Mackworth TX440 Advanced PT Service Manual
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Mackworth TX440 Advanced PT Service Manual

Ceiling track hoist
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TX Advanced Ceiling Track Hoist
Service Manual
Doc No. 995674
Revision of document: A
Revision Date: 08/07/2021

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Summary of Contents for Mackworth TX440 Advanced PT

  • Page 1 TX Advanced Ceiling Track Hoist Service Manual Doc No. 995674 Revision of document: A Revision Date: 08/07/2021...

  • Page 2: Table Of Contents

    Contents Introduction ...................................... 3 – Safety Precautions ..................................4 Servicing ......................................5 Program Mode Instructions..............................9 Lift Tape Condition ................................12 Test Procedure ....................................13 Tools, Equipment and Lubricants Required for Servicing ........................ 14 Decommissioning .................................... 15 Hoist Removal ..................................15 Hoist Dismantling .................................

  • Page 3: Introduction

    1.0 Introduction This Manual will explain how to carry out interim servicing and parts replacement on the Mackworth TX Advanced Ceiling Track Hoist safely and effectively. This document is divided into sections to help a Service Engineer find the correct information. Each section will show in a step by step fashion the correct way to disassemble and assemble the Ceiling Track Hoist.

  • Page 4: Safety Precautions

    2.0 – Safety Precautions Read and understand this manual in its entirety before servicing the Mackworth TX Advanced Hoist. • Mackworth authorised personnel must complete the Full and Interim services of the TX Advanced Ceiling Track Hoist. • The Hoist must not be in use by the user during any form of servicing.

  • Page 5: Servicing

    3.0 Servicing To be completed by Approved Service Engineer Maintenance should be completed by an approved service engineer every 6 months to ensure the products required standard is maintained. The service history of the product should be documented each service. When Servicing the Ceiling Track Hoist, ensure to fill out the Service Log which is located in the back of the User Manual.
  • Page 6 Limit Switch: Fully lower the Lift Tape to reach maximum length, at this point the lower limit switch should be activated and stop the Hoist. The LCD should display the message: “Down Lim_Sw!” Fully raise the Lift Tape to reach minimum length, at this point the upper limit switch should be activated and stop the Hoist.
  • Page 7 Batteries: If the Hoist is having power issues or difficulties charging, the Battery voltage should be measured using a Voltmeter to determine the status of the Batteries. Test the batteries on the Hoist using the battery tester to see if they still hold charge properly, test the two batteries while running the Hoist to see if they equally draw charge.
  • Page 8 Slings: Inspect the applied sling thoroughly with regards to the following points: Any damage such as cuts, frays, tears, burns on the sling or sling straps Any sign of stitching failure, where the fabric is found to be stretching, tearing and coming undone Are the straps fully intact The labels and serial numbers should all be legible.

  • Page 9: Program Mode Instructions

    Program Mode Instructions Use the flow chart below to access and edit all settings within the Program Mode. Page 9 of 63...
  • Page 10 Page 10 of 63...
  • Page 11 Page 11 of 63...

  • Page 12: Lift Tape Condition

    Lift Tape Condition In this section the images below will show two types of lift tape condition, one in which the wear is minimal and therefore in an acceptable condition, whereas the other Lift Tape has a level of wear which is unacceptable and requires a change during the current service.

  • Page 13: Test Procedure

    4.0 Test Procedure Below is the full testing procedure required to complete an Annual Hoist Service. The SWL of either 200kg or 272kg (440lb / 600lb) is an essential load for the testing of the Hoist. A mode of transportation to transport the weights to the Hoist is required. The weights must be attached to the Hoist carry bar securely and follow the below procedure in order: 1.

  • Page 14: Tools, Equipment And Lubricants Required For Servicing

    5.0 Tools, Equipment and Lubricants Required for Servicing When carrying out work on the Mackworth TX Advanced Hoist, you will require the following: Tools Required 2mm Allen Key 2.5mm Allen Key 3mm Allen Key 4mm Ball Ended Allen Key 5mm Allen Key 8mm Spanner No.

