Base User Manual
Contents
1. H f 7 g 1 NOSTRE TREE ren 14 X SUPERSEDED Page 132. ilt et n Eae rac eee 3C 10 11 ie SAS CIBLE STORE 12 13 ACCESSOT ES a du 14 Hydraulic Cylinder Replacement ER 15 Safety Precautions Li 9 09 0 63 ra nid Erea AC RUE wees 16 2 9 81 8 012 9 a aa a A 17 Wiring DIAgrAM PL 18 Hydraulic Circ it DIAQIAM series vaanii ue da ns de oc ee 19 Installation INSWUCTIONS aad 8 PERSTO eaaa e h 20 24 Width between columns 2650mm Overall width 3250mm Overall height 2770mm Overall length 1200mm Width base plate 575mm Height of base plate oomm Maximum raised height 1900mm Minimum lowered height 90mm Length of front lifting arms maximum 1020mm minimum 610mm Lifting time working height approx 20 secs Electric motor 3 phase 2 2kw 2700 rom 415 volts 50 heriz optional Single phase 2 2kw 2850 rpm 240 volts 50 hertz Hoist mass 22kg Wire rope 13mm diameter 6 x 29FW 14 7 7F 1 IWRC RHOL B1770 minimum breaking strength 107kn Hydraulic oil Castrol Hyspin AWH46 Shell Tellus TA6 Mobil DTE 25 BP Bartran HV46 or equivalent Capacity 3000kg 3 0 tonnes The Manufacturer reserves the right to alter these features and specifications without notice Page 3 INTRODUCTION Here is the MOLNAR TWO POST HOIST a space saving wheel free hoist and its many advantages It has been purposely designed for space saving and fo give versatility and profitability to the largest garage
3. Cable spring sleeve Cable spring Cable nut Pulley pin retaining bolt Pulley pin Top left pulley bracket Cableretaining COD dade deo toe testes y 2 Pulley assembly SHOUT cable bens ei e40 X OT Oe 2 Pulley pin Cable spring cap Cable spring cap Short cable spring Hydraulic cylinder assembly Outside cylinder Hydraulic cylinder assembly Straight adaptor Elbow adaptor Cylinder seal kit Power pack assembly Coupling assembly Electric motor 415v Electric motor kit 240v Power pack assembly Hydraulic pump Lowering handle Control valve assembly Starter assembly Starter bracket Limit switch bracket HYDRAULIC CYLINDER REPLACEMENT Procedure 1 Disconnect power Lower carrier Remove cover Unbolt and remove motor tank assembly from top of post 2 3 4 Disconnect hydraulic pipe at top of post 5 6 Disconnect twin ropes by removing safety mechanism lever and spring retainer and slide rope terminations out N 8 Unbolt post and lay down with exposed sheave facing upwards Remove sheave assembly 9 Ensure hydraulic pipe disconnected is inside post and then slide cylinder pipe out of post 10 To remove piston take out circlip and apply compressed air to inlet with caution Inspect cylinder wall for rust or scoring If scored the cylinder wall must be re honed or the malfunction will continue If rusted it must be re ho
4. 2 per side NOTE The 4 packing legs securing bolts are to be fitted into the base plates of the posts The nuts are to be discarded Cut strap holding packing legs to hoist Lift hoist off floor and remove packing legs Place hoist on floor Swing out tops of both posts horizontally anti clockwise right hand with motor first and place on wooden blocks with top of post 500mm from base Refer Figure 1 9 Remove bolts from base 10 Lift right hand post into position and bolt to base 11 Repeat with left hand post 12 Cut 2 straps marked DO NOT CUT THIS STRAP UNTIL THIS POST IS IN AN UPRIGHT BOLTED DOWN POSITION 13 Remove arms door protectors and packet of locking arms 14 Remove checker plates 15 Position correctly and bolt down page 6 16 Pour oil in tank and connect power 17 Raise hoist fo approx waist level 18 Check that cylinder is seated correctly with a 2mm gap when viewed through inspection hole above bottom right sheave If cylinder not seated correctly adjust its position with bent wire until it drops and seats under its own weight Refer Figure 2 19 Install locking arms Refer Figure 3 20 Install checker plates 21 Attach door protectors Refer Figure 4 22 Apply lubricant on wear pad tracks and roller tracks 23 Install covers on both posts 24 Left hand side carriage approx 25mm higher than right hand carriage to allow the cable to bed in 25 Final Test Drive a car over h
