powerlift maintenance manual clancy_wenger/jr clancy_powerlift_m… · standard clamps are for beam...

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003-1005 rev 3: January 7, 2011


PowerLift® Maintenance Manual

IMPORTAT SAFETY IFORMATIO ............................................................................................................... 2

PRODUCT USE REQUIREMETS ......................................................................................................................... 3

REPLACEMET PARTS .......................................................................................................................................... 3

RECOMMEDED TOOLS ....................................................................................................................................... 4

ISPECTIO AD MAITEACE PROCEDURES ......................................................................................... 5

BEAM CLAMPS AND MACHINERY FRAME .................................................................................................................... 5

BLOCKS AND WIRE ROPE ............................................................................................................................................ 6

GUIDE ROLLERS ....................................................................................................................................................... 10

CABLE DRUM .......................................................................................................................................................... 12

MOTOR AND GEAR REDUCER ................................................................................................................................... 12

SECONDARY LOAD BRAKE - ................................................................................................................................... 15

MANUALLY RELEASING THE HOIST BRAKES .............................................................................................................. 17

OUTPUT SHAFT PILLOW BLOCK ............................................................................................................................... 18

DRIVE SHAFT BEARING ............................................................................................................................................ 18

CONTROLS ENCOSURE ............................................................................................................................................. 18

CIRCUIT PROTECTION AND CONTROLS ELECTRONICS .............................................................................................. 19

LIMIT SWITCH SETTINGS .......................................................................................................................................... 21

WARNING SIGNS AND OPERATIONAL INSTRUCTIONS ................................................................................................ 24

DECOMMISIOIG AD DISPOSAL ................................................................................................................. 25

HOW TO COTACT JR CLACY ........................................................................................................................ 25

POWERLIFT MAITEACE AD ISPECTIO LOG ................................................................................. 26

PowerLift Maintenance Manual PAGE 2



003-1005 rev 3: January 7, 2011

IMPORTANT SAFETY INFORMATION

• The procedures in this manual are for use by qualified personnel only. If you are not qualified, contact the company that installed your system or the JR Clancy factory to find the nearest service provider.

• The PowerLift Inspection Checklist must be completely filled out and a copy returned to JR Clancy as proof of initial and subsequent annual inspections. Proof of inspection may be required to activate and maintain the warranty period for this product.

• An Identification Label is attached to the controls enclosure on each unit and it 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.

WARNING! Improper installation or maintenance can cause the

machine to fail.

• Hoisting machines impose significant loads on the structure to which they are attached. You are responsible for verifying that an engineer or other qualified person has determined that this structure can withstand the loads.

• Equipment must be installed and maintained by qualified personnel.

• Annual inspection and maintenance of this product is required. Some applications mayrequire 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 Identification Label on the hoist.

• Do not exceed 500 lbs [228 kg] on any one wire rope.

• Do not lift or support people or animals.

• Powerlifts can weigh up to 800 lbs [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.

DANGER! Electrocution Hazard

• Remove power before opening electrical panels.

• Electrical equipment must be installed by qualified electricians.

WARNING! 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 inches (2.7m) vertically from the floor and less than 60 inches (1.5m) horizontally from a safety barrier must be fitted with machine covers. Guards must be in place during use.




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PRODUCT USE REQUIREMENTS • Installation of this equipment must comply with local building codes.

• Equipment must be installed according to manufacturer’s drawings.

• PowerLift hoists must be inspected by qualified personnel every year, or more frequently depending on use and 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.

• PowerLifts are designed for indoor use only in buildings with temperatures between 50º and 100º F (10º- 38ºC). Do not expose machines to rain or condensing moisture.

• The recommended working load and duty cycle of each machine is marked on the Identification Label on the machine. Do not exceed.

• The hoist machinery must be protected from oil, excessive dust and other contaminants.

• PowerLift machines are approximately 168 inches (430 cm) long, 11 inches (28 cm) wide, and 30 inches (79 cm) tall. Units weigh up to 800 lbs. (363 kg) each depending on the horsepower.

MAINTENANCE SCHEDULE

NOTICE: This machinery must be inspected and maintained annually by qualified personnel. Proof

of inspection is required to maintain warranty status.