  • Page 15: Decommissioning

    6.0 Decommissioning The following section will instruct on how to correctly decommission the TX Advanced Hoist at the end of use. This section is relevant to both the TX440 Advanced and TX600 Advanced. The product may be contaminated and has to be disinfected before decommissioning. See section ‘Cleaning’...

  • Page 16: Spare Parts List

    For the full list of Spare Parts available for this product. Please refer to the latest revision of the Spare Parts Manual. Document Number: 992674 The Spare Parts Manual can be located on the Mackworth Website: http://mackworthusa.com Page 16 of 63...

  • Page 17: Troubleshooting

    Servicing. If the fault is not found and/or the solutions do not correct the problem, contact your local Mackworth authorized dealer immediately. Hoist doesn’t turn on Operate the handset to determine if the Hoist powers up. If it does not – Follow the Troubleshooting guide below.

  • Page 18: Hoist Doesn't Charge

    5. Re-attach the Battery Leads as shown in section 9.3. 6. Remove the Battery Leads and Replace as shown in section 9.3 7. Replace the Fuse as shown in section 9.12 8. Replace the Limit Switch Block – See section 9.7 9.
  • Page 19 Hoist doesn’t charge – Constant Charge Do not operate the Hoist and allow the Hoist to charge at its current location. If the display does not show “charging” or the LED does not flash orange, follow the Troubleshooting Guide below. Troubleshooting Guide 1.

  • Page 20: Hoist Doesn't Lift - No Error Message

    Hoist doesn’t Lift – No Error Message Attempt to raise/lower Hoist with handset, the LCD Displays the message “up” “down”, but Hoist is not responding. Follow the Troubleshooting Guide below. Troubleshooting Guide 1. Check the Lift Motor Wires are connected properly between the Toggle Switch and Motor. 2.

  • Page 21: Hoist Doesn't Lift - No Lim_Sw

    3. Check for lift tape fraying/wear that may be jamming the gears within the Hoist. 4. Check Battery Voltage using Battery Tester as high current could be due to low battery. 5. Check PCB for any damage, e.g. Blown components. 6.

  • Page 22: Hoist E-Lower Cord Is Not Working

    2. Check the LCD Display or LED wiring for damage such as cuts or breaks. Ensure they are plugged in. 3. Inspect the PCB for any damage such as blown components. 4. Replace the Bottom Cover Assembly. 5. Replace the PCB. Action Guide 1.

  • Page 23: Troubleshooting - Hoist Safety Mechanisms

    6. Replace the PCB as the Air Switch could be damaged. Action Guide 1. Re-attach the Handset to the Air Grommet – See User Manual on Handset attachment. 2. Remove the Handset from the Hoist and Replace – See User Manual on Handset attachment. 3.

  • Page 24: Servicing - Removal And Replacement

    Hoist. The step by step process is to be followed in sequence to perform a successful service on the Hoist. Unless stated otherwise, all images refer to a Mackworth TX600 Advanced with a Standard Wheel Assembly (Track Type 1). Where necessary, additional images for Alternative Track Types have been included.
  • Page 25 Step 2 – Use a slotted screwdriver to remove the two brass screws. (Arrowed) Step 3 – Gently remove the cover away from the Hoist. Step 4 – Rotate the Hoist 180 degrees and gently position the Hoist in the below orientation. Be careful positioning the Hoist on the Lift Motor.
  • Page 26 Step 5 - Using a slotted screwdriver remove the two brass screws from the second cover. (Arrowed) Step 6 – Gently remove the cover away from the Hoist. Step 7 – (Quick Release Trolley System Hoists only) – While removing the Cover, ensure to disconnect the charging lead from the PCB.

