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Moving and Handling
Products Division
The Huntleigh Tx 150
Service Manual
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Contents
Section 1 Preparation Page 4-5
Cleaning and Disinfecting
Recommended Tools
Consumables
Section 2 Lifting Operations and Lifting Equipment Regulations Page 6-9
Thorough Examination and Test Regulations
Thorough Examination Report
Thorough Examination Procedures
Load test Procedures
Label identification and location
Section 3 Servicing, Repairs and Maintenance Page 10-13
Spreader bar
Jib
Mast
Electric controls, plugs and sockets
Actuator – raising and lowering
Battery Pack
Optional charging unit
Actuator – Leg adjustment
Leg Pivots
Castors
Section 4 Dismantling and Re-assembly procedures Page 14-18
General
Spreader bar
Jib
Mast
Jib pivot
Actuator mounting pivot
Base
Actuator – raising and lowering
Control box
Battery Pack
Castors
Non repairable items
Section 5 Control box setting and test Page 19
Section 6 Troubleshooting Guide Page 20-21
Section 7 Spare Parts List Page 22-29
Section 8 Report Form ,Checklists, Actuator guidance notes Page 30-32
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Section 1
Preparation
Important Note
Always seek permission from the customer before commencing work on any equipment.
1.1. Cleaning & Disinfecting
WARNING:
Before cleaning make sure the hoist is disconnected from mains power supply
Gloves and protective clothing should always be worn when carrying out cleaning
procedures.
All surfaces can be cleaned by wiping with a soft cloth moistened with hot water and a mild
detergent. Rinse with a cloth moistened with clean water, dry with paper towels.
To remove potentially infectious material such as body fluids, or when used by a client with a
known infection, clean afterwards with NaDCC (e.g. Precept, Actichlor) at 10,000 ppm of
available chlorine. Rinse and dry. For further information refer to the Infection Control
Procedures booklet (LIT442/02) which is available on request from Huntleigh Healthcare.
Cautions
Avoid wetting electrical contacts, plugs, sockets etc.
Do Not use Hypocarbonate or Phenol based cleaning agents
Do not use abrasive compounds or pads.
Tests show undiluted Dettol may damage paint and plastic parts if prolong contact is
allowed.
Spreader bar cover. The spreader bar cover can be removed for cleaning. The cover is
retained by four plastic rivets. These can be removed by pulling up on the heads and
withdrawing complete rivet from the cover. The rivets can be reused to secure the cover
Fabric based equipment: Slings
Slings should be washed separately when soiled and weekly by washing machine at
minimum 80ºC sustained for 2 minutes. Seek Infection Control advice on the need for
sterilisation, which, depending on the risk, can be achieved by autoclaving.
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1.2 Recommended Tools
Below is a list of basic tools required to carry out the service procedures contained in
this manual:
WARNING
All tools can be dangerous if used incorrectly.
17mm AF Spanners (Dual ring, open end)
3.5mm, 4mm, 5mm, 6mm, AF Allen keys
No 2 Pozidrive screwdriver
RS Components potentiometer adjusting screwdriver
Nylon Faced Mallet
Hammer
6mm pin punch
Multimeter - minimum requirement to read DC voltage, current, and resistance
Torque Driver reading to 15Nm
1.3 Consumables
Loctite 480
Loctite 638
Rocol Sapphire grease (or equivalent mineral based grease)
Rocol Sapphire Hi-Load 2 grease (or equivalent molydenum disulphide based grease)
General purpose mineral based lubricating oil
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Section 2
Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)
Thorough Examination and Test (regulation 9)
Huntleigh Healthcare recommend the Huntleigh range of patient lifting devices and lifting
accessories receive a thorough examination and test every six months. A competent person,
as defined in the LOLER Approved Code of Practice and Guidance publication L113 paras.
294 & 295, should carry out the examination and test. This product should also receive a full
service once a year.
This is in line with the requirements of No2307 Health and Safety: The Lifting Operations
and Lifting Equipment Regulations 1998.
Huntleigh Healthcare can offer this after sales care, please ask for our Flexi-Serve brochure,
which contains details of the full range of service and maintenance contacts on this product.
Thorough Examination Report
Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)
LOLER requires certain information to be included on the report given to a customer after a
thorough examination. The information can be found in Schedule 1 (page 56) in the LOLER
L113 publication.
Huntleigh Healthcare has prepared a Thorough Examination Report that includes all the
required information and a copy can be found in Section 8
Thorough Examination Procedures:
Important Note:
The Tx 150 has a 12 month warranty. The component parts of this device should not be
opened or tampered with during this period, as it will invalidate the warranty.
1. Spreader Bar
Check for:
• freedom of rotation and swing.
