JRClancy PowerLift User manual

Important User Information � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
General �����������������������������������������2
Manufacturer �������������������������������������2
Intended Use�������������������������������������2
Warranty ����������������������������������������2
Safety Precautions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
Installation Procedure � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
1� Unload the Packaged Machinery �������������������4
2� Assemble the Beam Clamps onto the Machine ��������5
3� Hoist the Machinery into Position �������������������6
4� Attach the Machine to the Mounting Structure ���������7
5� Install the Cables onto the Drum �������������������8
6� Install the Cables into the Head and Loft Blocks �������9
7� Terminate the Cables at the Batten or Lifted Load ������10
8� Check the Position of the Cable Keeper Rollers �������11
9� Activate the Power and Control to the Hoist �����������13
10� Check the Basic Machine Functions����������������14
11� Set the Limit Switches���������������������������16
12� Check the Fleet Angle of the Cables to the Drum �����19
13� Check Drum Screw Lubrication �������������������21
14� Check Drum Alignment ��������������������������21
15� Check Reducer Lubrication and Vent ���������������21
16� Program the User Interface� ����������������������23
17� Install the Machine Covers �����������������������23
18� Install Safety Signs and Capacity Labels ������������24
19� Install the Motor Brake Handles �������������������24
20� Train The Operators ����������������������������24
21� Inspect the Completed Installation �����������������24
Installation Instructions
PowerLift®and PowerLite™Hoists
©Wenger Corporation 2023 Printed in USA 2023-12 Part #003-3100-02
Wenger Corporation - Syracuse Operations, 7041 Interstate Island Road, Syracuse, New York 13209
Questions? Call�����USA: [phone] • Worldwide: [phone] • jrclancy�com
Contents
Note: Please read and understand these instructions before starting the assembly or installation�
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� Do not install in locations that
prohibit access to the machinery 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
• 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�
• TherecommendedworkingloadanddutycycleofeachmachineismarkedontheIdenticationLabel
on the controls enclosure� Do not exceed�
• The hoist machinery must be protected from oil, dust and other contaminants�
• Installation of PowerLift and PowerLite Hoists must be coordinated with the location of loft blocks as well as
 electricalpowerandcontroldevices.Installationmustbedesignedbyaqualiedperson.
• PowerLift and PowerLite Hoists are pre-programmed at the factory with set and channel numbers�
These numbers are marked on the machine and marked at the power and control receptacles�
Machines must be installed so that the channel and set numbers on the hoist match the channel and set
numbers on the receptacle� These are also shown on the installation drawings�
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.
See Operation and Maintenance Manuals for user serviceable parts and procedures�
• 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 safe installation and use�
A competent person must be present and available
whenever any operation or maintenance procedures
are performed on any system.
!WARNING
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" (2692 mm)
vertically from the oor and less than 60" (1524 mm)
horizontally from a safety barrier must be tted with
machine covers.
!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

4
Installation Procedure
Followthesestepscarefullytohelpprovideasafeande󰀩cientinstallationofthehoists.
1. Unload the Packaged Machinery
The hoists are shipped in crates or on pallets� While packaged for shipment you must:
• Protect crates and pallets from rain and humidity�
• Keep equipment upright and prevent from tipping�
• Follow instructions and use safe material handling practices� The center of gravity and lifting points are
marked on the crates and pallets�
• Store packaged machinery in clean and dry locations that are protected from impact or other abuse�
Improper installation or maintenance can cause the load to fall.
• Hoisting machines impose signicant loads on the structure to which they are attached.
The installer is responsible for verifying that an engineer or other qualied person has determined that
this structure can withstand the loads.
• Equipment must be installed by qualied personnel.
• Do not substitute or modify components provided with this equipment.
• Do not exceed the capacity of the hoist. It varies by model and is marked plainly on the Identication Label.
• Do not exceed 500 lb (228 kg) on any one wire rope.
• The hoists are not designed to lift or support people or animals.
• Hoists weigh up to 800 lb (363 kg) each, plus the weight of any packaging.
Use appropriate handling equipment and safe work practices.
!WARNING
Before you start, locate the installation drawing that was prepared by J.R. Clancy for your specic
application. The information on that drawing is required to complete this installation.
NOTICE
The hoists are pre-programmed at the factory with a channel and a set number.
Before removing the machinery from its packing, look at the channel and set numbers on the machine,
the installation drawings, and the electrical receptacles. They must all match.
NOTICE