  • Page 27: Pcb

    This section will instruct the correct procedure on how to remove and replace the PCB. 9.2.1 Powered Traverse PCB This section will instruct the correct procedure on how to remove and replace the Powered Traverse PCB, this procedure can also be used as guidance when servicing a Manual Traverse PCB.
  • Page 28 Step 4 – Remove the coloured air tubes (Grey and Green) by gently pulling on the air tubes individually until they release from their individual air switches on the PCB. Step 5 – Using a 2.5mm Allen key remove the three M3 screws. (arrowed) Step 6 –...
  • Page 29 Step 3 – Remove the remaining connectors in the numerical order labelled below. 1. Toggle switch 2. Limit switch 3. LCD/Display 4. LED 5. Traverse Motor 6. Charging Beak 7. Communications Port Step 4 – Remove the coloured air tubes (Grey, Green, Yellow, Blue, White and Black) by gently pulling on the air tubes individually until they release from their individual air switches on the PCB.

  • Page 30: Batteries

    Batteries This section will instruct the correct procedure on how to remove and replace the Batteries. Removal Step 1 – Remove external covers of the Hoist. (refer to section 9.1) Step 2 - Disconnect the power lead from PCB. (See section 9.2 PCB for reference) Step 3 –...

  • Page 31: Traverse Motor - Powered Traverse Hoist Only

    Traverse Motor – Powered Traverse Hoist Only In this section it will explain the correct procedure on removing and reinstalling the Traverse Motor for servicing procedures or replacement. Removal Step 1 – Remove external covers of the Hoist (refer to section 9.1) Step 2 –...

  • Page 32: Lift Motor

    Lift Motor This section will instruct the correct procedure on how to remove and replace the Lift Motor. Removal Step 1 – Remove external covers of the Hoist. (refer to section 9.1) Step 2 - Disconnect the power lead from PCB. (further information refer to section 9.2) Step 3 –...

  • Page 33: Qrs Hook

    Step 7- Remove the Motor, by pulling away from the chassis. CAUTION! Motor might be hot. Refitting / Replacement Step 8- Refitting is a reversal of the removal process noting the following point: A) Ensure the motor aligns with the motor mount tapped holes. B) Ensure the motor gear shaft lines up with the Oilite bush QRS Hook This section will instruct the correct procedure on how to remove and replace the QRS Hook.

  • Page 34: Bottom Cover

    B) Ensure the hook is attached to the lift tape in the below orientation. Bottom Cover This section will instruct the correct procedure on how to remove and replace the Bottom Cover. Removal Step 1 - Remove external covers of the Hoist. (refer to section 9.1) Step 2 –...
  • Page 35 Step 5 - Gently pull the bottom cover away from the chassis and feed the Lift Tape through to detach it from the unit. Refitting / Replacement Step 6 - Refitting is a reversal of the removal process noting the following point: A) Make sure the lift tape is fed through the slot in the correct direction B) Ensure the E-lower cord is pulled through its designated slot.

  • Page 36: Limit Switch

    Limit Switch This section will instruct the correct procedure on how to remove and replace the Limit Switch Block. Removal Step 1 - Remove external covers off the Hoist. (refer to section 9.1) Step 2 – Remove the PCB from the Hoist. (refer to section 9.2) Step 3 –...
  • Page 37 Step 10 – Once all four screws have been removed, slide your hand inside the Hoist and push the limit switch block upwards. Ensure not to trap the wires while removing the Limit Switch Block. Step 11 – While guiding the limit switch block out of the chassis, carefully guide the wiring loom out with the unit.

  • Page 38: Hub

    This section will instruct the correct procedure on how to remove and replace the Hub. Removal Step 1 - Remove external covers off the Hoist. (refer to section 9.1) Step 2 – Remove the PCB from the Hoist. (refer to section 9.2) Step 3 –...
  • Page 39 Step 11 – Using a 4mm Ball point Allen Key, remove the three M6 x 16 over speed screws. Step 12 – Support the Hub with your hand, while removing the strap pin. Step 13 – Slowly guide the Hub out of the chassis. (As shown below) Refitting / Replacement Step 14 - Refitting is a reversal of the removal process noting the following point: A) If replacing Hub, grease with Morris Grease –...