• wear on the spreader bar/jib suspension points.
• wear on the central pivot.
• secure attachment to the jib.
• effective function of the safety latch.
• excessive wear on the sling hooks.
• sling strap retainers effective function.
2. Jib.
Check for:
• minimal side movement of the jib and alignment with the centreline of the hoist.
• jib is free to rotate on the jib/mast pivot.
• wear on the actuator mounting plate and retaining pin.
• presence and correct fitting of the keyrings on the actuator retaining pin.
• damage to jib end mouldings.
3. Mast:
Check for:
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• mast fully engaging with the mast spigot.
• correct operation of the mast-locking device.
• wear on the actuator mounting point.
• wear on the jib/mast pivot.
4. Electric controls, plugs and sockets.
Check:
• Emergency Stop button cuts all power. Confirm power is restored when the switch is
reset
• handset for correct functioning – raise/lower and leg opening.
• fit of the hand control plug and socket.
• for damage to charging socket.
• functioning of the emergency descent button.
• fit of actuator plugs and sockets
• for damage to cables and leads
5. Raising and Lower actuator.
Check:
• smooth operation in both directions.
• power cuts out at the ends of travel.
• for unusual noise which may indicate future break down
• correct functioning of actuators fitted with an emergency down mechanism.
• anti-crush precautions are operational.
• Record estimated number of cycles performed – assess replacement using Guidance in
Section 8 page 32
6. Batteries and Charging unit.
Check for:
• low battery alarm when operated. If sounding, place on charge and confirm charging is
taking place.
• the fit of the charger plug to the hoist charging socket.
• hoist inoperative when the charger is being used.
• charger unit is charging the hoist.
• mains plug fitted with the correct rated fuse.
• damage to the input and output lead wiring
7. Leg adjustment
Check for:
• Correct operation of handset.
• Smooth opening and closing of both legs.
• Power cut off at both ends of travel.
• Excessive movement of the legs. Investigate cause.
• Legs are parallel to each other and the centre line of the hoist.
8. Leg pivots
Check for:
• freedom of leg pivot. Any stiffness must be investigated.
• excessive play in the leg pivots. Investigate cause
• leg pivots are retained securely.
9. Castors
Check:
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• all castors for firm attachment to the legs.
• for free rotation of the castor and the wheels.
• for threads, hair or fluff around the wheels or swivel.
• for correct operation of the brakes.
10. Slings
Check:
• the load bearing straps for wear, cuts or fraying.
• the straps are securely stitched.
• the body of the sling for wear or cuts in the fabric.
11. Load Test
LOAD TEST:
A load test should be carried out in accordance with the manufacturers test procedures.
Maintenance, repair, thorough examination or testing should be carried out by a competent
person.
As part of the LOLER periodic examinations or the regular servicing of the Huntleigh range
of hoists it will be necessary to carry out a load test. It is recommended the testing be carried
out using either of the following procedures:
(i) Using the Huntleigh Load Test rig – Tx 150.
Equipment.
2 Skids complete with suspension bar.
2 Small straps
1 four position sling
2 suspension hooks
Weighing scale (Salter Model 235 0-300kg)
Method
• Remove the suspension bar from two mounting clips inside one of the skids.
• Place the skids on the floor approximately 600 mm apart, with the flanged faces on the
outside.
• The skids have two alternative hole positions through the sides. Slide the suspension bar,
from the outside of the skid, through the hole nearest to the end of the first skid. Pass the
suspension bar through the bottom loop of the four position sling and though the
matching hole in the other skid. Lock the suspension bar in place with the pins which are
attached to the skids
• Place the Tx 150 onto the skids with the spreader bar at the same end as the suspension
bar
• NOTE: Do not apply the brakes to the hoist during testing.
• Attach a small strap between the front hooks (foot symbol) of the hoist spreader bar.
• Attach a small strap between the back hooks (head symbol) of the hoist spreader bar.
• Attach one of the suspension hooks to the top suspension point of the weighing scale and
hang the scale on both small straps attached to the spreader bar.
• Fit the other suspension hook to lower suspension point on the scale and hook on the
second loop of the four position sling (see note below).
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• NOTE: The sling provides four positions or lengths. The shortest is for the Porta 130
(200 mm) the next for the Porta 150/155, Tx 150 and so on, the longest being for the
Porta 250. If in doubt, these positions should enable the test load to be applied at the
maximum reach of the hoist. If this is not the case then check the loop length used and
adjust accordingly.
• When the weighing scale is properly attached, raise the hoist jib until the scale reads the
test load of 150-155kg. Check the scale reading is steady and is not decreasing.