5
Installation Procedure (continued)
2. Assemble the Beam Clamps onto the Machine
The hoist beam clamps are typically shipped apart from the hoist� Follow these steps to install beam clamps
onto the machines�
1� Remove the packaging to expose the top of the machine� Locate the clamps and hardware shipped with
the hoist�
2. Refertotheinstallationdrawing.Locatethemountingdetailforthehoistandndthedimensionsfromtheend
of the hoist frame to the center of each clamp� See the illustration "Beam Clamp Mounting Positions" below�
3� Mark these locations on the hoist beam and install the correct length of clamp on each end so that the
threaded rod hangs over the end of the beam� See the illustration "Beam Clamp Assembly" below�
4. Slidetheclampassemblyovertopangeofthehoistbeamuntilthethrustplateisagainsttheendofthe
beam� See the illustration "Beam Clamp Assembly" below�
5. Drivethe(2)3/8"x1"rollpinsprovidedwiththeclampsintothetwoholesattheendofthetopangeof
the beam�
Motor
End
Beam Clamp Mounting Positions
Other
End
Beam Clamp Assembly
Thrust
Plate
3/8" x 1"
Roll Pin
Clamp
Assembly
Hoist
Beam
Slide top ange
of beam into
this slot
Locate these
dimensions

6
3. Hoist the Machinery into Position
Hoists weigh up to 800 lb (363 kg)� During and after removal from the packaging, the machine is designed to be
handled in several ways� See the illustration "Hoist Handling Features" below�
• Before you lift the machine out of its packaging be sure to identify the channel number marked on the top
and on the control cabinet of the machine� It is essential that you install the units with the correct numbering
as shown on the installation drawings�
• Thelast1.5"(38mm)ofthelowerangeofthemainbeamareusedasbearingpointsontowhichthe
machine can be set down�
• Thereisapatternof3/8"boltholesonboththeupperandlowerangeofthemainbeamateachend.
These can be used to attach steel legs that allow the unit to be free standing� A typical design for these legs
is available from J�R� Clancy by request� Note that the upper holes are used to insert roll pins that prevent
thebeamclampsfromslidingo󰀨ofthebeam.Thesepinsmaybedrivenoutofthebeamiftemporarylegs
are employed� They should be reinstalled at the time the machine is to be hoisted into position�
• Beamclampscanbeattachedontheupperangeofthemainbeamforhoisting.Notethattheshapeofthe
main beam will prevent many commercially available beam clamps from working� Clamps that are designed
totspecicallytothismachineareavailablefromJ.R.Clancy.
• 7/8" holes through the web of the main beam are provided at each end� These can be used to lift the unit
vertically�
• Themoste󰀩cientwaytoinstallthehoistunitistohoistitoutofitscrateorpalletanddirectlytothepoint
where it is to be installed� The center of gravity is marked on the top of the main beam for use while
hoisting�
• Often in smaller theaters the roof structure is placed directly above the beams onto which the hoist is to
be mounted, making it very hard to rig chain hoists or other standard rigging equipment to lift the units into
place.J.R.Clancyhascreatedasetofriggingtoolsspecicallyforthisapplication.
Please contact us to make arrangements to obtain them�
Make sure roll pins are installed in the top ange of the beam before
hoisting the hoist or the beam clamps can slide o and fall.
!WARNING
Installation Procedure (continued)
Bolt Pattern
Both Flanges,
Both Ends
Hoist Handling Features
Top Flange of
Main Beam
Hoisting Hole
Both Ends
Bearing
Point
Bearing
Point
The cover of the hoist is not structural. Do not set the machine down on the cover, or wrap slings
around it to lift the unit. Covers may be removed after unit is unpacked and replaced after the machine
is installed.
NOTICE