  • Page 40: Lift Tape

    Lift Tape This section will instruct the correct procedure on how to remove and replace the Lift Tape. Removal Step 1 - Remove external covers from the Hoist. (refer to section 9.1) Step 2 – Remove the PCB from the Hoist. (refer to section 9.2) Step 3 –...
  • Page 41 Step 9 – Slide the Strap Pin from the Chassis out until 85mm of Pin is showing. This will release the Lift Tape while securing the Hub. 85mm Step 10 - Gently pull the Lift Tape through the Limit Switch Block to release from the Hoist. Refitting / Replacement Step 11 - Refitting is a reversal of the removal process noting the following point: A) When reinserting the lift tape through the limit switch block make sure that the fold...

  • Page 42: Wheels

    C) When winding the lift tape back around the hub make sure to rotate the hub in a clockwise direction while looking at the Hoist in the direction shown in the image below. D) Use long noise pliers to reattach the 8mm E-Clip to the end of the strap pin. Wheels This section will explain the correct procedure on removing and reinstalling all wheel variants used with the Ceiling Track Hoist...
  • Page 43 Step 3 – From the front face of the Hoist, remove the Axel along with the other Wheels as shown. Refitting / Replacement Step 4 - Refitting is a reversal of the removal process noting the following points: A) If replacing with brand new wheels, the below image is an exploded diagram of how the Wheels are fitted together along the axel.
  • Page 44 9.11.2 QRT System Wheels Within this section it will explain the correct procedure on removing and reinstalling all wheel variants of the QRT System Hoists, this section will include Track Type 1, 3, 4 and 5. See Section 1 for guidance on the track type profiles.

  • Page 45: Charging Beak

    Charging Beak Within this section it will explain the correct procedure on removing and reinstalling all Charging Dock variants, Including Track Type 1, 2,3,4,5. See section 1 for guidance on the track type profiles. 9.12.1 Charging Beak – Standard (Track Type 1) Within this section it will explain the correct procedure on removing and reinstalling the Charging Beak for servicing procedures or replacement.
  • Page 46 Refitting / Replacement Step 7 - Refitting is a reversal of the removal process noting the following point: Three cable ties are required! – Re-secure the Wire with cable ties as instructed below: Insert the cable tie (100mm x 2.5mm) through the top hole in the Chassis plate and along the back of the red and black wires.
  • Page 47 9.12.2 Charging Beak – Track Type 2, 3, 4, 5 and Powered Auxiliary Within this section it will explain the correct procedure on removing and reinstalling the Charging Beak for servicing procedures or replacement. Removal Step 1 - Remove external covers off the Hoist. (refer to section 9.1) Step 2 –...
  • Page 48 9.12.3 QRT System Charging Beak Within this section it will explain the correct procedure on removing and reinstalling the QRT Systems Charging Beak for servicing procedures or replacement. Removal Step 1 – Disconnect the Charging Beak from the external cover plug in. Step 2 –...
  • Page 49 9.12.4 Constant Charge Within this section it will explain the correct procedure on removing and reinstalling the Constant Charge Charging Beak for servicing procedures or replacement. Removal Step 1 - Remove external covers off the Hoist. (Refer to section 9.1) Step 2 –...
  • Page 50 Step 7 – Remove the Pin and the Constant Charge Beak can be removed. Ensure not to lose the spring situated inside the beak. Refitting / Replacement Step 7 - Refitting is a reversal of the removal process noting the following point: A) While sliding the Constant Charge Beak into its position, ensure to fit the spring into the hole shown on the top face of the Chassis, with the beak securing it in place.
  • Page 51 Three cable ties are required! – Re-secure the Wire with cable ties as instructed below: A1) Insert the cable tie (100mm x 2.5mm) through the top hole in the Chassis plate and along the back of the red and black wires. A2) Fold the cable tie around the Black wire and pass the cable tie back through the hole and over the Red wire.