Annual inspection and operator training is required to maintain the warranty period specified in your

information binder, and proof of annual inspection and training may be required to obtain warranty service.

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.

REPLACEMENT PARTS

Lubricants and other components that can be procured locally are fully specified in the appropriate section

of this manual. Use only the specified type and grade of materials. Contact your local JR Clancy dealer to

obtain any parts not listed in this document.




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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 Nutdriver 9/16”, 3/4” Open-Ended Box Wrenches 3/4”, 17mm Socket Wrenches Torque Wrench Wire Rope Termination Tools, as necessary Castrol Inc Pyroplex Red NLGI #2 High Temperature Grease Portable Grease Pump Feeler Gauge Set 5/32” Hex (Allen) Key (2) ea M10-1.5 x 70 mm hex cap screws




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INSPECTION AND MAINTENANCE PROCEDURES

MACHINE COVERS

1. Machines that have moving parts within reach of people must be fitted with covers. See the

requirements in the Safety Information section of this manual. Covers may also be necessary to

prevent contamination of the machinery from the operating environment. Install or replace covers if

required. Contact JR Clancy if covers cannot be located on site.

2. Make sure that all fasteners are in place on the covers. See Figure 1.

Figure 1: Machine covers and proper sequence for installation

BEAM CLAMPS AND MACHINERY FRAME

1. Make sure that two roll pins are in place on each end of the main beam. See Figure 2.

2. Standard clamps are for beam flanges up to 11” (279 mm) wide and 1” (25 mm) thick. Flanges

must be at least 4” (10 cm) wide and 1/4” (6 mm) thick. Confirm 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 if Figure 2.

1. Loosely install these 10 screws into the aluminum frame

2. Slide this cover over the screws until it is approx. 1/8” from the face of the brake

5. Install this screw last and then tighten all of the other screws

3. Tighten the 6 fasteners on the first cover segment

4. Slide this cover over the screws and overlapping the first cover segment.

1/2” standoff(Do not remove)




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5. Check to make sure there is no loose hardware or materials set on top of the Main Beam.

Figure 2: PowerLift Mounting Clamp

BLOCKS AND WIRE ROPE

1. Check the fleet angle on all sheaves and adjust to keep within 1.5 degrees. This is equivalent to 3”

(76 mm) deviation in 10 ft (3 m).

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 third groove as

marked on the block. See Figure 3.

WARNING! Keep body parts away from the machinery in motion.

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).

Threaded rod

Nut and Jam nut Clamp

Fixed Nut Turn to tighten the clamp

Loose Nut

Thrust Plate

Roll Pins

Supporting structure




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Figure 3: Detail of the multi-line beam mounted loft block

5. Observe the machine while stationary. Inspect the fleet angle of the cable with respect to the drum

grooves as seen in Figure 4. Adjust the head block only if required using the following procedure.

5.1 Loosen but do not remove the locking nut on the axial head block constraint. See Figure 5.

Hoist does not need to be unloaded as long as nuts remain fully engaged with the threaded fastener.

WARNING! Improper adjustment of the constraint bolt can result in failure. Nut must remain

fully threaded on the bolt at all times.

5.2. Adjust appropriate nut on axial head block constraint to correct the fleet angle according to Figure 4.

NOTICE: Adjustment is limited by clearance at head block bracket. Stepped pin must not

contact head block side plate. See Figure 6.

WARNING! Do not over-tighten the constraint bolt.

5.3 Tighten the locking nut to 10 ft-lbs (13.5 Nm).

5.4 Test the operation of the machine. Cables entering the drum should not rub on the drum wraps or skip drum grooves.

These lines pass over but do not turn around the sheave

Only this one line turns over the sheave

The label indicates that only the third groove can be used to turn the line

Tighten nuts to 18 ft-lbs




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Figure 4: Inspecting the fleet angle at the drum

Figure 5: Head block constraints and adjustment nuts

HEAD BLOCK TRANSVERSE CONSTRAINTS

HEAD BLOCK AXIAL CONSTRAINT

LOCKING NUT (TIGHTEN TO 10 FT-LBS)

ADJUSTING NUT




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Figure 6: Clearance at head block bracket

6. Make sure the wire rope is free of kinks, distortions and broken wires. PowerLift hoists are to be used with 3/16” diameter 7x19 Small Diameter Specialty Cord as defined by ASTM standard A1023.