5. Very important Instruct operator how to use the hoist how the safety mechanism works and where to place lifting pads when lifting vehicles Point out maintenance requirements on wire ropes and that they should be checked monthly Point out that by law the operator and or owner are responsible for the maintenance and safe operation of the hoist When all the above points are checked the certificate must be signed by the installer Page 24 No person should be permitted to operate the MOLNAR TWO POST HOIST without first studying the operating instructions on page 7 and safety precautions on page 16 This manual should be kept in a safe place and referred to as necessary The installation requirements on page 24 must be completed and the certificate on the inside back cover must be signed by the installer The guarantee card must be completed and returned to MOLNAR ENGINEERING PTY LTD In tropical and steam cleaning conditions to prevent rust in the cylinder raise the hoist to full height and leave it there when not in use overnight and on weekends This vehicle hoist is not designed to be used for steam cleaning nor to be installed in the open exposed to the elements Vehicle hoists installed under such conditions are not covered by our guarantee DOOR PROTECTOR INSTALLATION PROCEDURE DOOR PROTECTOR INSTALLATION PROCEDURE MF 1705 85A 3T 5 Place door prote
6. and smallest service station Safe strong simply built to give years of trouble free service The MOLNAR TWO POST HOIST embodies many features that makes it the most up to date equipment for quicker and more profitable service SAFE AND EFFICIENT OPERATION Due to an electro hydraulic system which gives years of trouble free service Raising and lowering of vehicle is controlled by hydraulics plus built in mechanical safety against any failure plus deadman control mounted on the hydraulic column INSTALLATION The MOLNAR TWO POST HOIST is fast and simple to install only 10 bolts needed for a suitable floor No costly excavation It is also ideal for upper floor level where excavation is not possible The hoist is surface mounted a feature which means lower overall cost Compared with similar priced hoists the MOLNAR TWO POST HOIST can be quickly easily and economically re sited Page 4 INSTALLATION INSTRUCTION Figure 1 Figure 2 INCORRECT CORRECT Viewing window for correct fitting of the hydraulic cylinder NOTE The cylinder must be seated with a 2mm M ap above the cylinder support plate Hydraulic cylinder his is done by correctly positioning the location Bn on the bottom of the cylinder with the hole in the cylinder support plate Page 21 INSTALLATION INSTRUCTION Position hoist to installation position Remove wooden box Cut straps holding posts together Undo the packing legs securing bolts
7. or bushes pins and cables and bushes Carriage shuddering Lack of lubricant on wear pad Clean and re apply in lifting and lowering tracks causing wear lubricant on wear pad tracks mode pads to grip instead of sliding Excessive side Worn wear pads Replace wear pads movement of carriage Page SAFETY PRECAUTIONS DON T 1 Do not try to lift anything beyond the maximum capacity 3000 Kg 2 Do not operate without first ascertaining the safety of people and equipment in the area 3 Do not go under car or make adjustments while hoist is in operation 4 Do not to adjust bearer pads engaged to jack points while the hoist is in operation 5 Do not fail to inspect