• Confirm satisfactory test on the service record and/or the LOLER report form.
(ii) Using Dead Weights – Tx 150
• Attach the test load of 150-155kg to the spreader bar. Make sure the weight is evenly
distributed on all four arms of the spreader bar.
• Lift the test load from the lowest working position to the highest
• Confirm the load is held and the jib is not lowering.
• Lower the test weight and detach from the spreader bar
• Confirm satisfactory test on the service record and/or the LOLER report form.
12. Sharp Edges
Check for any sharp edges caused by damage, wear or missing parts. Make sure the client
or user is not placed in any risk of injury from such edges.
13. Instructions for Use
• Confirm an instruction manual relating to the model of hoist is readily available to the
user. A manual is an important part of ensuring safe use of a hoist. If the manual is
missing it should be replaced before the hoist is signed off as safe to use.
• Confirm the presence of all instruction or warning labels. Missing labels must be replaced
before the hoist is signed off as safe to use.
Label identification and location
Model: Tx 150
Part Number Description Location
803.109 Jib label Both side of jib between mast/jib pivot and
jib elbow
803.111 Jib location label RH side of jib at mast/jib pivot end
803.112 Actuator location label RH side of mast adjacent to actuator bracket
803.113 Mast location label Front face of mast – 63 mm up from
bottom.
803.114 Control box label LH side of mast adjacent to actuator bracket
803.115 ISO warning label Rear face of mast, below mast/jib pivot.
803.116 Spreader bar label RH side of jib at spreader bar pivot end.
803.117 Foot label Side face of spreader bar hook arm, narrow
hook side.
L1011 Head label Side face of spreader bar hook arm, wide
hook side.
760.168 Serial number label LH side of mast below mast/jib pivot
Note: RH & LH locations are looking from the rear of the hoist, forward to the spreader bar.
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Section 3
Servicing, Repairs and Maintenance
1. Spreader Bar:
The spreader bar is a main load bearing assembly of a hoist. It must be treated as a critical
item and receive priority attention during thorough examination, service, repair and
maintenance work.
1.1 Connection to the jib suspension pin.
The spreader bar is suspended from the jib suspension pin by a hook with a bayonet-type
fixing slot. It is retained on the jib pin by a spring-loaded safety latch. This allows the
spreader bar to be readily detached by operating the safety latch and disengaging the bayonet
connection from the jib pin.
• Check for wear on the suspension hook. Elongation of the main suspension point must
not exceed 3mm before replacement. Note: Check Dimension: The top of a new, unworn
suspension point is 13 mm from the top edge of the hook. At 3 mm elongation this
dimension would be reduced to 10 mm.
• Check for smooth operation of the safety latch. If the latch is difficult to push down or
fails to return to the locked position the cause must be fully investigated. This may
necessitate a strip down of the spreader bar assembly
• Check for any damage that could cause improper connection to the jib suspension pin.
• Maintenance: Lubricate the jib suspension point with Rocol Sapphire grease or any
equivalent light, mineral based grease.
1.2. Central pivot pin.
The central pivot pin passes through the complete spreader bar assembly and is retained on
the underside with a pinned boss. The pivot pin carries the entire load of the lift and its
condition and operation is a very important factor in the overall safety of the hoist.
Note: Examination of the central pivot pin will require at least the removal of the lower
spreader bar cover. Full examination will require a complete strip down of the assembly (see
section 4 Dismantling spreader bar assembly. page 14). A rough assessment of wear on the
central pivot can be made while the assembly is intact. Excessive up and down movement of
the spreader bar on the central pivot provides an indication of wear on the thrust washer or
pivot pin head. Rock or side to side movement on the spreader bar can indicate wear on the
spreader bar central boss, spring spacer or the central pivot itself.
• Check the security of the ø ¼”. pin through the boss.
• Check for wear on the thrust washer. Worn washers allowing excessive end float must be
replaced.
• Check for excessive wear on the diameter of the central pin. Reduction in diameter in
excess of 0.5 mm anywhere on the ø 12 mm length and the pin must be replaced.
• Check for excessive wear on the head of the central pin. The head is 5mm thick.
Reduction in head thickness in excess of 1.0 mm and the pin must be replaced.
• Check for any damage or wear that could cause excessive play or threaten the security or
load carrying capacity of the spreader bar.
• Lubricate the central pivot pin with Rocol Sapphire grease or any equivalent light,
mineral based grease.
1.3 Spreader bar sling hooks and retainers.
The sling hooks are the attachment points for the sling straps and therefore when in use carry
the full load of the client. The retainers are gravity operated wire latches, designed to prevent
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the accidental detachment of the sling straps. It is important the hooks are in good condition
and the retainers fulfil their purpose.