WARNING! Do not use wire ropes of different dimensional or structural characteristics.

Replace wire ropes as necessary using the following procedure:

6.1 Move the load to a location where it can be secured using other rigging e. g. to another batten or to the building structure.

6.2 Rotate the drum so that the cable termination holes are visible.

WARNING! Unplug the power before working on the machinery.

6.3 Secure the load being held by the hoist and remove the damaged cable.

6.4 Reeve the end of the new cable through the loft blocks and to the PowerLift.

6.5 Reeve the cable through the PowerLift 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”.

6.6 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.

6.6 Insert the swaged stop into the keyhole in the drum. Make sure the cable lays properly into the grooves on the drum.

6.7 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.

6.8. 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.

Stepped Pin

Head block side plate

Clearance must be maintained




003-1005 rev 3: January 7, 2011

• 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. Visually 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 PowerLift lift lines.

GUIDE ROLLERS 1. Make sure that there is a roller on every cable as shown in Figure 7. Note the position of the rollers in Figure 9.

2. Make sure roller arms are seated in the frame extrusion as seen in Figure 8. 3. Make sure the rollers are aligned with the cable as seen in Figure 9a and 9b. 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.

Figure 7: Position of cable keeper rollers

Two element rollers (Long and short arms) Up to seven places

Head block on opposite side




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Figure 8: Position of long and short armed cable rollers

A. View from head block side B. View from opposite side

Figures 9a and 9b: Position of cable keeper rollers on the cable drum

Connecting spring

Short arm rollers on side opposite the head block

Long arm rollers on same side as the head block

Connecting spring

Arms hook into slots in aluminum cap

Cable roller guide wheel rests in groove next to cable

Foam rollers rest on cable wrapped on drum

Long arm roller on same side as head block

Short arm roller on opposite side from head block

3 standing wraps at all times




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CABLE DRUM

Inspection Procedure

1. Examine the Drum Screw as seen in Figure 10. If the grease is contaminated with debris or excessive dust, wipe all of the contaminated grease off. 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 Figure 10. If the grease is contaminated with debris or excessive dust, wipe all of the contaminated grease off. 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 film of Castrol Inc Pyroplex Red NLGI #2 EP High Temperature Grease. Contact JR Clancy if you cannot locate a dealer with the specified 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.

Figure 10: Drum Screw and exposed portion of Drive Shaft

MOTOR AND GEAR REDUCER

1. Observe the machinery while raising the load, the brake on the electric motor should engage and

stop the load before the secondary load brake engages. 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 brake should be serviced. Contact the JR Clancy factory.

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. Figure 13 shows the drain plug and fill levels for the machines based on

mounting position. 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. See Figure 12. (For

servomotors, the label is located on the back of the motor near the electrical junction box.) Note that

Drum screw must be clean and well lubricated

Exposed portion of drive shaft must be clean and well lubricated

NOTICE: Do not let end of drum hit end of

screw before the limit switches are set Limit Switches




003-1005 rev 3: January 7, 2011

bearings inside the electric motor are lifetime lubricated and sealed and do not require periodic

lubrication.

3. Inspect for any loose fasteners and retighten as necessary.

4. Use the chart in Figure 13 to locate the reducer breather valve and make sure that the protective

rubber band is removed and discarded. See Figure 11.

Figure 11: Reducer breather valve with protective band

Figure 12: Powerlift motor and secondary load brake

Reducer label

Electric Motor with motor brake

Gear Reducer

Output shaft pillow block

Secondary load brake

Brass breather valve Rubber protective band Remove after installation

Motor Mounting Bracket

Reducer label (on servomotors only)

Zerk grease fitting




003-1005 rev 3: January 7, 2011

Figure 13: Reducer Oil Levels

Mounting Position Lubrication Ports

Underhung Hoist

Reducer Position M3

Upright Hoist

Reducer Position M1

Wall M

ounte

d

Reducer

Positio

n M

2

Dimension d = 1 1/8” (28 mm)

for all models

For units mounted at angles between

horizontal and vertical, or for other

positions not shown on this chart. CONTACT J R CLANCY

FILL LEVEL

BREATHER VALVE

DRAIN PLUG




003-1005 rev 3: January 7, 2011

SECONDARY LOAD BRAKE

The PowerLift is equipped with two brakes: a primary motor brake and an electrically operated secondary load brake.