safety devices periodically to see they are in proper working condition 6 Do not make unauthorised changes to safety equipment In emergency consult this manual or your local dealer 7 Do not oil or grease swivel arms as they should not move in or out while hoist 5 operating 8 Do not fail to protect operating switch from water if the hoist is used for car washing Ropes should be smeared with water resistant grease 9 Do not try to adjust relief valve as it has been set at maximum operating efficiency 10 Do not turn off mains power while hoist is operating 11 Do not force safety lever into the off position while weight is resting on safety 12 Do not attempt to operate the hoist from under vehicle Page 16 MAINTENANCE YEARLY S
8. up pad Extension arm Telescopic arm Locking arm pivot PIN uenisse Sng we on ee eh ed Pate are du 2 Locking arm bracket Locking plate as dame eae eee JE Ap OE RUE doy wee da 2 Spring LOCKING arm bracket bolt Less 088 eae eeiedsasdadawabdeddas 2 Locking rod Foot pedal E Clip Foot pedal shaft Foot operated locking arm bracket Foot operated locking arm kit for four arms Pick up pad Elevated pad Stabiliser pad Locking arm kit Left hand carriage assembly Left hand carriage Safety toggle SIN esuada Geen eee vi SEE REY RES 2 Saftey INKOS awdaradi DRAG ee hehe RES Rhea de eee W 2 Safety toggle Safety toggle Toggle shaft Wedl Pad 44 646 acri 3 9 d E dieu 1 4 nel 4 Washer ACetrdgl 53 4 quac dor dbi Rh Ea d dee A ARRA 16 Right hand carriage assembly Right hand carriage Safety pivot arm Safety toggle Safety toggle Safety on off arm assembly Safety control assembly Linkage Linkage Activator Safety actuating assembly Activating spring Page 11 MODEL MF 1705 85A 3T Page 12 129 3 ixe ER 11 im ERLEIEBE j Z VESSIE EP UT mim 8 V geisha 44 PER x ZA NN A en e Ht Pa Ta OO IS NN ni 1 7722 gO ko T H x i iere M 111 MI PLA B Mi l 5 N z 1 STE UT ff f H 1 A a mi
9. MOLNAR MANUFACTURED BY MOLNAR ENGINEERING PTY LTD A B N 54 007 740 794 16 20 Coglin Street Brompton 5 5007 AUSTRALIA 1 11 Wood Avenue Brompton S A 5007 AUSTRALIA Telephone 08 8346 6893 08 8346 6894 08 8346 8006 Fax 08 8346 0097 Email molnarhoists adam com au MOLNAR TWO POST HOIST MF 1705 85A 3T INSTALLATION OPERATION amp MAINTENANCE MANUAL CERTIFICATION hereby certify that the hoist has been checked and is in a safe operating condition and that the purchaser operator has been duly instructed in the operation thereof OPTIONAL 240 VOLT SINGLE PHASE MINIMUM REQUIREMENTS FOR ELECTRICAL CONNECTION OF MOLNAR HOISTS Important All installations should be carried out by suitably qualified persons Failure to comply may void warranty The following information is a guide only based on the latest standards as set out in AS NZS 3000 for installations Purchaser outside of Australia amp New Zealand refer to local E standards regulations Model No DUE LABES MIB prices Circuit Breakers should be of D curve type motor start Serial NO high inrush current Ratings given as a maximum for circuit amp motor protection based DOL selection guide Voltage operating range 6 to 10 of motor nameplate Voltage Motor Voltage 240V Operation range 225V to 264V Cable sizes are given as a guide on
10. covered by the Hoist covers The 2 Front Tracks and the 2 Side Tracks also have to be regularly lubricated Both Posts Molnar Engineering suggests Teflon or Silicon Sprays may be used because the Hoist will be totally clean and there is no fear of lubricant accidentally being rubbed onto clothing TAC 2 lubricant may also be used Page 9 REPLACEMENT PARTS LIST 85A AA 85A A 218 85A BB 85A B 14 85A B 16 85A B 8 1 85A B 83 85A B 84 85A B 119 85A B 151 85A CC 85A C 14 85A C 17 85A C 40 85A DD 85A D 9A 85A D 10 85A D 11 85A D 13 85A D 24 85A D 25 85A D 36 85A D 37 85A D 38 85A D 39 