• Check for wear on the sling hooks. The hooks are normally ø 8.0 mm., replace if there is
a reduction in diameter of more than 1.0 mm anywhere on the hook.
• Check for the presence and the function of the sling retainers. Replace any missing or
damaged retainers
• Check for any damage or wear that could threaten the security or load carrying capacity
of the spreader bar.
• Maintenance: Light application of any general purpose lubricating oil on the sling retainer
pivots.
2. Jib
• Check the jib end covers are present and undamaged. Replace as necessary.
• Make sure the jib is aligned with the centreline of the hoist
• Check the jib is free to rotate on the jib pivot.
• Check for wear on the jib pivot – see Mast below.
• Check for wear on the actuator mounting plate. Elongation of the mounting hole should
not be allowed to exceed 3mm before replacement.
• Check for wear on the actuator mounting pin. Wear of the pin diameter (ø 12mm) should
not be allowed to exceed 0.5mm before replacement.
• Confirm the security of the keyring retainers.
• Check for firm attachment of the spreader pivot bushes. Re-fit M6 screws if loose. Use
Loctite 638 on fixing screw threads.
• Examine spreader pivot bushes for wear. Wear of the bush diameter (ø 13mm) should not
be allowed to exceed 0.5mm before replacement.
• Maintenance – lubricate jib/mast pivot, spreader pivot bushes and actuator unit mounting
with Rocol Sapphire grease (or equivalent mineral based grease).
3. Mast
• Make sure the mast fully engages in the mast spigot Any tightness, obstruction or
excessive movement must be investigated.
• Check the operation of the mast-locking knob. Replace missing or damaged knobs
• Check for firm attachment of the actuator pin. Re-fit M6 screws and washers if loose. Use
Loctite 638 on fixing screw threads.
• Check for wear on the actuator mounting pin. Wear of the pin diameter (ø 14mm) should
not be allowed to exceed 0.5mm before replacement.
• Check the push handles are securely attached and fixing pins are in place. Excessive
movement must be investigated.
• Check for wear on the jib pivot pin. Wear of the bush diameter (ø 22mm) should not be
allowed to exceed 1.0mm before replacement.
• Check for firm attachment of the control box mounting plate to the mast. Tighten if
necessary
• Maintenance – lubricate the actuator mounting pin and the jib pivot pin with Rocol
Sapphire grease (or equivalent mineral based grease).
4. Electric controls, plugs and sockets
The control box, handset and associated plugs, sockets and leads are not generally repairable.
There is a limited amount of maintenance and repair work which can be carried out.
Operational failure will require complete replacement.
• Check for firm attachment of the control box to the mounting plate
• Check the Emergency Stop button cuts all power. Confirm power is restored when the
switch is reset
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• Check the parking magnet is firmly fixed to the handset. Re-fix or replace if missing.
• Check handset for correct functioning – press up/down buttons and confirm the jib raises
and lowers correctly. Operate the leg buttons and confirm the legs open and close
correctly.
• Check fit of the hand control plug and socket. Examine plug pins for damage
• Examine charger socket for damaged pins.
• Check the functioning of the emergency descent button.
• Check for fit and damage to the actuator plugs and sockets
• Check for damage to cables and leads
• Check the contacts on top of the control box. Dirty or corroded contacts can be cleaned
with a mild abrasive
5. Actuator – Raising & Lowering
The actuator is a sealed unit. This limits the amount of maintenance and repair work which
can be carried out. Operational failure will require complete replacement.
• Record estimated number of cycles performed – assess replacement using Guidance in
Section 8 page 32
• Check for smooth operation in both directions.
• Confirm the power cuts out at the end of travel in both directions.
• Listen for unusual noise which may indicate early break down.
• Confirm anti-crush precautions are operational.
• Check correct functioning of the emergency down mechanism. This device will only
operate with a load of 50kg or more. It is adjustable by a screw accessed through the hole
in the top face of the red moulding. Turn the screw clockwise to decrease the operating
load and anti-clockwise to increase it. Caution: over adjustment can result in a very rapid
descent. Any new adjusted setting must be checked against a known weight.
• Check the lower actuator mounting, confirm presence of 1 off E clip on cross pin. Check
for excessive wear on ø 14mm cross hole.
• Maintenance – lubricate pivot hole with Rocol Sapphire grease (or equivalent mineral
based grease).
6. Battery Pack
Batteries are not repairable and require no maintenance other than regular charging. A
fully charged battery pack should register 24.2 – 24.6 VDC. A discharged battery pack
with a voltage of 16 VDC or less is not likely to be recoverable and should be replaced.
