Mackworth TX440 Advanced PT User manual

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

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Contents
1.0 Introduction ......................................................................................................................................................................................3
2.0 –Safety Precautions..........................................................................................................................................................................4
3.0 Servicing............................................................................................................................................................................................5
Program Mode Instructions....................................................................................................................................................9
Lift Tape Condition ...............................................................................................................................................................12
4.0 Test Procedure................................................................................................................................................................................13
5.0 Tools, Equipment and Lubricants Required for Servicing................................................................................................................14
6.0 Decommissioning............................................................................................................................................................................15
Hoist Removal ......................................................................................................................................................................15
Hoist Dismantling .................................................................................................................................................................15
Hoist Disposal.......................................................................................................................................................................15
7.0 Spare Parts List................................................................................................................................................................................16
8.0 Troubleshooting..............................................................................................................................................................................17
Hoist doesn’t turn on ...........................................................................................................................................................17
Hoist doesn’t charge.............................................................................................................................................................18
Hoist doesn’t Lift – No Error Message..................................................................................................................................20
Hoist doesn’t Lift – Up Inhibit! .............................................................................................................................................20
Hoist doesn’t Lift – High Current ..........................................................................................................................................20
Hoist doesn’t Lift – No lim_sw!.............................................................................................................................................21
Hoist is functioning but LCD and/or LED is inactive..............................................................................................................21
Hoist E-Lower Cord is not working .......................................................................................................................................22
Hoist has Power but does not respond to Handset commands............................................................................................22
Troubleshooting –Hoist Safety Mechanisms .......................................................................................................................23
9.0 Servicing –Removal and Replacement............................................................................................................................................24
External Covers.....................................................................................................................................................................24
PCB.......................................................................................................................................................................................27
Batteries...............................................................................................................................................................................30
Traverse Motor –Powered Traverse Hoist Only...................................................................................................................31
Lift Motor .............................................................................................................................................................................32
QRS Hook .............................................................................................................................................................................33
Bottom Cover .......................................................................................................................................................................34
Limit Switch..........................................................................................................................................................................36
Hub.......................................................................................................................................................................................38
Lift Tape................................................................................................................................................................................40
Wheels .................................................................................................................................................................................42
Traverse Shaft and Idle Gear (Powered Models Only)..........................................................................................................53
Charging Beak.......................................................................................................................................................................45
–Battery Lead Fuse ..............................................................................................................................................................52
Air Grommet ........................................................................................................................................................................55
Toggle switch........................................................................................................................................................................56
E-Lower cord ........................................................................................................................................................................58

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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. The aim of the Manual is to advise
and assist you, so that you can provide a successful service for the end user.
The Mackworth TX Advanced is available in different configerations dependent on track profile. The
track profiles are shown below:
When Servicing the TX Hoist, one of the above track profiles should match.
The list below includes all types of TX that are covered by this Service Manual and which track type
they are suitable for.
TX400 Advanced Hoist Type
Track Type
TX600 Advanced Hoist Type
Track Type
TX440 Advanced PT –122617
Type 1
TX600 Advanced PT –122622
Type 1
TX440 Advanced PT –122656
Type 3
TX600 Advanced PT –122666
Type 3
TX440 Advanced PT –122659
Type 4
TX600 Advanced PT –122669
Type 4
TX440 Advanced PT –122662
Type 5
TX600 Advanced PT –122672
Type 5
TX440 Advanced QRT –122678
Type 1
TX600 Advanced QRT –122679
Type 1
TX440 Advanced QRT –122688
Type 3
TX600 Advanced QRT –122689
Type 3
TX440 Advanced QRT –122693
Type 4
TX600 Advanced QRT –122694
Type 4
TX440 Advanced QRT –122698
Type 5
TX600 Advanced QRT –122699
Type 5
TX440 Advanced RTC –122703
Type 1
TX600 Advanced RTC –122704
Type 1
TX440 Advanced RTC –122708
Type 3
TX600 Advanced RTC –122709
Type 3
TX440 Advanced RTC –122713
Type 4
TX600 Advanced RTC –122714
Type 4
TX440 Advanced RTC –122718
Type 5
TX600 Advanced RTC –122719
Type 5
TX440 Advanced MTCC –122616
Type 1
TX600 Advanced MTCC –122621
Type 1
TX440 Advanced MTCC –122655
Type 2
TX600 Advanced MTCC –122665
Type 2
TX440 Advanced MTCC –122658
Type 3
TX600 Advanced MTCC –122668
Type 3
TX440 Advanced MTCC –122661
Type 4
TX600 Advanced MTCC –122671
Type 4
TX440 Advanced MTCC –122664
Type 5
TX600 Advanced MTCC –122674
Type 5
TX440 Advanced PTCC –122619
Type 1
TX600 Advanced PTCC –122624
Type 1
TX440 Advanced PTCC –122657
Type 3
TX600 Advanced PTCC –122667
Type 3
TX440 Advanced PTCC –122660
Type 4
TX600 Advanced PTCC –122670
Type 4
TX440 Advanced PTCC –122663
Type 5
TX600 Advanced PTCC –122673
Type 5
TX440 Advanced MTPA –122615
Type 1
TX600 Advanced MTPA –122620
Type 1
TX440 Advanced PTPA –122618
Type 1
TX440 Advanced PTPA –122623
Type 1
Type 1
Type 2
Type 3
Type 4
Type 5