7
Installation Procedure (continued)
4. Attach the Machine to the Mounting Structure
• Thehoisthasbeenprovidedtoyouwithbeamclampsthataredesignedtotbeamangewidthsof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�
• Thethreadedrodsthatsecuretheclampstothemainbeamhavebeenmadetoaspeciclengthtosuitthe
needs of you particular installation� See the installation drawings�
• The threaded rods are turned to open and close the clamps� The rods can be turned either by turning the
xednut(weldedtothethreadedrodadjacenttothebeamclamp),orbyusingtheclamproddriver
(a long nut with a set screw in one end shipped on the end of one of the clamp rods)� The clamp rod
driver should be removed after installation�
Use the following procedure to secure the hoist to the building structure�
1� Before hoisting the unit out of the shipping cradle, mark out the position of the roof beams on to the top of
thehoistframe.Turnthethreadedrodstoopenthebeamclampswideenoughtoreceivetheangeofthe
roof beam� Make sure that the ends of the threaded rod are long enough to pass through the thrust plate
and both a nut and jam nut�
2. Opentheclampswideenoughtopasstheangeofthemountingbeams,andlifttheunituntilthetopofthe
main beam contacts the underside of the mounting beam�
3� Make sure that the pin of the loose clamp nut engages the slot in the beam clamp to prevent the loose nut
from rotating� See the illustration "Hoist Mounting Clamp" below�
4� Turn the threaded rod to close the beam clamps onto the roof beam� Tighten the rods to approximately
50 ft-lb (67�8 Nm)� Note that some bending of the threaded rod will be observed after tightening�
5� Once the clamps are tightened onto the mounting steel, tighten the nuts and jam nuts at the thrust plate�
Make sure that both thrust plate nuts are properly tightened at both ends of the main beam�
Thrust
Plate
Hoist Mounting Clamp
Clamp Rod
Driver
Threaded
Rod
Jam
Nut
Fixed
Nut
Nut
Beam
Clamp
Nut
Supporting
Structure

8
Do not use wire ropes of dierent
dimensional or structural characteristics.
!WARNING
Installation Procedure (continued)
5. Install the Cables onto the Drum
The hoists are typically provided with cables already terminated at the drum and with only the three standing
("dead") wraps wound onto the drum� The hoists are designed for use with a 3/16" diameter 7x19 small diameter
specialtycordasdenedbyASTMStandardA1023.Ifalineisdamaged,orneedstobeinstalledforsomeother
reason, the following procedure should be used�
1� Remove the machine cover to expose the entire drum assembly�
2� Rotate the drum so that the cable termination holes are visible�
3� Reeve the end of the cable from the loft blocks through the hoist head block, making sure that the cable
rests on the sheave and not on the head block spacer bolts�
4� Wrap the cable around the drum enough times to match the number of wraps on the other lines of the hoist�
Note that a minimum of three standing (dead) wraps must be maintained on the drum when the machine is
at the lowest limit of travel�
5� Swage a Nicopress stop onto the end� Inspect the swage using the manufacturer's recommended gauge�
The end of the cable must protrude from the compressed sleeve, but by no more than 1/16" (1�5 mm)�
6� Insert the swaged stop into the keyhole in the drum� Make sure the cable lays properly into the grooves on
the drum�
Unplug the power before working on the machinery.
!WARNING

