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Contents
Important User Information � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
General � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
Manufacturer � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
Product Use Requirements � � � � � � � � � � � � � � � � � � � � � � � � � � 2
Warranty � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
Safety Precautions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
Important Safety Information � � � � � � � � � � � � � � � � � � � � � � � � � 3
Maintenance Schedule � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Replacement Parts � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Recommended Tools � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Inspection and Maintenance Procedures � � � � � � � � � � � � � � � � � � � 5
Machine Covers � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
Beam Clamps and Machinery Frame � � � � � � � � � � � � � � � � � � 6
Visit the Hoists web page at jrclancy.com for more information.
Note: Please read and understand these instructions before starting any procedures�
Note: If you need additional information, contact Wenger Corporation using the information below�
©Wenger Corporation 2023
Wenger Corporation - Syracuse Operations, 7041 Interstate Island Road, Syracuse, New York 13209
Questions? Call�����USA: (800) 836-1885 • Worldwide: +1-315-451-3440 • jrclancy�com
PowerLift
Printed in USA 2023-12
Maintenance Manual
and PowerLite
®
Blocks and Wire Rope� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Guide Rollers� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 11
Cable Drum (Inspection Procedure) � � � � � � � � � � � � � � � � � � � 13
Motor and Gear Reducer � � � � � � � � � � � � � � � � � � � � � � � � � � � 14
Secondary Load Brake � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 16
Output Shaft Flange Bearing� � � � � � � � � � � � � � � � � � � � � � � � � 18
Drive Shaft Bearing � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 18
Controls Enclosure � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 18
Circuit Protection and Controls Electronics � � � � � � � � � � � � � � 19
Limit Switch Settings � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20
Warning Signs and Operational Instructions � � � � � � � � � � � � � 23
Decommissioning and Disposal � � � � � � � � � � � � � � � � � � � � � � � � � � 23
Hoist Maintenance and Inspection Log � � � � � � � � � � � � � � � � � � � � � 24
Hoists
™
Part #003-1005-04
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Table of Contents
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Summary of Contents for JRClancy PowerLift
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Page 1: Table Of Contents
Hoist Maintenance and Inspection Log � � � � � � � � � � � � � � � � � � � � � 24 Visit the Hoists web page at jrclancy.com for more information. Note: Please read and understand these instructions before starting any procedures�... -
Page 2: Important User Information
Do not install these machines in locations that prohibit access to the machinery or controls or prevents removal of any machine covers� • PowerLift and PowerLite Hoists are designed for indoor use only in buildings with temperatures between 50º and 100º F (10º- 38º C)� •... -
Page 3: Safety Precautions
Safety Precautions Throughout this document you may find cautions and warnings which are defined 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�... -
Page 4: Maintenance Schedule
Maintenance Schedule Annual inspection and operator training is required� Certain applications may demand more frequent inspections and maintenance� It is the responsibility of the user to monitor the machinery and adjust the maintenance schedule accordingly� Be aware of government regulations concerning the inspection of hoisting equipment�... -
Page 5: Inspection And Maintenance Procedures
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� Install or replace covers if required� Contact J�R� Clancy if covers cannot be located on site� 2� Make sure that all fasteners are in place on the covers� 3�... -
Page 6: Beam Clamps And Machinery Frame
Inspection and Maintenance Procedures (continued) Beam Clamps and Machinery Frame 1� Make sure that two roll pins are in place on each end of the main beam� 2. Standard clamps are for beam flanges 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. 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�... -
Page 7: Blocks And Wire Rope
Inspection and Maintenance Procedures (continued) 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' (3048 mm)� 2� Check the machine mounted loft blocks, if provided� Only one line is allowed to wrap more than 20 degrees around these sheaves� On the multi-line block that groove must be the fourth groove as marked on the block�... - Page 8 Inspection and Maintenance Procedures (continued) Blocks and Wire Rope (continued) 5. Observe the machine while stationary. Inspect the fleet angle of the cable with respect to the drum grooves as seen below� Adjust the head block only if required using the following procedure� Cable Climbs Out Of Cable is Parallel Cable Rubs Against Drum Groove With Drum Grooves Wraps On Drum Incorrect: Correct...
- Page 9 Inspection and Maintenance Procedures (continued) Blocks and Wire Rope (continued) b. Adjust appropriate nut on axial head block constraint to correct the fleet angle according to the "Inspecting the Fleet Angle at the Drum" image on the previous page� Tighten the locking nut to 10 ft-lbs (13�5 Nm)� Test the operation of the machine� Cables entering the drum should not rub on the drum wraps or skip drum grooves�...