WARNING! The primary and secondary brakes must be properly adjusted or the load can fall if

the hoist loses power.

The secondary brake is adjusted at the JR Clancy factory, but the following procedure should be used to check the brake during inspection. See Figure 14.

Figure 14: Brake face and bolt locations

1. Locate the three locking nuts on the face of the brake. Confirm that all three nuts are in place.

2. Locate the manual release bolt holes in the face of the brake. Confirm that the release bolts have been removed. If the brake is to be manually released for testing or maintenance see the procedure below.

3. Slide the protective rubber boot back to expose the air gap between the brake magnet and the armature assembly. The edge of the paper disk will be visible. See Figures 15A and 15B.

4. Check the brake for rust, dust, oil and other contaminants. Also look for heat marks or abnormal wear that may indicate that brake is improperly calibrated. If any of these symptoms are present, contact JR Clancy.

5. Check the gap between the paper disk and magnet at at least three locations around the brake. This gap should be set to 0.9 mm (0.035 inches). A mechanic’s feeler gauge is recommended to inspect this gap.

Output shaft pillow block

Brake control cable

Aluminum Block

Manual Release Bolt(Must be removed)

Locking nuts

Manual Release Bolt (Must be removed)




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6. Adjust the nuts on the face of the brake as necessary to maintain the proper clearance. The nuts must remain fully threaded on the studs at all times.

7. Replace the rubber boot around the brake when adjustment is complete.

Figure 15A: Side view of brake with rubber boot

Motor Mounting Bracket

Gearbox

Brake Control Cable

Output Shaft Pillow Block

Protective Rubber Boot (Slide to left to expose gap between armature and magnet)

Locking Nuts

See detail below

Secondary Load Brake




003-1005 rev 3: January 7, 2011

Figure 15B: Detail view of brake air gap

MANUALLY RELEASING THE HOIST BRAKES

It is possible to manually release the hoist brakes for testing or maintenance.

WARNING! Releasing either brake can cause the load to fall. This procedure is for use by

qualified personnel only. Secure the load and/or keep the area below the hoist clear when

working on the hoist brakes.

DANGER! Releasing both brakes will cause the load to fall. Remove or secure the load on the

hoist before releasing both brakes.

To release the motor brake:

1. Locate the threaded manual brake release handle. It is clipped to the fins of the motor or screwed into the reducer adjacent to the encoder.

2. Locate the matching threaded socket in the fan shroud of the motor and screw in the release handle.

3. Pull the release handle towards the back of the motor shroud until resistance increases sharply and then slightly further to release the brake. Note that only after the resistance increases sharply will the brake be released. Take care to not bend the release handle.

4. The brake will reengage when the handle is released. Replace the brake handle in its storage position on the motor fins or gear case after work is complete.

To release the secondary brake

1. Locate the manual release bolt holes in the face of the brake. See Figure 14.

2. Insert but do not tighten an M10-1.5 x 70 mm hex bolt in each of the release bolt holes. Install them with the head of the bolt finger tight against the magnet housing.

3. Use a wrench to alternately and evenly tighten the two bolts about ½ turn at a time until the brake is released.

WARNING! The manual release bolts must be removed to restore function of the secondary

brake. Brake can be released for testing and maintenance only and must be reengaged prior to

the hoist being returned to service.

Magnet

Armature

Rubber boot (slide back for access)

Paper disk

Air gap




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4. Use a wrench to alternately and evenly loosen the two bolts until the brake is reengaged.

OUTPUT SHAFT PILLOW BLOCK

1. Observe the output shaft pillow block bearing while the machine is operating. The bearing should

operate without noise or vibration. See Figure 12.

2. Pump several shots of Castrol Inc Pyroplex Red NLGI #2 EP High Temperature Grease into the Zerk

grease fitting on the bearing. Wipe away any grease that appears at the seals. Contact JR Clancy if

you cannot locate a dealer with the specified grease in your area.

DRIVE SHAFT BEARING

1. The drive shaft bearing should operate without noise or vibration. See Figure 16.

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 fitting for the internal bearing is visible through one of the

access holes. See Figure 16.

