on following page.

9
Inspection and Maintenance Procedures (continued)
Blocks and Wire Rope (continued)
b. Adjustappropriatenutonaxialheadblockconstrainttocorrecttheeetangleaccordingtothe
"Inspecting the Fleet Angle at the Drum" image on the previous page�
c Tighten the locking nut to 10 ft-lbs (13�5 Nm)�
d Test the operation of the machine� Cables entering the drum should not rub on the drum wraps or skip
drum grooves�
Do not over-tighten the locking nut on
the constraint bolt.
!WARNING
Head block
side plate
Clearance at Head Block Bracket
Clearance must
be maintained
Stepped
Pin
NOTICE
Adjustment is limited by clearance at head block bracket.
Stepped pin must not contact head block side plate.

10
Inspection and Maintenance Procedures (continued)
Blocks and Wire Rope (continued)
6� Make sure the wire rope is free of kinks, distortions and broken wires� The hoists are to be used with
3/16"diameter7x19SmallDiameterSpecialtyCordasdenedbyASTMstandardA1023.
Replace wire ropes as necessary using the following procedure:
a� Move the load to a location where it can be secured using other rigging e� g� to another batten or to the
building structure�
b� Rotate the drum so that the cable termination holes are visible�
c� Secure the load being held by the hoist and remove the damaged cable�
d� Reeve the end of the new cable through the loft blocks and to the hoist�
e� Reeve the cable through the hoist head block being careful to stay below the sheave spacers�
Swage a Nicopress stop sleeve onto the end of the cable and inspect the swage using the
manufacturer's recommended gage� The cable must protrude from the stop sleeve after it is pressed,
but no more than 1/16"�
f� Wrap the cable around the drum enough times to match the number of standing wraps on the other lines
of the hoist� Note that a minimum of three wraps must be maintained on the drum when the machine is
at the lowest limit of travel�
g� Insert the swaged stop into the keyhole in the drum� Make sure the cable lays properly into the grooves
on the drum�
h� Prior to terminating the lift lines, inspect the reeving and check the following:
• Cables must lie smoothly in the grooves of the drum�
• Double check that the cables are reeved properly through the blocks�
i Cut the lines to length and terminate at the batten�
• Install a trim chain, turnbuckle, or other rated load leveling device on each lift line connection�
• Use terminating hardware that is properly rated for the load� Follow hardware manufacturers'
instructions carefully; e�g�, use inspection gages for swaged sleeves�
• Swaged sleeves are recommended for most installations� If wire rope clips are used, annual
maintenance must include checking the clip nuts with a torque wrench�
7� Inspect any wire rope clips that may be used on the system and use a torque wrench to make sure the nuts
are tightened according to the manufacturer's recommendations�
8� Inspect swaged (Nicopress or similar) terminations to look for signs of damage or overstress�
At least 1/16" of the dead end of the cable should be protruding from the swaging sleeve�
9� Inspect all wire rope thimbles for deformation or other damage�
10� Inspect all other components used to attach the loads to the hoist lift lines�
Do not use wire ropes of dierent
dimensional or structural characteristics.
!WARNING
!WARNING
Unplug the power before working on the machinery.

11
Inspection and Maintenance Procedures (continued)
2� Make sure roller arms are seated in the frame extrusion�
Head Block on
Opposite Side
Two Element Rollers
(Long and Short Arms)
Position of Cable Keeper Rollers
Guide Rollers
1� Make sure that there is a roller on every cable�
Note the position of the rollers in the "Position of Cable Keeper Rollers on the Cable Drum" image on the
following page�
Short-arm rollers on side
opposite the head block
Position of Long and Short Armed Cable Rollers
Arms hook into slots
in aluminum cap
Long-arm rollers on same
side as the head block
Connecting
spring

12
Inspection and Maintenance Procedures (continued)
Position of Cable Keeper Rollers on the Cable Drum
A. View from Head Block Side B. View from Opposite Side
Long arm roller
on same side as
head block
Connecting Spring
Short arm roller
on opposite side
from head block
Cable roller guide
wheel rests in
groove next to cable
Foam rollers rest on
cable wrapped on
drum
3 standing wraps
at all times
4� Observe the surface of the rollers to look for abrasion or other damage�
Note that the short-arm rollers are foam rubber and designed to conform to the cable and drums when
stationary� If the foam roller is not round it is not necessarily damaged�
5� Observe the machine while operating and make sure that all rollers are turning�
3� Make sure the rollers are aligned with the cable�

