Mackworth 180 Mobile Hoist, Service Manual

Page 1: ...Doc No 995051 Revision of document A Rev Date 26 04 2021 180 Mobile Hoist Service Manual...

Page 2: ...oist E Stop button not working 12 8 7 Hoist Leg Actuator is not responding 12 8 8 Hoist has Power but does not respond to Handset commands 12 8 9 Hoist doesn t respond to the correct Handset commands...

Page 3: ...end user 2 0 Safety Precautions Read and understand this manual in its entirety before servicing the Mackworth Essentials 180 Hoist Mackworth authorised personnel must complete the Full and Interim s...

Page 4: ...e if they are loose if so tighten accordingly Check all pivot points for wear Ensure all Hand Knobs are functioning as intended and without damaged thread Ensure Handgrips are attached and or in an ac...

Page 5: ...ist on a flat and level surface and away from any obstacles 2 Using the handset raise the Carry Bar to the upper limit Listen for unusual noise 3 Lower the Carry Bar to bottom limit and ensure that th...

Page 6: ...m Allen Key 6mm Allen Key 10mm Spanner 12mm Spanner 13mm Spanner x2 17mm Spanner x2 19mm Spanner 24mm Spanner Flat Head Screwdriver Nylon Hammer Equipment Required Marker Pen Cloth Lint Free Cloth Tes...

Page 7: ...s for disposal within the community the device is being used within If there is any uncertainty of the below guidelines contact your local authorities to determine the proper method of disposal of pot...

Page 8: ...123905 LH Leg Assembly 123906 RH Leg Assembly 123907 Leg Actuator Kit 123908 Lift Actuator Kit 123909 Mast Fixing Kit 123910 Front Castor Kit Pair 123911 Rear Castor Kit Pair 123904 Essentials 180 Ba...

Page 9: ...d 2 Check the Handset is correctly connected to the correct control box port 3 Check the Handset lead is not damaged e g cuts and breaks 4 Check to see if hoist battery is out of charge and requires c...

Page 10: ...le Attachment 4 Connect the Battery correctly to the Control Box as shown in section 9 2 4 5 Replace the Battery see section 9 1 6 Replace the Control Box see section 9 3 7 See section 9 2 4 on Charge...

Page 11: ...ow Troubleshooting Guide 1 Lift Actuator is broken 2 Control Box is broken Action Guide 1 See section 9 5 for guidance on Lift Actuator replacement 2 See section 9 3 for guidance on Control Box replac...

Page 12: ...he Control Box Action Guide 1 Connect the Cable between the two components See section 9 2 3 for Leg Actuator Cable fitting 2 Replace the Control Box to Leg Actuator cable See section 9 2 3 for guidan...

Page 13: ...s error could be to a specific button on the handset while the other buttons still function Follow the same procedure 8 9 Hoist doesn t respond to the correct Handset commands Troubleshooting Guide 1...

Page 14: ...d remove any external power source Prior to any servicing the Emergency Stop Button on the Control Box must be activated to remove any power to the product 9 1 Battery This section will instruct the c...

Page 15: ...ent 9 2 1 Cables Handset Removal Step 1 Remove the Handset connecter from the Control Box by pulling downward out of the Port Step 2 Unhook the Handset from the Hoist Refitting Replacement Step 3 Refi...

Page 16: ...ling downward This is the middle Control Box Port as shown in the image Step 2 Release the cable from the Actuator by lifting the locking device upward it is recommended a flat head screwdriver is use...

Page 17: ...wnward as shown in the image 9 2 3 Cable Leg Actuator Removal Step 1 Remove the Jack End of the Cable which ports the Control Box by pulling downward This is the port on the right hand side of the Con...

Page 18: ...re routing it along the Hoist Refitting Replacement Step 5 Refitting is a reversal of the removal process noting the following points A When fitting the Cable into the Actuator port ensure the locator...

Page 19: ...he image below and pull the lead connecter from the Control Box as arrowed Step 4 If the Plug has not already been removed from the wall socket detach the plug from its fixing to the Hoist Refitting R...

Page 20: ...p 2 Remove all the Cabling leads from the Control Box Refer to section 9 2 Step 3 Use a 3mm Allen Key to remove the Screw fixing the Control Box to the Bracket Step 4 Lift the Control Box from its pos...

Page 21: ...procedures or replacement Removal Step 1 Remove the Battery refer to section 9 1 Step 2 Remove the Cables Leads from the Control Box refer to section 9 2 Step 3 Remove the Control Box refer to section...

Page 22: ...r servicing procedures or replacement Removal Step 1 Remove the Lift Actuator Cable See section 9 2 2 Step 2 Remove the Four Black Caps from the Actuator fixing points Step 3 Using two 13mm Spanners r...

Page 23: ...t Slowly lower the Boom until it rests against the Mast Refitting Replacement Step 6 Refitting is a reversal of the removal process noting the following point A Ensure the Actuator is fitted in the co...

Page 24: ...aps from the Actuator fixing points Step 3 Using two 13mm Spanners remove a nut from the fixing pin Repeat for the second fixing point Step 4 Slide the pin out to release the Actuator Repeat for the s...

Page 25: ...re on removing and reinstalling the Carry Bar for servicing procedures or replacement Removal Step 1 Remove the two Black Caps from the Carry Bar Pivot Step 2 Using two 17mm Spanners remove a nut and...

Page 26: ...pect the Wear washer circled replacement is necessary if thickness is measured to be 0 5mm or under 9 8 Leg Rod Assembly Within this section it will explain the correct procedure on removing and reins...

Page 27: ...to four to detach the other fixing point of the Leg Rod Assembly to fully detach the Leg Rod Refitting Replacement Step 6 Refitting is a reversal of the removal process noting the following point A W...

Page 28: ...the countersunk bolt and use a 10mm Spanner on the underside of the Castor as shown and loosen Rev B To release the Front Castor place a 6mm Allen Key into the countersunk bolt and use a 17mm Socket o...

Page 29: ...the countersunk bolt and use a 12mm Spanner on the underside of the Castor as shown and loosen Rev B To release the Rear Castor place a 6mm Allen Key into the countersunk bolt and use a 17mm Socket on...

Page 30: ...ep 2 Remove the Leg Actuator Refer to section 9 6 Step 3 Place the Hoist in its side for easier service Gently rest the Hoist on its side to avoid damage such as paint scratching Step 4 Remove the Leg...

Page 31: ...er face of the Leg assembly Step 11 Remove the bolt from the Leg and the leg can be removed Refitting Replacement Step 12 Refitting is a reversal of the removal process noting the following points A E...

Page 32: ...rrect procedure on removing and reinstalling the Base for servicing procedures or replacement Removal Step 1 Remove the Leg Actuator Cable Refer to section 9 2 3 Step 2 Remove the Leg Actuator Refer t...

Page 33: ...sal of the removal process noting the following point A Ensure the Star Knob is fully tightened to disallow any play between the Mast and Base of the Hoist 9 13 Boom Within this section it will explai...

Page 34: ...the thread of the Pivoting Pin 9 14 Mast Within this section it will explain the correct procedure on removing and reinstalling the Mast for servicing procedures or replacement Removal Step 1 Remove...

Page 35: ...tep 5 Remove the Base Assembly from the Hoist Refer to section 9 12 The Leg Actuator Leg Rod and Legs do not need to be removed while following section 9 12 Refitting Replacement Step 6 Refitting is a...

Page 36: ...ntained in this assembly and installation manual no liability can be accepted by Mackworth for any errors or omissions Mackworth operates a policy of continuous improvement Specifications and other da...