9
Installation Procedure (continued)
6. Install the Cables into the Head and Loft Blocks
1� The hoists are typically provided with cables already reeved through the integral head blocks and beam
mounted loft blocks (if provided)� See the illustration "Typical Arrangement of Blocks" below�
2. Awidevarietyofblockscanbeusedinconjunctionwiththehoisttocreateriggingsystemsspecictoyour
application� Follow the bill of materials and color-coded reeving plan shown on the manufacturer's drawings
toinstallthecomponentsspeciedforyourapplication.Useonlyblocksthataregroovedfor
3/16"wireropeandofsu󰀩cientloadrating.
3� As the wire rope is reeved into the hoist and blocks, the following rules must be obeyed:
• Cables must not rub the side plates of any block or any other stationary object�
• Cables should not touch other cables�
• Cables must lay neatly in the groove of the sheave and be underneath all block spacers�
• Innocasemaytheeetangle(theangleofthecablewithrespecttotheplaneofthepitchcircleofthe
sheave)exceed1.5degrees.Minimizetheeetangleofalllinesforthebestperformance.
• Only one lift line can wrap around the multi-line beam mounted loft block sheave by 90 degrees and
drop as a lift line� That lift line must be in the indicated groove� No other cables may wrap the block at
any time� See the illustration "Detail of the Seven Line Beam Mounted Loft Block" below and follow the
inspection label on the block�
4� Cables are coiled by machine at J�R� Clancy and the coils are attached to the hoist prior to shipment�
Carefully unroll the coils or otherwise take precautions to prevent imparting a twist to the cable as it is
unwound and reeved�
Typical Arrangement of Blocks
Detail of the Multi-Line Beam Mounted Loft Block
Multi-Line Beam Mounted
Loft Block (Optional)
Head Block
Single Line Beam Mounted
Loft Block (Optional)
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
To loft
block

10
Installation Procedure (continued)
7. Terminate the Cables at the Batten or Lifted Load
1� Prior to terminating the lift lines, inspect the reeving and check the following:
• The cable should be fully paid out from the machine and there must be at least three standing (dead)
wraps remaining on the drum�
• Cables must lie smoothly in the grooves of the drum�
• Double check that the cables are reeved properly through the blocks�
2� Cut the lines to length and terminate at the batten�
• Install a trim chain, turnbuckle, or other 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�
• Terminations must be made with swaged sleeves� Sleeves are required�
The J.R. Clancy 8" x 3/16" groove molded nylon loft block can be distinguished from the 1/4" version
by looking between the side plates to the outside diameter of the sheave. On the 3/16" grooved blocks
there is a line molded in on both sides of the cable groove. On the 1/4" sheave, this area is smooth.
See the illustration "Identifying Grooves on J.R. Clancy 3/16" Groove Mounted Nylon Sheaves" below.
NOTICE
Identifying
Grooves
Identifying Grooves on J.R. Clancy 3/16" Groove Molded Nylon Sheaves
3/16" Cable
Groove
1/4" Cable
Groove
Smooth

11
Installation Procedure (continued)
8. Check the Position of the Cable Keeper Rollers
• The hoists are typically provided with cable keeper rollers already installed�
• Cable keeper rollers may be removed as necessary to aid the installation process�
• Cable keeper rollers need to be inspected after the cables are reeved and before energizing the machine�
Use the following procedure to replace and/or inspect the proper placement of the cable rollers�
1� Attach one end of the spring to a long-arm roller guide and the other end to a short-arm roller guide�
The roller portion of the guides should face away from each other with the hooks at the top pointing towards
each other� See the illustration "Position of Long and Short Armed Cable Rollers" below�
2� Start with the roller set closest to the motor and brake� Place the hooks of the long-arm roller guide in the
slots in the cap and the roller against the drum� Slide the short-arm roller guide over the drum and gently
pull tension in the spring until the short roller guide hooks can be placed into the slots on the opposite side
of the cap� See the illustration "Position of Cable Keeper Rollers on the Cable Drum" on page 12�
Unplug the power before working on the machinery.
!WARNING
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
Installation Procedure (continued)
8. Check the Position of the Cable Keeper Rollers (continued)
3� Pull gently on the long arm where it hooks into the cap slot and slide the roller left or right until the cable
rollerguidewheelrestsinthegroovenexttowherethecableleadso󰀨ofthedrum.
See the illustration "A� View from Head Block Side" below�
4� Then pull gently on the short arm where it hooks into the cap slot and slide the roller over until the roller
rests as shown in the illustration "B� View from Opposite Side"�
5� Repeat Steps 1 thru 4 for each of the cables on the machine� Rollers are not necessary where no cables
are present�
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