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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.
•The Hoist must be turned OFF during any servicing that requires the external covers of the
Hoist to be removed, or any dismantling of standard parts.
•Always ensure suitable clearance to remove the Hoist from the ceiling track.
•Ensure that the all servicing procedures are followed correctly as instructed in this manual.
•All listed tools and equipment stated in this manual must be used to safely service this Hoist.
•Ensure you have assessed all risks for your environment and any persons within that
environment before commencing work.
•Ensure you have all PPE available to carry out the work before commencing.

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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. When doing so, ensure the Serial Number of the Product and the User Manual
match up. Each Ceiling Track Hoist has its designated User Manual which is supplied to the User
during commissioning.
Component
Service/Inspection required
Generic:
Visual inspection of the externals of the Ceiling Track Hoist. Significant
damage that may affect the function of the Hoist along with a clear
safety hazard is unacceptable.
Check the Labelling on the Hoist to ensure they are all still legible, this
includes the Serial Number and other important markings.
Clean the Hoist at the end of each service. See User Manual for
cleaning details.
Check all main nuts and bolts, screws and fixing to see if they are
loose, if so tighten accordingly.
Lift Motor:
Inspect the components for damage that may affect the function and
safety of the product.
Listen for any unusual sounds when operating the Motor, this should
be done loaded and unloaded.
Fully Lift and Lower the Hoist to ensure that the Motor is performing
as intended. The lifting and lowering speed should be fairly consistent
throughout the motion of travel.
Ensure the Manual Emergency Lowering Device is performing.
Hub and Gearing:
Ensure that the Hub gearing is in good condition, excess wear should
be cleaning and an inspection on the condition must be conducted to
ensure the gearings are in a safe condition until the next service.
The Hub should be re-greased during service.
Ensure that the meshing of the Hub and Motor gearing is smooth.
Test the function of the Over-Speed Cam. Using a small Allen Key, place
it through the slot in the Chassis and test the functionality of the Cam
by pushing it outward. The Cam should automatically spring back to
position once the force has been removed.
Lift Tape:
Inspect the full length of the Lift Tape for any damage such as fraying.
See section 3.2 below as a reference for unacceptable wear.
There must be no signs of failure to the stitching of the Lift Tape, this
is most noticeable at the lowered where the Carry Bar is attached.
Toggle Switch:
Ensure that the Emergency Stop can be activated by pulling the E-
Lower Cord down one step. The operation should be smooth and can
be reversed when pressed back to the ON position.
Ensure that the emergency lower is functioning when activated. When
released it must become jammed in the E-Lower position.