  • Page 52: Battery Lead Fuse

    – Battery Lead Fuse This section will instruct the correct procedure on how to remove and replace the Battery Lead Fuse. Removal Step 1 - Remove external covers off the Hoist (refer to section 9.1) Step 2- Disconnect the power lead from PCB. Step 3 –...

  • Page 53: Traverse Shaft And Idle Gear (Powered Models Only)

    Traverse Shaft and Idle Gear (Powered Models Only) Within this section it will explain the correct procedure on removing and reinstalling the Traverse shaft and Idle Gear for servicing procedures or replacement. Removal Step 1 - Remove external covers off the hoist (refer to section 9.1) Step 2 –...
  • Page 54 Refitting / Replacement Step 9 - Refitting is a reversal of the removal process noting the following point: A) While reinserting the Traverse Shaft, you must one by one, align the spacers and Idle Gear to allow the Traverse Shaft to pass through B) The LONGER Spacer (37.1mm –...

  • Page 55: Air Grommet

    Air Grommet This section will instruct the correct procedure on how to remove and replace the Air Grommet. Removal Step 1 - Remove external covers off the Hoist. (refer to section 9.1) Step 2 – Remove the Battery from the battery brackets. (refer to section (9.3) Step 3 –...

  • Page 56: Toggle Switch

    Step 8 - Refitting is a reversal of the removal process noting the following point: A) Ensure that when repositioning the Air Grommet, it is in the correct orientation as shown below B) Once the Air Tubes have been refitted, make sure to have pulled the tubes all the way through the Chassis.
  • Page 57 Step 8 – Using Snips, cut the cable ties to release the Toggle Switch wires, see image above for guidance on location. Step 9 - Using as small flat head screwdriver, detach the grommet (arrowed) from the chassis by forcing it through the hole. Step 10 –...

  • Page 58: E-Lower Cord

    A) Cable ties is required! – Reroute the Toggle Switch wires as shown in the image and cable ties into position, cut the surplus once secured E-Lower cord Within this section it will explain the correct procedure on removing and reinstalling the E- Lower Cord for servicing procedures or replacement.
  • Page 59 Step 8 – The E-Lower Cord can now be removed through the slit in the Chassis. Refitting / Replacement Step 9 - Refitting is a reversal of the removal process noting the following point: A) When inserting the E-Lower Cord through the Slit, ensure the labelled face is facing the Lift Motor.
  • Page 60 Refitting / Replacement Step 5 - Refitting is a reversal of the removal process noting the following point: A) Ensure when fitting the male and female parts together that the shim washers are still in place. B) The Female part of the Traverse Idle Gear must be on the same face as the PCB C) When securing the two gears together, do not overtighten.
  • Page 61 Step 6 – Using a 2mm Allen Key, Remove the M3x12 Screws and M3 Nyloc Nuts to release the Charging Beak. Refitting / Replacement Step 7 - Refitting is a reversal of the removal process noting the following point: Three cable ties are required! – Re-secure the Wire with cable ties as instructed below: Insert the cable tie (100mm x 2.5mm) through the top hole in the Chassis plate and along the back of the red and black wires.
  • Page 62 Tie the cable tie retaining the Black wire and Red wire. A4) Repeat this process for the second cable tie. For the bottom hole a cable tie 100mm x 2.5mm can be passed through the hole then around the Black and Red wires and tied off. Finally, snip of the surplus cable once secured.
  • Page 63 Disclaimer While every effort has been made to ensure the accuracy of information contained in this service manual, no liability can be accepted by Mackworth for any errors or omissions. Mackworth operates a policy of continuous improvement. Specifications and other data are subject to change without notice.

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