• Check the contacts on the base of the pack. Dirty or corroded contacts can be cleaned
with a mild abrasive
• Check the operation of the retaining latch - if not operational replace the battery pack.
• Check for damage to the case. Damaged packs should be replaced as they may represent
a fire risk.
7. Remote charging unit.
The charger is a sealed unit. This limits the amount of maintenance and repair work
which can be carried out. Operational failure will require complete replacement.
• Check the mains pins. Replace charger if pins are loose or damaged.
• Check output lead and plug. Replace charger if damaged.
• Check output voltage – charger should output 27 – 28 VDC. Chargers with output voltage
less than this should be replaced.
8. Actuator – Leg adjustment.
• The actuator is a sealed unit. This limits the amount of maintenance and repair work
which can be carried out. Operational failure will require complete replacement.
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• Operate the handset and confirm smooth opening and closing of both legs.
• Confirm the power cuts out at the end of travel in both directions.
• Make sure the legs are parallel to each other and the centreline of the hoist when in the
closed position. If not see Section 4 Dismantling and re-assembly procedures.
9. Leg Pivots.
• Check the legs are free to pivot. Any stiffness must be investigated (see Section 4
Dismantling and re-assembly procedures) Strip out the leg pivots and lubricate with a
molydenum disulphide based grease.
• Make sure there is no excessive play in the leg pivots.
• Make sure the leg pivots are retained securely.
• Maintenance – lubricate the pivot pins.
10. Castors
Castors are not a repairable item. This limits the amount of maintenance and repair work
which can be carried out. Operational failure will require complete replacement.
• Check all castors for firm attachment to the legs.
• Check for free rotation of the castor and the wheels.
• Remove any build up of threads, hair or fluff.
• Check correct operation of the brakes.
• Maintenance – lubricate swivel and axle bearings with any general purpose lubricating
oil.
11. Load test.
See Section 2 para 11
12. Sharp Edges
Check for any sharp edges caused by damage, wear or missing parts. Make sure the client
or user is not placed in any risk of injury from such edges.
13. Instructions for Use
• Confirm an instruction manual relating to the model of hoist is readily available to the
user. A manual is an important part of ensuring safe use of a hoist. If the manual is
missing it should be replaced before the hoist is signed off as safe to use.
• Confirm the presence of all instruction or warning labels. Missing labels must be replaced
before the hoist is signed off as safe to use.
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•
Section 4
Dismantling and re-assembly procedures.
1. General
• Lubrication: Grease - use Rocol Sapphire grease or any equivalent light, mineral based
grease unless otherwise stated..
• Oil – use any light, general purpose, mineral based lubricating oil. Do not use silicone or
vegetable based oils.
2. Dismantling spreader bar assembly.
• Remove 4 off 4mm plastic rivets (Item 15 drwg. 803.49-1) from the spreader bar cover.
This will release the lower cover (Item 11 drwg. 803.49-1) but the top cover (Item 6
drwg. 803.49-1) will still be retained.
• Knock out the ø ¼ roll pin (Item 10 drwg. 803.49-1) from the central pivot pin and boss
(Items 1 & 9 drwg. 803.49-1).
• Remove the boss (Item 9 drwg. 803.49-1) and M12 plain washer (Item 12 drwg. 803.49-
1).. This will release the spreader bar (Item 7 drwg. 803.49-1), top cover (Item 6 drwg.
803.49-1), safety latch spring (Item 5 drwg. 803.49-1), spring spacer (Item 4 drwg.
803.49-1) and spreader retaining pressing (Item 3 drwg. 803.49-1).
• The central pivot pin (Item 1 drwg. 803.49-1) can now be removed from the spreader
bracket (Item 2 drwg. 803.49-1).
Re-assembly
Examine the component parts following the guidelines in the Full Service section.
Re-assemble as follows:
• Assemble the central pivot pin to the spreader bracket. Lubricate the pin with grease.
• Fit spring spacer over the central pivot. Lubricate outside of spacer with grease.
• Assemble the spreader retaining pressing to the spreader bracket; pay attention to the
correct orientation of the pressing to the bayonet slot in the spreader bracket.
• Fit the spring over the spring spacer.
• Lubricate the central hole in the spreader bar with grease.
• Take the top spreader bar cover and fit over the boss on the spreader bar fabrication.
• Fit the spreader bar to the central pivot making sure the spreader bar is the correct way
up.
• Fit M12 plain washer. Note: Fit new washer - Do not reuse the old washer.
• Fit the boss to the central pivot, line up the cross holes and fit the ¼ roll pin. Note: Fit
new pin – Do not reuse old pin.
• Fit the lower cover over the spreader bar and engage with the top cover – retain with 4 off
plastic rivets.