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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. The LCD
should display the message: “Up Lim_Sw!”
Lower the Lift Tape without any load (do not remove the carry bar),
the Lift Tape should reach the bottom limit without any issues. If the
Hoist performs a stop/start motion, the limit switch may be damaged.
Remove the Carry Bar, the Limit Switch should display “Down
Lim_Sw!”
Carry Bar:
Inspect the Carry Bar for damage, this includes deformation, cracking
or large dents that may affect its function or safety.
Ensure that the Carry Bar Spring Clips remain functional.
No sharp edges shall be found on the Carry Bar as this has the potential
to damage the Slings.
Ensure that the Carry Bar is fitted to the QRS Hook correctly. Refer to
the User Manual for correct attachment.
Handset:
Inspect the components for damage that may affect the function and
safety of the product.
Verify that all the Handset controls are functioning.
Ensure that the Handset is connected to the Hoist correctly and that
the connections are secure.
PCB and electrics:
Inspect the PCB for any electrical burns.
Ensure that all the wires are connected to the PCB correctly, as well
any other wire connections.
Inspect all wires for any damage.
Ensure that the Air Tubes are connected to the PCB and Air Grommet
properly, as well as being fitted to the correct air switches. Ensure that
there are no cuts in the Air Tubes.
LED Indicator:
Ensure that the LED is functioning correctly. See the Display message
table in the User Manual to confirm.
Ensure that the LED is not cracked or damaged.
LCD Display:
Ensure that the LCD is functioning correctly. See the Display message
table in the User Manual to confirm.
Ensure that the LCD Display is not cracked or damaged. The display text
should be legible.
Using the Display Screen and Handset, enter the program mode to
view the Hoist data, such as total lifts. The relevant information should
be filled into the service log.
Enter the program mode to ensure that the pre-set amps have not
been altered. Or edit the amps when required.
Enter the program mode to reset the preventative maintenance. For
guidance using the program mode, see section 3.1.
Charging:
Check that the Charging beak is able to dock into the charging dock
smoothly without excess force.
Ensure the Charging is active when the Hoist is docked into the
charging dock. The Hoist LED will flash orange along with the display
stating it is “charging”, or it will display “charged” which will result in a
LED displaying Green.
Ensure that there are no exposed wires from the charging dock or port.

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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.
Check for any damage or leaks on the Batteries.
Wheels:
Examine the products Wheels for signs of damage or wear, ensure they
run freely and are not cracked.
Ensure the product is able to traverse freely with ease.
Powered Traversing:
Ensure that the Hoist is able to Power Traverse along the Track
smoothly without issues, such as stop/starting.
Ensure that the Powered Traverse is able to dock into the Charging
Dock correctly.
Ensure that the direction of Powered Traversing corresponds
correctly with the directional arrows on the Bottom Cover.
Communications Port:
Ensure that the Communications Port is not damaged, such as cracks
or burns.
Ensure that the Communications Port is functional with the given
accessory.
Return to Charge:
Ensure that the function of the return to charge is functional when
operated.
Ensure the RTC docking is successful and charging occurs.
Quick Release System:
Ensure that the QRS attachment to the Trolley is safe and as
intended. See User Manual for correct attachment procedure.
Inspect the traversing of the QRS Trolley, ensure the traversing is
smooth.
Constant Charge:
Ensure that the Constant Charge Beak is in contact with the Ceiling
Track Charging Strips.
Inspect the Beak for damage that may affect its function or safety.
Ceiling Track:
Perform a quick inspection on the Ceiling Track to ensure that the
Hoist is safe for use on the Ceiling Track.
Assess all track fixings to ensure they are safe for use until the next
service.
Ensure the joints between the two track sections (if any) have no gap
between them and that they are smooth and level. If there is a rough
transition, use a small file to blend the two surfaces for smooth
transition.
Ensure that the Installation of brackets are correct and fitted properly,
as well as the correct amount of brackets have been installed. If
necessary, tighten the bracket screws with a 3mm Allen Key.
Ensure that the Bolt Ends Stops have been installed in the track for
safety. Tighten the bolts if necessary. If non-existent, see Installation
manual on how to install. The end stop is a safety component that
ensure the Hoist is confined to the track.
If the track is up against the wall, ensure that a track bolt has been
fitted correctly. If non-existent, see Installation manual on how to
install.
Clean the internal of the Ceiling Track if there is any debris that could
affect the function of the Hoist.

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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.
If there is a problem discovered with the sling, it should be noted on
the service sheet and be brought to the attention of the person(s) who
requested the service to be carried out. In addition, notify the
customer on-site or the Manager if it is a care facility. The serial
number, type of sling, and condition should be noted on the service
sheet. Mark the date of inspection on the sling service label.

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Program Mode Instructions
Use the flow chart below to access and edit all settings within the Program Mode.

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