13
Inspection and Maintenance Procedures (continued)
Cable Drum (Inspection Procedure)
1� Examine the drum screw� If the grease is contaminated with debris or excessive dust, wipe all of the
contaminatedgreaseo󰀨.Lookfordebrisorothersignsofdamagetothenutinsidethedrumthatrunson
the screw�
2� Examine the exposed end of the drive shaft seen in� If the grease is contaminated with debris or excessive
dust,wipeallofthecontaminatedgreaseo󰀨.Checkforscoringorwearofthealuminumshaftwherethe
drum translates�
3. LubricatethescrewandtheexposeddrumwithathinevenlmofCastrolPyroplexRedNLGI#2EPHigh
TemperatureGrease.ContactJ.R.Clancyifyoucannotlocateadealerwiththespeciedgreaseinyour
area�
4� Observe the machine in operation through the entire range of motion to make sure the drum moves
smoothly�
5� Check the drum tension rods to make sure that they are snug�
Note that these are not fully tightened� The nuts should be tight enough to hold the drum segments securely
together, but not so tight as to compress the plastic drum segments�
The rods should be tightened in a way that ensures the screw remains centered in the opening of the nut
housing plate� See below�
6� Locate the drum screw nut housing and verify that there is a uniform opening between the outside diameter
of the screw and the inside diameter of the nut housing�
DO NOT LET END OF DRUM HIT END OF SCREW
BEFORE THE LIMIT SWITCHES ARE SET!
Drum Screw and Exposed Portion of Drive Shaft
Drum screw must be
clean and well lubricated
Limit Switches
Exposed portion of drive shaft
must be clean and well lubricated
Opening must be
uniform around
the drum screw
Nut
Housing

Motor and Gear Reducer
1� Observe the machinery while raising the load� The load should stop quickly and without any back-winding�
If the load backwinds, or if the load brake is engaged under these circumstances, the electric motor should
be serviced� Contact J�R� Clancy for assistance�
2� Check the gear reducer oil level� The gear reducer oil must be replaced every two years, or analyzed
annually by a commercial laboratory to ensure that the oil properties and contamination levels are
acceptable�
The"ReducerLubrication"chartonthefollowingpageshowsthedrainplugandlllevelsforthemachines
based on mounting position� For hoists mounted in the M2 position, the vent plug should be removed and a
dipstick inserted to verify the oil level as seen in the "Reducer Lubrication" chart on the following page�
Any oil added to the reducer must match the manufacturer and type marked on the reducer label that is
fastened directly onto the side of the gear case� Note that bearings inside the electric motor are lifetime
lubricated and sealed and do not require periodic lubrication�
3� Inspect for any loose fasteners and re-tighten as necessary�
14
Inspection and Maintenance Procedures (continued)
Hoist Motor and Motor Brakes
Motor Mounting
Bracket
Gear
Reducer
Electric
Motor
Motor Fan
Cover
Motor
Brake #1
Motor
Brake #2
Load
Cell
Grease
Fitting

Inspection and Maintenance Procedures (continued)
Motor and Gear Reducer (continued)
15
Vent Oil Level Oil Drain
Dimension “d”
SK3282 = 2-1/2”
SK4282 = 3”
d
Reducer Lubrication