3. Pump one shot of Castrol Inc Pyroplex Red NLGI #2 EP High Temperature Grease into the Zerk

fitting on the bearing. Do not overfill. Contact JR Clancy if you cannot locate a dealer with the

specified grease in your area.

4. Replace the rubber plugs into their holes. Be sure they fit snugly and will not fall out. If the plugs are

damaged or missing, please contact JR Clancy for replacements.

CONTROLS ENCOSURE

DANGER! Electrocution hazard. Make sure power is off before opening 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.

4. Make sure that any unused receptacles in the controls raceway are closed and latched. Raceways for

the SceneControl system will need a shunt plug in each unused receptacle.




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Figure 16: Cutaway view of the aluminum drum spacer and internal bearing

CIRCUIT PROTECTION AND CONTROLS ELECTRONICS

DANGER! Electrocution hazard. Remove power source before opening electrical

enclosures.

Fixed speed machines

Fixed speed machines are controlled through the use of a self-protected motor starter inside the controls enclosure. See Figure 17. This unit includes both overload sensors and a disconnect switch to shut off the motor power. The disconnect handle is turned to the “twelve o’clock” position to turn the power on, and to “nine o’clock” to turn the power off. This handle also functions as a fault indicator; when the sensors detect an overload, the power will automatically be disconnected and the handle will snap to the “ten-thirty” position. To reset a fault turn the disconnect handle to the “reset” position (seven o’clock) and then back to the “on” position. The dial of the overload sensor is set at the factory to match the motor’s Full Load Amperage (FLA). Do not adjust this setting unless directed by a JR Clancy factory representative. For all other adjustments to the control electronics contact the JR Clancy factory.

Access Hole

Aluminum Spacer

Zerk Fitting

Drive Shaft Bearing

Access Holes (2)




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Figure 17: Fixed Speed Starter Module

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 SceneControl console. The Fault Reset button on the main screen of the controller will reset the drive electronics.

The circuit breaker for the drive module is located either inside the drive enclosure or mounted into the electrical raceway adjacent to the power plug, depending on your installation. 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 JR Clancy factory.




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Figure 18: Location of Identification Label.

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 PowerLift 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 Figures 10 and 19.

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. Confirm that the soft limit stops the hoist before the hoist reaches its hard lower limit (see below). 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. Confirm 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.

Identification Label

Controls Enclosure




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CHECK THE HARD LIMITS

The PowerLift features adjustable switches that limit normal travel of the hoist in both the up and down directions. The machine also features redundant “overtravel” switches, but unlike some other machines these 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 will vary with the speed of the unit, but will be no more than 6 inches (15 cm). This is not adjustable in the field. 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 sufficient clearance from any obstruction. (See step 1 for clearance measurements.)

NOTICE: The hoist should never strike the hard limit switches during normal operation. The

limits set in the control system (“soft” limits) should always activate first. To check the hard

limits, a Maintenance Control Pendant should be used.

The limit switch indicator lights on the Maintenance Control Pendant should be used to

facilitate setting the limit switches.

Please contact JR Clancy to obtain a control pendant in order to check the hard limits. See the PowerLift Installation Manual for more information.

Limit switches must be set in the same way regardless of whether the hoist is controlled by a computerized control system or by push buttons.

WARNING! Cable must have at least three complete wraps around the drum at all times to avoid

failure of the termination.

1. Run the machine to its lower direct struck (“hard”) limit. (See Figure 19) For all PowerLift units, confirm

that the machine stops the load at least 6 inches (15 cm) from any obstruction.

WARNING! Load can hit surrounding structure and fall if clearance to obstruction is not

maintained.

2. If adjustment of the limit switches is required use the following procedure:

2.1 Position the operator or an observer so that the limit switches and both ends of the cable drum can be seen. See Figures 10 and 19.

2.2 Position the operator or an observer so that all parts of the lifted load can be seen.

2.3 Start with the batten at the lower end of travel.

NOTICE: Do not allow hoist drum to hit the machine frame. Observe during operation prior

to setting limit switches.

2.4 Drive the hoist upward a few feet, and then down again until the switch stops the machine or until the hoisted load approaches an obstruction.