13
Machinery and loads can collide with surroundings when operated before limit switches are set.
Operate machine at slow speed only. Operator or observer must be in sight of all obstacles in the path
of the machine or load. Do not operate over the heads of people.
!WARNING
Installation Procedure (continued)
9. Activate the Power and Control to the Hoist
• Each hoist features separate electrical connections for power and control�
See the illustration "Power and Control Connections" on page 14� Each of these must be plugged into
hard-wired receptacles that match the particular motor voltage and control scheme of your system�
Three phase motor power must be available in order to install these machines�
• Eachhoisthasbeenmanufacturedtofunctionwithaspecictypeofcontrolsystem.
 Ifyoursystemfeaturesanetworkedautomationcontrolsystem,youwillneedtorstruneachofthe
machines individually using a maintenance control pendant to adjust and verify the installation of the
machinery and the setting of the limit switches� Once that is complete the computerized control system
can be activated�
• If your system features pushbutton control instead of computer control, a maintenance control pendant
may be ordered as an option, but is not strictly necessary�
• If your system features pushbutton control with a SureTarget system, the control system incorporates soft
limits� During initial operation, the soft limits may have to be bypassed to allow the winch to move through
its full range� Operating the hoist with the Maintenance Control pendant will bypass the soft limits�
It is also possible to bypass the soft limits while operating the hoist from the SureTarget hoist's control panel�
Refer to the SureTarget Operation Manual for information on bypassing the soft limits from the hoist control
panel� The SureTarget Operation Manual also contains information needed to set the soft limits, once the
hoist's hard limits have been set�
• The speed of the hoist is not adjustable while using the Maintenance Control Pendant� It is set to
 approximately15%ofthefullspeedofvariablespeedmachinesandtothefullspeedofthexedspeed
machines�
• A commissioning or "bypass" power supply is only required if the Vantis, SceneControl, or SureTarget
system is not supplying control power to the machine� This power supply requires 120-240VAC, 50 or 60Hz,
single phase power and supplies the low voltage DC power needed by the hoist's internal control circuitry�
• A temporary three phase power cord is available for order� If the permanent hoist power and control
wire-ways are not yet installed, the cord can be used to run power from a suitable three phase source to
the hoists� The power cord, commissioning power supply, and the Maintenance Control Pendant can be
used together to temporarily activate the hoists and set limit switches before the permanent wiring is
complete�

14
Installation Procedure (continued)
9. Activate the Power and Control to the Hoist (continued)
Power and Control Connections
Controls
Enclosure
Maintenance
Control Pendant
Receptacle
Industrial
Ethernet
Control
Cable 4-Pin Power
Cable
ID
Label

15
Installation Procedure (continued)
9. Activate the Power and Control to the Hoist (continued)
Follow the procedure below to connect the hoist to power and control:
1� Prior to connecting the hoist power the electrician should double check that the supply voltage matches the
motorvoltageindicatedontheIdenticationLabel.Checkvoltageacrossallthreephases.
2� Plug the hoist power cable into the matching power receptacle on the electrical raceway or wall-mounted
plug box, depending on your installation� The power receptacle should be marked with the hoist channel
number.ConsulttheInstallationDrawingstoconrmpowerreceptaclelocations.Gentlytwisttheplug
clockwise to lock it into place�
3� If you are NOT using the Maintenance Control Pendant, plug the control cable into the control receptacle
that is marked with the same channel number as the hoist control cabinet and skip to Section 10�
4� If you ARE using the Maintenance Control Pendant, follow these steps:
a� Make sure that the hoist control cable is connected either to the permanent control system receptacle
and the permanent control system is both operational and on, or to the commissioning power supply�
b� Plug the control cable of the Maintenance Control Pendant into the receptacle on the hoist control
enclosure�
c� Allow approximately 10 seconds for the electronics in the hoist to boot before attempting to operate the
hoist� Moving the hoist before the internal processor is running may corrupt the unit's position data�
10. Check the Basic Machine Functions
Followtheprocedurebelowtoconrmthatthehoistisoperatingcorrectly.
1� Position the operator or an observer so they can see both ends of the cable drum�
2� "Jog" UP or FWD by pressing the UP or FWD buttons just long enough to see the direction that the drum is
rotating.Conrmthattheloadmovesupward.
3� "Jog" DOWN or REV by pressing the DOWN or REV buttons just long enough to see the direction that the
drumisrotating.Conrmthattheloadmovesdownward.
4� If the load moves down when the UP button is pressed take the following steps:
a. ExaminetheIdenticationLabelofthehoist.
b. Ifthemachineisaxedspeedunit,anelectricianmustswaptwolegsofthethreephasepowerfeedto
the wireway�
c� If the machine is a variable speed unit, contact the J�R� Clancy factory for assistance�
Machinery and loads can collide with surroundings when operated before limit switches are set.
Operate machine at slow speed only. Operator or observer must be in sight of all obstacles in the path
of the machine or load. Do not operate over the heads of people.
!WARNING
Do not modify the wiring of the hoist or power cord.
NOTICE