3. Removal and replacement of Jib assembly
• Disengage the safety latch and detach the spreader bar assembly from the jib.
• Remove one keyring (Item 9 drwg. 803.40-1) from the actuator top mounting pin (Item 8
drwg. 803.40-1)..
• Withdraw the pin and release the jib mounting plate from the actuator ram clevis. Lean
the actuator (Item 4 drwg. 803.40-1) back against the mast.
• Rotate the jib around the mast pivot and align the slot in the end of the jib with the flats
on the mast pivot. The jib can now be detached.
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• The pivot bushes (Item 4 drwg. 803.39-1) at the spreader bar suspension point are
removed by unscrewing 2 off M6 x 12 socket headed screws (Item 6 drwg. 803.39-1) and
2 off M6 x ø 20 washers (Item 5 drwg. 803.39-1)..
Re-assembly
• Replace the pivot bushes on the spreader bar suspension point, flange side out. Apply
“Loctite 638 to the screw threads of the 2 off M6 x12 socket headed screws and screw in
place with the 2 off M6 x ø 20 washers.
Fully tighten. Apply a light coat of grease to the pivot bushes
• Lubricate the pivot hole in the jib with grease.
• Align the slot in the end of the jib with the flats on the mast pivot. Engage the slot and
rotate the jib forward.
• Swing the actuator forward and engage the ram clevis with the mounting plate on the jib.
• Lubricate the actuator mounting pin (Item 7 drwg. 803.38-1) with grease.
• Align the through holes in the top of the actuator with the mounting plate on the jib.
Replace the mounting pin.
• Replace the pin retaining keyring.
• Reattach the spreader bar assembly.
4. Removal and replacement of Mast assembly
• Remove Spreader bar assembly and Jib assembly (2&3 above.)
• Unplug the actuator lead from the control box (Item 11 drwg. 803.38-1).
• Swing the actuator around the lower mounting pivot to approximately 90° to the mast.
This will align the slots in the actuator coupling with the flats on the mounting pivot and
allow the actuator to be detached.
• Slacken off the mast locking knob (approx. 1 full turn) (Item 10 drwg. 803.38-1)..
• Unplug the leg actuator lead (Item 27 drwg. 803.37-1). from the control box.
• Lift the mast (Item 1 drwg. 803.38-1). off the base spigot.
Re-assembly
• Apply a light coat of grease to the base spigot. Slide the open end of the mast over the
spigot and engage fully (check with engagement label on the side of the mast).
• Fully tighten the mast locking knob. If necessary lubricate the thread with oil.
• Apply a light coat of grease to the actuator mounting pivot.
• Align the slot in the actuator coupling with the flats on the mounting pivot and engage.
• Rotate the actuator through 90° and rest against the mast.
• Reconnect the actuator leads to the control box. Note: Lifting actuator (white lead)–
socket 1 Leg actuator (black lead) – socket 2.
• Replace Jib and Spreader bar assemblies.
5. Jib pivot pin – removal and replacement
• Remove 4 off 1¼ x ¼ roll pins (Item 2 drwg. 803.38).from the push handles.
• Remove handles. (Items 4 & 6 drwg. 803.38).
• Knock out jib pivot pin (Item 3 drwg. 803.38).from the mast clevis.
• Fit new jib pivot pin through the mast clevis and align the pin holes with the cross holes
in the handle mounting bosses.
• Check the alignment of the cross holes in the handle tube (Item 5 drwg. 803.38).
• Refit the handles, making sure all the cross holes line up.
• Refit 4 off new 1¼ x ¼ roll pins (Item 2 drwg. 803.38). Do not reused the old pins.
• Lubricate the jib pivot pin with grease.
6. Actuator mounting pin – removal and replacement
• Unscrew and remove 2 off M6 x 12 socket button screws (Item 9 drwg. 803.38) and 2 off
M6 plain washers (Item 8 drwg. 803.38).
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• Remove actuator mounting pin (Item 7 drwg. 803.38) from the mast bracket.
• Refit new actuator mounting ping through the mast bracket.
• Apply Loctite 638 to 2 off M6 x12 socket button screws and with 2 off M6 plain washers
fully tighten into tapped ends of the actuator mounting pin.
• Lubricate the actuator mounting pin with grease
7. Base – dismantling and re-assembly
• Remove Spreader bar, jib and mast (2, 3 & 4 above).
• Remove 6 off 4mm plastic rivets (Item 10 drwg. 803.37-1) from crossmember cover
(Item 20 drwg. 803.37-1). This will also release the cover support plate (Item 30 drwg.
803.37-1).