NOTICE: For variable speed units striking the limit switch will actually cause the machine

to stop and then drive backwards by approximately 4 inches. The stop position is

considered to be where the load first stopped, before it drove backwards.

2.5 Observe the position of the load and the wraps remaining on the drum to decide if the limit switch stops the load in the desired position.

NOTICE: Carefully observe the movement of the limit switches while adjusting. Do not

drive limit switches into the machine frame or the drum limit striker plate.

2.6. If the switch requires adjustment, loosen the locking nut on the down limit adjustment bolt and use a hex (Allen) key to turn the end fitting to move the limit as indicated in Figure 20. Adjust the limit




003-1005 rev 3: January 7, 2011

switch until the switch activates 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 (see Figure 11). Tighten the locking nut when adjustment is complete.

2.7 Repeat steps 2.4, 2.5, and 2.6 until the lower limit switch is set in the desired position.

2.8 Raise the load slowly until it reaches its upper limit switch, or until the hoisted load approaches an obstruction.

2.9 Observe the position of the load to decide if the limit switch stops the load in the desired position. Remember that for variable speed units, striking the limit switch will actually cause the machine to stop and then drive backwards by approximately 4 inches. The stop position is considered to be where the load first stopped, before it drove backwards.

2.10 If the upper limit switch requires adjustment, loosen the locking nut and use a hex (Allen) key to turn the end fitting to move the limit as indicated in Figure 20. Adjust the limit switch until the switch activates against the striker plate. Tighten the locking nuts when adjustment is complete.

Figure 19: Limit Switches and Striker Plate

Direct Struck “DOWN” limit switches

Limit striker plate

Direct Struck “UP” limit switches




003-1005 rev 3: January 7, 2011

Figure 20: Limit switch adjustment fittings

2.11 Drive the hoist down a few feet, and then up again until the switch stops the machine.

2.12 Repeat steps 2.9, 2.10, and 2.11 until the upper limit switch is set in the desired position.

2.13 Retighten the locking nuts that hold the adjusting bolts on both the lower and upper limits.

2.14. Test the overtravel switches in both directions by manually triggering the switch and confirming 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.

WARNING SIGNS AND OPERATIONAL INSTRUCTIONS

In the event that operation, service, or training questions arise, the users must have contact information

for qualified service personnel readily available.

1. Make sure that the JR Clancy “Motorized Rigging” safety sign (Part # 002-WINSIGN) is placed in a

prominent location and that the service contact information is filled in.

2. Make sure that the capacity labels are in place on each batten, and that the labels match the

capacity of the machines to which they are attached.

3. Interview the user and make sure that they have access to the “Operation and Maintenance

Manual.” Also, a service log form is provided at the end of this manual. Locate this log and examine

it. The following information should be recorded for each occasion of service:

• Date of service

• The provider of the service, with contact information.

• The machinery, i.e channel number, on which the service was performed.

• The work or inspection that was performed.

NOTICE: Documentation of annual inspection is required to maintain the full warranty period of

the hoist and may need to be provided upon request to obtain warranty service.




003-1005 rev 3: January 7, 2011

SERVICE LIGHT A service indicator light has been provided on the equipment to remind the users of the annual inspection and service requirement. Contact the JR Clancy factory or an authorized dealer if the service light is on. After service is complete the light timer must be reset by an authorized JR Clancy dealer.

DECOMMISIONING AND DISPOSAL Remove machines if necessary using qualified personnel and safe rigging practices. Any modifications to the structure and wiring must be performed by qualified persons and conform to local codes. Do not defeat interlock switches or any other safety features of remaining machines or control system. Dispose of all materials according to local codes.

HOW TO CONTACT JR CLANCY Contact the factory at any time with questions and comments concerning this product:

JR Clancy Incorporated 7041 Interstate Island Road Syracuse, NY 13209 USA Telephone (315) 451-3440

www.jrclancy.com




003-1005 rev 3: January 7, 2011

POWERLIFT MAINTENANCE AND INSPECTION LOG

Use this log to keep track of required annual inspections and any service performed on your motorized rigging equipment. Keep this in a binder along with other service information such as inspection reports.

DATE SET # SERVICE PERFORMED SERVICE PROVIDER INITIALS




003-1005 rev 3: January 7, 2011

Attach Additional Pages As Necessary.

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