16
Secondary Load Brake
The hoist is equipped with two brakes attached to the rear of the electric motor� The brake air gap and the brake rotor
thickness must be inspected periodically to ensure they remain within the allowable limits seen in the table below�
Follow these steps to inspect the brake dimensions�
Use the table below and the "Secondary Load Brake" image on the following page�
1� Locate the model of the motor and the brake on the hoist�
2. Consultthetablebelowtondthedimensionallimitsofthebrakethatyouareinspecting.
3� Remove the steel shroud covering the brakes�
4� Pull the rubber dust boot to the side to reveal the brake disk�
5� With the brake in the closed (engaged) position, measure the air gap between the armature and the magnet�
Compare this to the values in the table�
6� With the brake in the closed (engaged) position, measure the rotor thickness�
Compare this to the values in the table�
7� If the components are outside the allowable limits the hoist should be removed from service�
Contact the J�R� Clancy to arrange a repair�
Inspection and Maintenance Procedures (continued)
Do not expose the friction surfaces to any amount of
oil or grease. It may cause the brake to stop working.
!WARNING
Releasing both of the brakes at the
same time will cause the load to fall.
!WARNING
Brake Air Gap and Rotor Dimensional Limits
Hoist
Model
Hoist
Voltage
Motor
Model
Brake Model Nominal
Air Gap
Maximum
Air Gap
Nominal Rotor
Thickness
Minimum Rotor
Thickness
018-P0225F 480 90S/4 CUS Nord DBR12.5
(Precima FDD Size 10 w/ 7 springs)
0.3 mm
(0.012")
0.65 mm
(0.025")
8.5 mm
(0.335")
5.5 mm
(0.217")
018-P0225F 208 90S/4 CUS Nord DBR12.5
(Precima FDD Size 10 w/ 7 springs)
018-P0225V 480 90S/4 CUS Nord DBR12.5
(Precima FDD Size 10 w/ 7 springs)
018-P0225V 208 90S/4 CUS Nord DBR12.5
(Precima FDD Size 10 w/ 7 springs)
018-P0225F 400 90L/4 CUS Nord DBR25
(Precima FDD Size 13 w/ 5 springs)
0.3 mm
(0.012")
0.75 mm
(0.029")
10.3 mm
(0.406")
7.5 mm
(0.295")
018-P0225V 400 90L/4 CUS Nord DBR25
(Precima FDD Size 13 w/ 5 springs)
018-P1212V 400 100LA/4 CUS Nord DBR50
(Precima FDD Size 15 w/ 5 springs)
0.3 mm
(0.012")
0.75 mm
(0.029")
12.5 mm
(0.492")
9.5 mm
(0.374")
018-P1212V 208 100LA/4 CUS Nord DBR50
(Precima FDD Size 15 w/ 5 springs)
018-P1217V 480 112M/4 CUS Nord DBR50
(Precima FDD Size 15 w/ 7 springs)
018-P1812V 400 112M/4 CUS Nord DBR50
(Precima FDD Size 15 w/ 7 springs)
018-P1812V 480 112M/4 CUS Nord DBR50
(Precima FDD Size 15 w/ 7 springs)
018-P1217V 400 132S/4 CUS Nord DBR75
(Precima FDD Size 17 w/ 5 springs)
0.3 mm
(0.012")
0.75 mm
(0.029")
14.5 mm
(0.571")
11.5 mm
(0.452")
018-P1812V 208 132S/4 CUS Nord DBR75
(Precima FDD Size 17 w/ 5 springs)
018-P1217V 208 132S/4 CUS Nord DBR75
(Precima FDD Size 17 w/ 5 springs)
018-P1817V 400 132M/4 CUS Nord DBR125
(Precima FDD Size 20 w/ 4 springs)
0.4 mm
(0.156")
0.75 mm
(0.029")
16.0 mm
(0.630")
16.0 mm
(0.630")
018-P1817V 480 132M/4 CUS Nord DBR125
(Precima FDD Size 20 w/ 4 springs)
018-P1225V 480 132M/4 CUS Nord DBR125
(Precima FDD Size 20 w/ 4 springs)
018-P1225V 400 132M/4 CUS Nord DBR125
(Precima FDD Size 20 w/ 5 springs)

17
Inspection and Maintenance Procedures (continued)
Secondary Load Brake (continued)
Secondary Load Brake
Air Gaps
Brake
Rotor
Static
Disk
Rubber
Dust
Boot
Magnet
Armature
Rotor Distance