16
Installation Procedure (continued)
11. Set the Limit Switches
• The hoist features adjustable switches that limit the normal travel of the hoist in both the up and down
directions� The machine also features redundant "overtravel" switches, but unlike some other J�R� Clancy
hoist products the overtravel switches are rigidly linked to the normal end of travel switches, so they are
automatically set when the normal limits are set� The distance between the normal stopping position and the
overtravelstoppingpositionisnotadjustableintheeld.Inordertoleaveenoughroomforanemergency
stop of the lifted load at full speed, the switches must be set so that striking the normal, hard limit will stop
theloadwithsu󰀩cientclearancefromanyobstruction.(SeeStep3forclearancemeasurements.)
• Limit switches must be set in the same way regardless of whether the hoist will be controlled by a
computerized control system or by push buttons�
• Limit switches must be properly set by the installer before the computerized controller can be activated�
Follow the procedure below to set the hard-wired limit switches�
1� Position the operator or an observer so that the limit switches and both ends of the cable drum can be seen�
See the illustration "Drum Screw and Exposed Portion of Drive Shaft" on page 21�
2� Position the operator or an observer so that all parts of the lifted load can be seen�
The limit switch indicator lights on the Maintenance Control Pendant (see Section 9) should be used to
facilitate setting the limit switches.
NOTICE
Cables must have at least three complete wraps around the drum at all times to avoid failure of the
termination.
!WARNING
Do not allow hoist drum to hit the tail stock. Observe during operation prior to setting limit switches.
See the illustration "Do Not Allow the Hoist Drum to Hit the Tail Stock" below.
NOTICE
Machinery and loads can collide with surroundings when operated before limit switches are set.
Operate machine at slow speed only. Operator or observer must be in sight of all obstacles in the path
of the machine or load. Do not operate over the heads of people.
!WARNING
Do Not Allow the Hoist Drum to Hit the Tail Stock
Hoist
Drum
Tail
Stock

17
Installation Procedure (continued)
11. Set the Limit Switches (continued)
3� Start with the batten at the desired lower limit of travel� For all hoists, the hard limit switch should stop the
batten no less than 6" (154 mm) from any obstruction�
4. Conrmthatthehoisthasatleastthree(3)standing"dead"wrapsonthedrumatalltimes.
5. Loosenthelockingnutonthedownlimitadjustmentboltanduseahex(Allen)keytoturntheendttingto
move the limit as indicated in the illustration "Limit Switch Adjustment Fittings on page 18"� Move the limit
switch until the switch arm is activated against the striker plate� There is a soft audible "click" when the
switch is activated� When using the Maintenance Control Pendant, the Lower Limit Indicator will also light
up when the switch is activated (refer to the Maintenance Control Pendant Manual)� Tighten the locking nut
when adjustment is complete�
6. Drivethehoistupwardafewfeet,andthendownagainuntiltheswitchstopsthemachine.Conrmthatthe
hoisted load stops at the desired position�
Carefully observe the movement of the limit switches while adjusting. Do not drive limit switch arms
into the machine frame or the drum limit striker plate.
NOTICE
For variable speed units, striking a limit switch will actually cause the machine to stop and then drive
backwards by approximately 4" (102 mm). The stop position is considered to be where the load rst
stopped, before it drove backwards. See the illustration "Limit Switches and Striker Plate" below.
NOTICE
Direct Struck "DOWN"
Limit Switches
Limit Switches and Striker Plate
Direct Struck "UP"
Limit Switches
Limit Striker
Plate
Load can hit surrounding structure and potentially fall if clearance to obstruction is not maintained.
!WARNING