• Lift off cover and disconnect 2 off push-on terminals (Item 28 drwg. 803.37-2) to the leg
opening actuator (Item 17 drwg. 803.37-2).
• Remove leg pivots – 2 off Leg pivot bolts (Item 13 drwg. 803.37-1) 2 off M10 Nyloc
nuts (Item 15 drwg. 803.37-1) 2 off M10 washers (Item 25 drwg. 803.37-1).
• Remove 2 off plastic rivets (1 per cover) from rear leg covers (Items 6 & 11 drwg.
803.37-3). The cover is also retained by Dual Lock strips (Item 29 drwg. 803.37-2) on
the top face of the castor bracket. Remove leg covers.
• Remove 2 off E clips (Item 19 drwg. 803.37-1) and 4 off M12 plain washers (Item 14
drwg. 803.37-1) from 2 off leg actuator clevis pins (Item 18 drwg. 803.37-1). Lift out pin
from each ram.
• The legs (Items 4 & 7 drwg. 803.37-1) can now be detached from the crossmember (Item
16 drwg. 803.37-1) and leg actuator (Item 17 drwg. 803.37-2).
• Cut and remove tie-wrap (Item 26 drwg. 803.37-2).retaining the actuator and lift the
actuator out. Note Measure the distance between the mounting centres of the actuator.
This measurement will be required when fitting a replacement.
Re-assembly
• Actuator replacement. Check the distance between the mounting points on the new
actuator are the same as the one being replaced. Make sure this measurement results in
the legs being parallel to each other and the centreline of the hoist. Adjustment of the
centres can be achieved by rotating the ram end. This will wind the ram in or out and
increase or decrease the ram extension.
• Fit the actuator to the mounting bracket (see drawing 803.37 sht. 2)
• Fit M10 washer to the actuator pivot pin, lubricate pin with grease and pass through the
ram clevis and leg plate. Fit M10 washer to pin and secure with E clip. Repeat for other
end.
• Pass tie-wrap around the motor and secure to the bracket on the crossmember.
• Replace and secure rear leg covers
• Grease leg pivot bolts with Rocol Hi-load Sapphire grease or any equivalent Molydenum
Disulphide grease. Pass bolt through leg pivot tube, fit M10 washer and M10 Nyloc nut.
Fully tighten. Note: Nyloc nuts should be used once only.
• Re-connect the actuator push-on terminals and refit cover support plate and crossmember
cover. Secure with 6 off plastic rivets.
• Refit mast. Jib and spreader bar assemblies.
8. Lift Actuator removal and replacement.
• Unplug the actuator lead from the control box (Item 11 drwg. 803.38).
• Remove the retaining keyring (Item 9 drwg. 803.40) from one end of the ram pin (Item 8
drwg. 803.40).
• Withdraw the pin and release the top of the actuator (Item 4 drwg. 803.40).
17
• Swing the actuator around the lower mounting pivot (Item 7 drwg. 803.38) to
approximately 90° to the mast. This will align the slots in the actuator coupling (Item 2
drwg. 803.67) with the flats on the mounting pivot and allow the actuator to be detached.
Re-assembly
• Grease the actuator coupling
• Align the slot in the actuator coupling with the flats on the lower mounting pivot and
engage.
• Rotate the actuator through 90° and rest against the mast.
• Swing the actuator forward and engage the ram clevis with the mounting plate on the jib.
• Lubricate the actuator mounting pin with grease.
• Align the through holes in the top of the actuator with the mounting plate on the jib.
Replace the mounting pin.
• Refit the pin retaining keyring.
• Plug the actuator lead into the control box.(socket 1).
9. Control box removal and replacement
• Operate battery pack latch and remove pack (Item 12 drwg. 803.38).
• Unplug handset (Item 6 drwg. 803.40) actuator leads and mains lead (Item 7 drwg.
803.40) from the control box.
• Unscrew control box retaining screw, situated at the rear of the top face of the control
box.
• Lift the control box until it disengages from the mounting bracket (Item 13 drwg. 803.38).
• Mounting bracket can be removed by slackening (but not removing) three fixing screws
and lifting the bracket until it disengages.
Re-assembly
• Reverse the procedure above.
10. Battery removal and replacement.
• Lift latch at top of battery pack (Item 12 drwg. 803.38) - detach battery pack from
mounting plate.
Re-assembly
Reverse the procedure above.
11. Castor removal and replacement
Front castors.
• Remove 2 off 10 x ½ self-tapping screws (Item 24 drwg. 803.37-1) and 2 off M6 plain
washers (Item 9 drwg. 803.38-1) on the underside of the castor bracket. This will allow
the front leg cover to be removed.