- Page 10 Inspection and Maintenance Procedures (continued) Blocks and Wire Rope (continued) 6� Make sure the wire rope is free of kinks, distortions and broken wires� The hoists are to be used with 3/16" diameter 7x19 Small Diameter Specialty Cord as defined by ASTM standard A1023. WARNING Do not use wire ropes of different dimensional or structural characteristics.
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Page 11: Guide Rollers
Inspection and Maintenance Procedures (continued) Guide Rollers 1� Make sure that there is a roller on every cable� Note the position of the rollers in the "Position of Cable Keeper Rollers on the Cable Drum" image on the following page� Head Block on Opposite Side Two Element Rollers... - Page 12 Inspection and Maintenance Procedures (continued) 3� Make sure the rollers are aligned with the cable� Long arm roller Short arm roller on same side as on opposite side head block from head block Connecting Spring Cable roller guide Foam rollers rest on wheel rests in cable wrapped on 3 standing wraps...
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Page 13: Cable Drum (Inspection Procedure)
Inspection and Maintenance Procedures (continued) Cable Drum (Inspection Procedure) 1� Examine the drum screw� If the grease is contaminated with debris or excessive dust, wipe all of the contaminated grease 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� 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�... -
Page 14: Motor And Gear Reducer
Inspection and Maintenance Procedures (continued) Motor and Gear Reducer 1� Observe the machinery while raising the load� The load should stop quickly and without any back-winding� If the load backwinds, or if the load brake is engaged under these circumstances, the electric motor should be serviced�... - Page 15 Inspection and Maintenance Procedures (continued) Motor and Gear Reducer (continued) Dimension “d” SK3282 = 2-1/2” SK4282 = 3” Vent Oil Level Oil Drain Reducer Lubrication...
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Page 16: Secondary Load Brake
Inspection and Maintenance Procedures (continued) Secondary Load Brake The hoist is equipped with two brakes attached to the rear of the electric motor� The brake air gap and the brake rotor thickness must be inspected periodically to ensure they remain within the allowable limits seen in the table below� WARNING WARNING Do not expose the friction surfaces to any amount of... - Page 17 Inspection and Maintenance Procedures (continued) Secondary Load Brake (continued) Rotor Distance Static Disk Air Gaps Armature Magnet Brake Rotor Rubber Dust Boot Secondary Load Brake...
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Page 18: Output Shaft Flange Bearing
Inspection and Maintenance Procedures (continued) Output Shaft Flange Bearing 1. Observe the output shaft flange bearing while the machine is operating. The bearing should operate without noise or vibration� See the "Hoist Motor and Motor Brakes" image on page 14� 2� Pump several shots of Castrol Pyroplex Red NLGI #2 EP High Temperature Grease into the Zerk grease fitting on the bearing. Wipe away any grease that appears at the seals. Contact J.R. Clancy if you cannot locate a dealer with the specified grease in your area. -
Page 19: Circuit Protection And Controls Electronics
Inspection and Maintenance Procedures (continued) Circuit Protection and Controls Electronics DANGER Electrocution hazard. Remove power source before opening electrical enclosures. A circuit breaker for the hoist assembly is mounted in the electrical raceway adjacent to the hoist's power plug� The circuit breaker can be manually switched to the ON or OFF positions� In the event of a fault condition the breaker may switch to a TRIPPED position midway between ON and OFF�... -
Page 20: Limit Switch Settings
Inspection and Maintenance Procedures (continued) Limit Switch Settings WARNING Machinery and loads can collide with surroundings if limit switches are incorrectly adjusted. Operate machine at slow speed only when setting limits. Operator or observer must be in sight of all obstacles in the path of machine or load. Do not operate over the heads of people. Check the Soft Limits The hoist has upper and lower limits that are set from within the control system software ("soft"... - Page 21 The limit switch indicator lights on the Maintenance Control Pendant should be used to facilitate setting the limit switches. Please contact J�R� Clancy to obtain a control pendant in order to check the hard limits� See the PowerLift and PowerLight Hoist Installation Manual for more information�...
- Page 22 Inspection and Maintenance Procedures (continued) Limit Switch Settings (continued) Check the Hard Limits (continued) d� 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"...
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Page 23: Warning Signs And Operational Instructions
Inspection and Maintenance Procedures (continued) 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 J�R� Clancy "Motorized Rigging" safety sign (Part # 002-WINSIGN) is placed in a prominent location and that the service contact information is filled in. -
Page 24: Hoist Maintenance And Inspection Log
Hoist 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...
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