18
Installation Procedure (continued)
11. Set the Limit Switches (continued)
7� If the switch requires further adjustment, repeat Steps 4 through 6 until the lower limit switch is set in the
desired position�
8� Raise the load slowly and then stop it at 6" (152 mm) from any obstruction above the load, as indicated in
Step 3�
9� While directly observing the striker plate and limit switch, loosen the locking nut and move the UP limit
switch until the switch activates against the striker plate� See the illustration "Limit Switches and Striker
Plate" on page 17� There is a soft audible "click" when the switch is activated� When using the
Maintenance Control Pendant, the Upper Limit Indicator will also light up when the switch is activated�
Tighten the locking nut when adjustment is complete�
10� Drive the hoist down a few feet, and then up again until the switch stops the machine� Recall that for
variable speed units, striking a limit switch will actually cause the machine to stop and then drive backwards
by approximately 4" (102 mm)�
11� Observe the position of the load and decide if the limit switch stops the load in the desired position�
Thestoppositionisconsideredtobewheretheloadrststopped,beforeitdrovebackwards.
12� If the switch requires further adjustment, repeat Steps 8 though 11 until the upper limit switch is set in the
desired position�
13� Retighten the locking nuts that hold the adjusting bolts on both the lower and upper limits�
14. Testtheovertravelswitchesinbothdirectionsbymanuallytriggeringtheswitchandconrmingthatthe
motor stops� Note that when an overtravel switch is activated, the machinery cannot be moved again until
the switch is no longer pressed, or the overtravel bypass switch in the control cabinet is activated�
Limit Switch Adjustment Fittings
Specied clearance to structure must be maintained or the load can fall. See above.
!WARNING
UP LIMIT
Down
Down
DOWN LIMIT
LOCKING NUTS
• Loosen to adjust
• Tighten when complete
Locking nuts must be tightened when adjustment is complete

19
Installation Procedure (continued)
12. Check the Fleet Angle of the Cables to the Drum
• Theeetangleofthedrumhasbeengivenaninitialadjustmentatthefactory,butitmustbeveriedonce
installed�
Usethefollowingproceduretoinspectandadjusttheheadblockeetangle.
1� Observe the angle of the drum grooves and determine if the cable is parallel to the drum grooves�
Seetheillustration"InspectingtheFleetAngleattheDrum"below.Iftheeetangleiscorrect,skipto
Section 13� If adjustment is required, proceed to Step 2�
2� Loosen but do not remove the locking nut on the axial head block constraint� See the illustration "Head
Block Constraints and Adjustment Nuts" below� The hoist does not need to be unloaded as long as the nuts
remain fully engaged with the threaded fastener�
Inspecting the Fleet Angle at the Drum
Improper adjustment of the constraint bolt can result in failure. The adjusting nut must remain fully
threaded on the bolt at all times.
!WARNING
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

20
Installation Procedure (continued)
12. Check the Fleet Angle of the Cables to the Drum (continued)
3. Adjustappropriatenutonaxialheadblockconstrainttocorrecttheeetangleaccordingtotheillustration
"Inspecting the Fleet Angle at the Drum" on page 19�
4� Tighten the locking nut to 10 ft-lb (13�5 Nm)�
5� Test the operation of the machine� Cables entering the drum should not rub on the drum wraps or skip drum
grooves�
Adjustment is limited by clearance at head block bracket. Stepped pin must not contact head block
side plate. See the illustration "Clearance at the Head Block Bracket" below.
NOTICE
Head block
side plate
Clearance at Head Block Bracket
Clearance must
be maintained
Stepped
Pin
Do not over-tighten the locking nut on
the constraint bolt.
!WARNING