Power Lift Maintenance Manual

Design, Manufacture and Installation of Theatrical Equipment Worldwide
PowerLift® Maintenance Manual

IMPORTA T SAFETY I FORMATIO ...............................................................................................................2
PRODUCT USE REQUIREME TS .........................................................................................................................3
REPLACEME T PARTS ..........................................................................................................................................3
RECOMME DED TOOLS .......................................................................................................................................4
I SPECTIO A D MAI TE A CE 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
DECOMMISIO I G A D DISPOSAL .................................................................................................................25
HOW TO CO TACT JR CLA CY........................................................................................................................25
POWERLIFT MAI TE A CE A D I SPECTIO LOG.................................................................................26

(315) 451-3440 Fax (315) 451-1766 www.jrclancy.com
003-1005 rev 3: January 7, 2011
PowerLift Maintenance Manual PAGE 2
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 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 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.
1/2” standoff
(Do not
remove)
1. Loosely install these

10 screws into the
aluminum frame
2. Slide this cover over the
screws until it is approx. 1/8”
4. Slide this cover over the from the face of the brake
screws and overlapping the
first cover segment. 3. Tighten the 6 fasteners on
the first cover segment
5. Install this screw last and
then tighten all of the other
screws
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.

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5. Check to make sure there is no loose hardware or materials set on top of the Main Beam.
Roll Pins
Thrust Plate Supporting
structure
Nut and Jam nut Clamp
Threaded rod
Fixed Nut
Turn to tighten the clamp
Loose Nut
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).

003-1005 rev 3: January 7, 2011
Tighten nuts to
18 ft-lbs
These lines pass over but do

not turn around the sheave
Only this one line turns over

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

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Figure 4: Inspecting the fleet angle at the drum
ADJUSTING NUT
LOCKING NUT (TIGHTEN TO 10 FT-LBS)
HEAD BLOCK AXIAL CONSTRAINT
HEAD BLOCK TRANSVERSE CONSTRAINTS
Figure 5: Head block constraints and adjustment nuts

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Stepped Pin
Head block
side plate
Clearance must be
maintained
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.

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• 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.
Head block on opposite side
Two element rollers

(Long and short arms)
Up to seven places
Figure 7: Position of cable keeper rollers

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Short arm rollers on

side opposite the head
block Arms hook into
slots in aluminum
cap
Connecting spring
Long arm rollers on

same side as the head
block
Figure 8: Position of long and short armed cable rollers
Connecting spring
Long arm roller Short arm roller

on same side as on opposite side
head block from head block
Foam rollers rest on

cable wrapped on
Cable roller guide drum
wheel rests in groove
next to cable
3 standing wraps
at all times
A. View from head block side B. View from opposite side
Figures 9a and 9b: Position of cable keeper rollers on the cable drum

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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.
NOTICE: Do not let end of drum hit end of Limit Switches

screw before the limit switches are set
Drum screw must be

clean and well Exposed portion of drive shaft must
lubricated be clean and well lubricated
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

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.
Rubber protective band Brass breather valve

Remove after installation
Figure 11: Reducer breather valve with protective band
Motor Mounting
Bracket
Gear Reducer
Reducer label
Electric Motor
with motor brake
Output shaft pillow

block
Secondary Zerk grease fitting

load brake
Reducer label (on

servomotors only) Figure 12: Powerlift motor and secondary load brake

003-1005 rev 3: January 7, 2011
Mounting Position Lubrication Ports
Underhung Hoist
Reducer Position M3
Upright Hoist
Reducer Position M1
Reducer Position M2
Wall Mounted
Dimension d = 1 1/8” (28 mm)

for all models
For units mounted at angles between
horizontal and vertical, or for other CONTACT J R CLANCY
positions not shown on this chart.
FILL LEVEL BREATHER VALVE DRAIN PLUG
Figure 13: Reducer Oil Levels

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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.
Aluminum
Block
Locking nuts
Manual Release Bolt Manual Release Bolt

(Must be removed) (Must be removed)
Output shaft
pillow block
Brake control
cable
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.

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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.
Protective Rubber Boot

(Slide to left to expose gap
between armature and magnet)
Secondary Load Brake
Motor Mounting Output Shaft

Bracket Pillow Block
Gearbox
Locking Nuts
Brake Control Cable
See detail below
Figure 15A: Side view of brake with rubber boot

003-1005 rev 3: January 7, 2011
Armature
Paper disk
Magnet
Rubber boot (slide

back for access)
Air gap
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.

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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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Drive Shaft
Bearing
Access Holes (2)
Aluminum Spacer
Access Hole
Zerk Fitting
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.

003-1005 rev 3: January 7, 2011
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.

003-1005 rev 3: January 7, 2011
Identification Label
Controls Enclosure
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.

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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.
Direct Struck “DOWN” limit switches
Limit striker plate
Direct Struck “UP” limit switches
Figure 19: Limit Switches and Striker Plate

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.

003-1005 rev 3: January 7, 2011

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