85A D 63 85A D 66A 85A D 67A 85A D 72 85A D 75 85A D 77 85A D 131 85A EE 85A E 108 85A E 108A 85A E 220 85A E 221 85A E 1S 85A FF 85A F 96 85A F 101TP 85A F 101SP 85A F 163A 85A F 167 85A F 197 85A F 208A 85A HH 85A H 82 85A H 85 Page 10 Basemember and floor plate assembly Floorplate a ssaaciceor gri ie dcr ded don don de ri a ae die 2 Right hand post assembly Cover Base plate anchoring bolt 4 dau ssa e a ar oo Top plate Large power unit carrier bracket Small power unit carrier bracket Right hand post Cover mounting bracket Left hand post assembly Cover Left hand post Cover mounting bracket Cables and pulleys Pulley assembly 218151 PTT 2 Pulley pin retaining Dolt 24 2 2sc0 cade 9 8 S espt eet 2 Long cable
11. ctor into position as shown in above drawing Make sure the door protector ends are flush with the edge 2 Push the protector in at the bend until the holes in the bracket and the MF 1705 85A 3T carriage line up complies fully with the Australian Standard 3 Screw the M6 bolt into position as shown in diagram 1418 9 1987 Page 2 Page 23 INSTALLATION INSTRUCTIONS INSTALLATION PROCEDURE 1 Bolt locking bracket 1 to pick up arm using 7 16 U N F bolts 2 Locate arm 7 in pivoting bracket 3 Slide locking lug 2 followed by spring 6 followed by another locking lug 2 along arm 7 4 Locate locking lugs 2 in locking bracket 1 9 Push pins 3 into position and secure using circlips 6 Push pin 10 into position and secure using circlip 11 7 Place foot pedal 9 over locking bracket 1 8 Push shaft 8 through foot pedal and locking bracket and secure with E clip 12 Page 22 CONTENTS 1117 11 111105 5 20 2 9 5 295 85 6 0 9 8 86 59 0 9 9 9 4 5 Hoist Base Requirements 4 8 6 3 8 8 1 6 b ne beer esee ria Operating INStrUCTIONS 35a cu xacr het Ram eae CC do a Re 7 DULCI TII acp ep ene VOTOS 8 9 Lubrication Procedures for Molnar 2 Post Hoists 9 Replacement Parts List vind neon met 48 06
12. ervice and safety inspection on the hoist must be performed by a competent person This inspection must be recorded If the 12 monthly service and safety inspection is not performed the warranty is null and void NOTE Yearly service must include removal of rollers and pulleys to inspect clean and lubricate bushes and pins 2 YEARLY Hydraulic oil and filter should be replaced Fill Oil Tank to Oil Level Line with Shell Tellus T46 oil Mobil DTE25 oil Castrol Hyspin AWH46 oil BP Bartran HV46 oil or equivalent WIRE ROPE INSPECTION Wire ropes must be inspected by a COMPETENT person Inspect for wear rust and broken wires Ropes are to be discarded according to the criteria Wire rope must be replaced if a At any point the visible number of broken wires exceeds 10 in any length of rope equivalent to 20 times the rope diameter i e for 18mm diameter rope 10 broken wires in 260mm of cable b A strand of wire is broken C Arope has been physically damaged by crushing or deforming LUBRICATION PROCEDURES FOR MOLNAR 2 POST HOISTS It is the Hoist Owner s responsibility and Duty of Care to maintain the Hoist as per the Maintenance Schedule in the Hoist Owner s Manual All Tracks must be lubricated regularly Both Posts This includes the roller tracks behind the covers Both Posts Molnar Engineering suggest that the rear tracks be heavily lubricated You may use grease on the rear tracks because the rear tracks are fully