• The front castor is fixed with a M10 c’sk socket screw (Item 3 drwg. 803.37-1) and a
M10 Nyloc nut (Item 2 drwg. 803.37-1). Undo with a 6mm AF allen key and a 17mm AF
ring spanner
• Refit in reverse.
Rear castor: easier to remove with leg detached from crossmember but can be done in-situ
with care.
• Ease up the rear leg cover (Items 6 & 11 drwg. 803.37-1) and release the Dual Lock grip.
• The rear castor is fixed with a M8 c’sk socket screw (Item 12 drwg. 803.37-1). Undo with
a 5mm AF Allen key. Note Do not bend the leg cover more than is necessary to insert the
Allen key. Take care not to permanently bend or snap the cover moulding.
• Refit in reverse – use Loctite 638 on the thread.
18
10. Non repairable items
The following items are not repairable and should not be taken apart. If any of the following
fail in use they should be replaced complete.
• Castors
• Control Box
• Battery pack
• Lift actuator
• Leg opening actuator
• Handset
• Remote Charger unit
• Charger mains lead
19
Section 5
Control box setting and testing
When a control box is replaced the new box must be set to limit the lifting capacity. Use the
following procedures for setting.
Equipment required:
187.5 kg dead weight (a spring balance and Porta test rig may be used if a dead weight is not
available see Load Test – Section 2 para 11)
Chains or straps for attachment to hoist spreader bar.
Potentiometer adjustment screwdriver.
Purpose: To adjust the control box current limit so that the hoist will lift 125% of the SWL
(= 125% x 150 kg = 187.5 kg)
Method:
1. Attach the dead weight to the spreader bar and attempt a lift using the handset. If the hoist
fails to lift the weight and cuts out, the potentiometer needs to be turned up (clockwise). If
the hoist lifts the weight it may need to be turned down (anticlockwise).
2. The potentiometer is located on the left side of the control box and is accessed through a
hole in the casing. The potentiometer must be adjusted so it just lifts the test weight of
187.5 kg.
3. Insert the blanking plug provided by Linak into the potentiometer access hole.
Acceptance:
1. Confirm the selected setting will allow the hoist to lift the test load from the lowest to the
highest positions without cutting out.
2. Check the hoist holds the test load without component failure or permanent distortion.
Documentation:
Record result on check list or service report.
20
Section 6
Troubleshooting Guide
Symptom Possible cause Remedy
Hoist dead – nothing happens when
handset buttons pressed
1. Emergency stop button pressed
in.
2. Handset not plugged in.
3. Handset faulty.
4. Damaged handset
lead/plug/socket.
5. Battery fuse blown.
6. Charger still connected
1. Reset emergency stop switch.
2. Plug in correctly.
3. Replace handset
4. Check for damage – replace
damaged item.
5. Check for cause – replace fuse
(once only) – replace battery
pack if problem persists.
6. Disconnect charger
Hoist dead – but relays clicking
when handset buttons pressed.
1. Actuator failed
2. Broken wire in actuator
lead/jack plug
3. Bad contact in control box
socket.
4. Anti-crush device activated.
1. Replace actuator.
2. Replace actuator.
3. Replace control box
4. Investigate cause – check
jib/mast pivot and jib/actuator
pivot
Hoist lacks lifting power 1. Low battery.
2. Actuator drawing too much
power.
3. Control box set too low.
4. Control box failing.
1. Charge battery or replace with
charged pack.
2. Check hoist pivot points for
tightness. If OK - replace
actuator.
3. Check cut-out load with load
test rig. Reset control box if
appropriate.
4. Replace control box.
Actuator stops intermittently during
lifting
1. Load too heavy
2. Battery low.
3. Actuator overheating.
4. Actuator failing
5. Control box failing.
6. Bad contact in Handset, handset
lead, actuator lead, control box
socket.
7. Control box not set correctly
1. Check load applied
2. Charge battery or replace with
charged pack
3. Confirm duty cycle with
customer.
4. Replace actuator
5. Replace control box
6. Check all points where
intermittent contact is possible
7. Set control box (see Section 5)
Actuator noisy
1. Actuator failing
1. Replace actuator
Actuator runs but does not lift 1. Stripped gears
2. Emergency lowering set too
low or damaged.
1. Replace actuator
2. Try setting screw adjustment. If
problem not solved replace
actuator
Actuator runs in one direction only 1. Handset switch faulty
2. Bad Contact in handset/
lead/plug/socket.
3. Control box failing
1. Replace handset.
2. Check for obvious damage
3. Replace control box
Battery will not charge 1. Mains lead unplugged
2. Mains socket not switched on.
3. Mains lead/plug/socket
1. Connect to mains
2. Switch on.
/