18
Inspection and Maintenance Procedures (continued)
Output Shaft Flange Bearing
1. Observetheoutputshaftangebearingwhilethemachineisoperating.Thebearingshouldoperatewithout
noise or vibration� See the "Hoist Motor and Motor Brakes" image on page 14�
2� Pump several shots of Castrol Pyroplex Red NLGI #2 EP High Temperature Grease into the Zerk grease
ttingonthebearing.Wipeawayanygreasethatappearsattheseals.ContactJ.R.Clancyifyoucannot
locateadealerwiththespeciedgreaseinyourarea.
Drive Shaft Bearing
1� The drive shaft bearing should operate without noise or vibration�
2� Locate the access holes in the aluminum spacer at the end of the drum and remove the rubber stoppers�
RotatethedrumuntiltheZerkttingfortheinternalbearingisvisiblethroughoneoftheaccessholes.
3. PumponeshotofCastrolPyroplexRedNLGI#2EPHighTemperatureGreaseintotheZerkttingonthe
bearing.Donotoverll.ContactJ.R.Clancyifyoucannotlocateadealerwiththespeciedgreaseinyour
area�
Cutaway View of the Aluminum Drum Spacer and Internal Bearing
Drive Shaft
Bearing
Zerk
Fitting
Access
Hole
Aluminum
Spacer
Access
Holes (2)
Controls Enclosure
1� Check that the power and controls plugs are latched into their receptacles�
2� Check for any missing fasteners in the enclosure�
3� Check to make sure that the strain relief clamps hold the power and control cables tightly in the plugs�
Electrocution hazard. Make sure power
is o before opening controls enclosure.
!DANGER

19
Inspection and Maintenance Procedures (continued)
Circuit Protection and Controls Electronics
A circuit breaker for the hoist assembly is mounted in the electrical raceway adjacent to the hoist's power plug�
The circuit breaker can be manually switched to the ON or OFF positions�
In the event of a fault condition the breaker may switch to a TRIPPED position midway between ON and OFF�
To reset the circuit breaker, move the switch to the OFF position and then back to the ON position� For all other
adjustments to the control electronics contact the J�R� Clancy factory�
Fixed Speed Machines
Fixed speed machines are controlled through the use of a 3-Form-X relay, commonly referred to as a
"3-phaseline-contactor",andtwo(2)additional3-Form-Xrelaysinterlockedandconguredasa3-phase
reversing starter inside the controls enclosure� A 3-phase thermal overload relay is connected to the output
of the line-contactor and interrupts the supply power if the hoist's motor draws excessive current�
In the event of thermal fault, the overload relay will automatically reset after a "cool-down" period� A thermal
fault can also be manually reset by pressing the "reset" button on the face of the overload relay� The dial of the
overload relay is set at the factory to match the motor's Full Load Amperage (FLA)�
Do not adjust this setting unless directed by a J�R� Clancy factory representative� For all other adjustments to
the control electronics contact the J�R� Clancy factory�
Variable Speed Machines
Variable speed machines are controlled by an electronic drive module as well as being protected by a circuit
breaker� In the event of an overload or over-current situation the sensors built into the drive module will trigger a
drive fault that will shut down the drive� A fault condition will be reported to the user at the console�
Location of Identication Label
Controls
Enclosure
Identication
Label
Electrocution hazard. Remove power source
before opening electrical enclosures.
!DANGER

20
Inspection and Maintenance Procedures (continued)
Limit Switch Settings
!WARNING
Machinery and loads can collide with surroundings if limit switches are incorrectly adjusted.
Operate machine at slow speed only when setting limits. Operator or observer must be in sight of
all obstacles in the path of machine or load. Do not operate over the heads of people.
Check the Soft Limits
The hoist has upper and lower limits that are set from within the control system software ("soft" limits)�
These limit the travel of the hoist to prevent damage to the machine and the surrounding structure, and to
prevent the load from hitting an obstruction and causing an unsafe condition�
1� Position the operator or an observer so that both ends of the cable drum can be seen�
See the "Drum Screw and Exposed Portion of Drive Shaft " image on page 13 and the "Limit Switches and
Striker Plate" image below�
2� Position the operator or an observer so that all parts of the lifted load can be seen�
3. Slowlyrunthehoistdownuntilitreachesitssoftlowerlimit,orapproachesanobstruction.Conrmthatthe
soft limit stops the hoist before the hoist reaches its hard lower limit� If the soft limit requires adjustment,
see the Control System Operations and Maintenance Manual�
4. Slowlyrunthehoistupuntilitreachesitssoftupperlimit,orapproachesanobstruction.Conrmthatthe
soft limit stops the hoist before the hoist reaches its hard upper limit (see below)� If the soft limit requires
adjustment, see the Control System Operations and Maintenance Manual�
Direct Struck "DOWN"
Limit Switches
Limit Switches and Striker Plate
Direct Struck "UP"
Limit Switches
Limit Striker
Plate