13. ety HOLON OL 5 During the lifting of the car a clicking sound should be noticeable which indicates the safety mechanism 15 operating If this sound is not heard immediately cease using the hoist and call an authorised service agent Z O 2 Q I D m un a T gt n m 6 The following steps are to be taken when lowering the hoist Raise hoist approximately 20mm Push safety catch 1 the OFF position SAFETY CATCH R H POST 7 Pull release lever down and lower hoist 000 SV HIIM AldINOO OL LINN SIHL OL SNIeIIM 8 If car is to be worked on at an intermediate position re apply safety catch 4 1 OL HSfld 9 To lower to ground level raise car approximately 20mm Release safety catch and lower 10 WARNING Do not go under vehicle under any circumstances while vehicle START NOLLNG BUTTON is being lifted or lowered LEVER Page 18 Page 7 MAINTENANCE CHECK DAILY Check safety mechanism to see that it functions properly CHECK MONTHLY 1 Safety mechanism operation 2 Condition of sheaves shafts and shaft locks 3 Condition of wire ropes 4 Overall cleanliness 5 Clean tracks of dry lubricant and re apply lubricant on wear pad tracks and roller tracks CHECK 6 MONTHLY 1 State of swivel arms 2 Oil leaks from cylinder 3 Oil leaks at pipe joints 4 Anchor bolts 9 Wire ropes CABLE ADJUSTMENT If the long cable has stretched
14. ly for a maximum cable length to 30m Longest cable runs and in area where supply voltage is below motor voltage calculation should be made to ensure Voltage Drop will Installation DV ics suce cR ae x a Re not fall below minimum operating voltage 2155 MT When installed motors must be tested under Full Load checking Voltage at motor terminals 0 0 0 00000 ttt sun dod dog dod dog a a rn NAME T Motor 2 2kW 240V Single phase model CWC3640F i SIONATUE 6 Full Load Current 12 4 Amps Min Cable Size 2 5mm 2 core earth Date isse nnns Circuit Breaker 1 phase 32 Amp 10kA Recommended Clipsal 4CB132 10 or equivalent Page 25 INSTALLATION REQUIREMENTS INSTALLER MUST CHECK THE FOLLOWING LIST WHEN INSTALLING A 77 7 2 7 3 MOLNAR TWO POST HOIST A suitable floor where the hoist is to be bolted down must have a level surface to ensure the hoist base frames lie flat When the hoist is bolted down check all nuts and bolts to ensure they are correctly tightened Check wire ropes and sheaves for possible transport damage or dislocation When power is connected to the hoist terminal box the motor must rotate clockwise If hoist will not lift exchange wires on two phases Check safety mechanism for loose nuts or bolts Check operation of safety mechanism on both sides then test hoist with load Recheck hoist operation Demonstrate the hoist to the operator
15. m should be laid Cement 1 Sand 3 Metal 6 If the floor is solid but not quite level it may be compensated for with steel shims SeeFig 2 If shims are used they must also be placed at the points A B C D and E as required to maintain the level and stability of the Hoist See Fig 3 A concave or convex section to be used as a floor for the Hoist base may be levelled with the use of sand and cement mix See Fig 4 Cement 1 Sand 5 20mm dyna bolts x 82mm length with a thread size 16mm are recommended for fastening down This may differ in some States PACKING SHIMS FIG 2 LEVEL WITH CEMENT 20mm DYNA BOLTS A B C D E 20mm DYNA BOLTS FIG 3 LEVEL WITH CEMENT FIG 4 Page HYDRAULIC CIRCUIT DIAGRAM DESCENT CONTROL VALVE LOWERING VALVE WITH DAMPER PRESSURE RELIEF VALVE COMBINED P R amp MANUAL RELEASE VALVE ASSEMBLY RESERVOIR NON RETURN VALVE m J iL EE lt NON RETURN VALVE WITH RESTRICTED RETURN Ex SINGLE ACTING CYLINDER Page 19 WIRING DIAGRAM OPERATING INSTRUCTIONS 1 Drive car to be centred 2 Place the four pads under edge of car fore and aft at jack points 3 Press starter button and raise car to required height Do not go under car until load rests on safety 4 When car reaches maximum height limit switch will come into operation and stop hoist When hoist has stopped pull release lever until load rests on saf
16. ned or replaced Page 15 ACCESSORIES AVAILABLE FROM MOLNAR ENGINEERING Optional EPO2 Elevated Extension Pads enables easy pickup for vans and 4 wheel drives J3AB Stabilizing Pads prevents pickup pads from slipping Stabilizes the vehicle from rocking movement Page 14 MOLNAR ENGINEERING recommends to all new owners the purchase of our accessories to cover all working situations Featuring JJ3 Large Pickup Pads Rubber size large 140mm FEE Que BHA iil Bill Uu UL DAL 27 LL AZ 5 Ve 2 1 Ni 58 E He IRON N E i M lt D E MES Zar JD REPLACEMENT PARTS LIST 85A H 94 85A H 153 85A H 155 85A H 157 85A JJ 85A J 49 85A J 50 85A J 52 85A J 53 85A J 54 85A J 55 85A J 57 85A J 58 85A J 59 85A J 60 85A J 61 85A J 354 85A J 355 85A J 356 85A J 357 85A J 85357 85A JJ3 85A J3AA 85A J3AB 85A J 8550 85A KL 85A KL 2 85A KL 27 85A KL 30 85A KL 31 85A KL 32 85A KL 35 85A KL 42R 85A KL 216R 85A KL 217A 85A KR 85A KR 3 85A KR 140 85A KR 125 85A KR 126 85A KR 152 85A LL 85A L 79 85A L 142 85A L 145 85A L 146 85A L 148 Superseded Limit Switch Junction box Saddles Cera aao bao Haas Pis des dhe OR ede bee Re ea ees 3 Starter box Lifting arm assembly 4 Locking rod pivot pin Lifting arm pivot pin Pick
17. oist base plate and simultaneously observe the top of both posts for any movement If there is any movement you must check dyna bolts and shims Refer page 6 until the car can be driven over hoist base plate and no movement in the post is observed 26 Clean the hoist of anit corrosion spray Poe oN Page 20 INTRODUCTION FOR SPEEDIER SERVICE With the MOLNAR TWO POST HOIST maximum accessibility is assured No cumbersome beams or cross sections impede the operator in any way giving the hoist unlimited advantages when used for unit replacement With this lifting method the suspension springs are relaxed facilitating lubrication and repair work Wheel service brake adjustment washing underbody spraying or sealing or any underbody repairs can be speedily carried out EASY TO OPERATE The MOLNAR TWO POST HOIST is operated with the greatest of ease The telescopic adjustable arms and contact pads are easily placed in position by one man The operator has full confidence due to the mounting of the arms and the area of the chassis which can be contacted The vehicle is immediately wheel free and stable at any height Page 5 FLOOR REQUIREMENTS FOR HOIST BASE For correct installation of the Hoist the floor must be flat and level A level tolerance between post of 10mm is allowable Check with straight edge and spirit level See Fig 1 In situationss where the floor is too soft a reinforced concrete slab 3850 x 2200 x 120m
18. provision is provided for cable adjustment by winding the cable up SPRING ROLL PIN SLEEVE NUT BRACKET LINKAGE SPLIT PIN Sa stat RSs LEE LE E See LT nn we RS eI SH SE SSS SSS iim Page 8 FAULT CHART FAULT PROBABLE CAUSE REMEDY Leakage of oil at joints Loose joints in the high pressure Inspect the piping and tighten pipes joints Leakage of oil at top Worn packing seal in hydraulic Replace packing seal or of hydraulic cylinder cylinder cylinder Lack of lifting power Release valve not seating properly Rotate valve stem one full turn or a loose connection inside of tank Tighten connections Obstruction in suction side of pump Remove and clean out tank refill with fresh oil Hoist fails to stay up Release valve not seating properly Rotate release valve stem one Loose joints in oil line in the tank full turn or replace Tighten joints or outside If non return valve is not seated Check for dirt or possible damage correctly return oil pressure will to valve seat rotate electric motor Clean or replace Hoist does not respond Power supply to motor is interrupted Check main fuse power source to operation switch Motor turning in opposite direction magnet switch and terminal relay Cables either cut or damaged Interchange 2 terminals in 3 phase circuit Damaged cable Worn sheaves and sheave pins Replace sheaves sheave
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