All Rounder Operation Manual
Contents
1. L K Maximum pad load differential 60 40 e 40 ki For asymmetric hoists ensure the correct direction of vehicle Ld dats WER i i 1 Molnar Two Post Hoists Operation amp Maintenance N mmm Use only recommended wire rope lubricants Ca S NUS Precautions TO RAISE 1 Centre vehicle between posts with centre of gravity midway between pick up pads 2 Identify correct pick up points and position four support pads ensuring contact two at front two at rear 3 Ensure LOCK lever is ON 4 Hold down CONTROL button to raise vehicle to required height During lift the auto load hold lock will click Ifyou do not hear a clicking sound STOP hoist immediately by releasing CONTROL button Do not operate hoist until it has been inspected by an authorised service agent Operation TIAN f Y OPERATION TO LOWER 1 Hold down CONTROL button and raise hoist approximately 50mm 2 Move LOCK lever to OFF to disengage load hold lock 3 Pulldown on LOWERING handle to lower hoist TO LOCK TO UNLOCK 1 Release CONTROLbutton 1 Holddown CONTROL to stop hoist at desired button and raise hoist height approximately 50 mm 2 Pull down on LOWERING 2 Move LOCK lever to OFF position to disengage load lock handle to lower hoist until load hold lock engages and load is supported Hoist will auto stop at maximum height You must lock hoist b2. or shaking during raising or lowering Hoist not staying up Motor will not run Motor runs but will not lift Vehicle leans towards Non Control Post Oil leaks Safety not releasing Safety not staying off Hoist will not goto top Qualified electrician only Trouble Shooting Roller tracks dry Wear pads sticking A Remove covers and grease outer roller tracks lubricate inner wear tracks with dry lubricant Apply dry lube on slide wear tracks Roller bushes dry Sticking lowering handle Remove rollers and grease bushes Lube pivot on handle Contaminated oil Change oil Faulty control valve Replace control valve Bent lowering handle No power supply Stuck limit switch Replace or straighten lowering handle Check circuit breakers Check operation of both limit switches Faulty contactor Phase rotation Replace contactor Check and change rotation of motor Lowering valve open Close valve Hoist overloaded Wire Rope stretched Loose fittings Remove vehicle Remove cover and adjust Wire Rope Tighten fittings Faulty Fittings Replace fittings Ram seal Replace seal Hoist not raised Raise hoist Damaged mechanism Dry pivots in mechanism Replace mechanism Lube pivots Damaged mechanism Low in oil 12 Replace mechanism Top up oil Molnar Two Post Hoists Operation amp Maintenance zs ee AY UY ACCESS
3. the manufacturer reserves the right to change specifications without notice Information is correct and true at time of printing Juty 2012 Contents 2 Molnar Two Post Hoists Operation amp Maintenance zs AY yl OVERVIEW All Rounder Base Asymmetric Quick Lift 4Tonne Number MF1705 93 OH 3T MF1705 85A 3T MF1705 OH 3T AS MF1705 OH 3T QL 2P4T PREMIUM Length 1200 mm lt lt lt 1000 mm Width 3250mm lt lt lt 3450mm Height 3860mm 2770mm 3860 mm 3860mm 3890mm Preferred Clearance Height 150 mm above Height for installation Width Between Posts 2650 mm lt 4 lt Width Between Carriages 2420mm Maximum Raised Height 1900 mm 1900 mm 1900 mm 1855mm 1900 mm Minimum Lowered Height 110mm Reach of Lifting Arms 610 mm min 1020 mm max Wire rope 13mm diameter 6 x 29FW 14 7 7F 1 IWRC RHOL B1770 minimum breaking strength 107kn Motor 3 Phase 3 HorsePower 415 Volt requires 3 Phase and Earth 5 Amp Or Single phase 240 Volt requires 240 Volts under load at motor hard wired on 20 Amp circuit Gross Weight 722 kg Lifting Capacity 3 tonnes 3 tonnes 3 tonnes 3 tonnes 4 tonnes Minimum Lifting Time 27 seconds lt lt lt 35 seconds Hydraulic Oil high quality 46 weight anti wear ik WN N T iia T KN UULU O98 E LHIITH LS5Od UULU O9GE LHOIIH LS5Od ULU OIGE LHOIIH 150d UULU OGBE LHOITH LSOd UULU ZLE LH IIH TWNAFLNI ULU ZLE LH OIF TVNAFLNI UUL OL
4. the structural components for damage deformation corrosion or any other signs of deterioration VISUAL APPEARANCE Check the overall appearance of the hoist for damage signs of deterioration or other potential indicators of faults or hazards OPERATOR S MANUAL AVAILABLE The operator s manual for the hoist must be available in good condition and easily accessible to operators DISPLAYED NOTICES Critical hoist information needs to be displayed on the hoist clearly easily visible and legible for operators RATED CAPACITY is the safe working limit of the hoist LOAD DISTRIBUTION is how vehicles should be loaded safely ona hoist OPERATING INSTRUCTIONS detail how to safely operate the hoist COMPLIANT CLEARANCE Ensure there are no temporary or permanent obstructions around the hoist or vehicles when on the hoist that encroach into the safe area clearance limits Molnar Two Post Hoists Operation amp Maintenance LIMIT SWITCH Ensure that limit switches prevent operation of the hoist beyond the limits of travel WIRE ROPES The wire ropes must be visually checked for signs of deterioration and if necessary cleaned and re lubricated LUBRICATION All lubrication points must be inspected and re lubricated as required ACCESSORIES Accessories should undergo the same inspection as the hoist PULLEYS Visually check rotation during raising and lowering of hoist top pulley A control post pu
5. LE LA DIFH TUNAFLNI UL OLL2 LHOIIH LSOd Molnar Two Post Hoists Operation amp Maintenance Overview zs yl AY SAFETY PRECAUTIONS For your own safety and the safety of equipment always take the following precautions Failure to comply with these precautions may result in loss of load damage to unit and or personal injury lt i gt KTJ Donot make changes to safety equipment 9 Use only vehicle manufacturer s pick up points Ensure you carefully read and understand the operation and safety instructions detailed in this Manual before using the equipment lt D Do not oil or grease extension arms as they should not move in or out while hoistis operating om Monitor vehicle hoist A and area before use and during operation of hoist Ensure area is clear of any personnel or obstructions when raising or lowering 4000 kilograms 4 Tonne ki Do not try to adjust relief valve as it has been set at maximum operating efficiency lt D Do not force safety lever into the off position while weight is resting on safety Load must be locked at all times except when raising or lowering Do not K Donotexceedtherated wm the rated lifting capacity of the unit 3000 kilograms All Ro
6. ORIES l Length 160 mm EP10 Provides valuable extra Width 160mm A clearance for four wheel Height min 130mm 9 EXTENSION PAD drives and vans Height max 225mm a Auxiliary support for J3AB stability Diameter 100mm amp lasting vulcanised rubber BASE JJ3 Supports and stabilises Diameter 140 mm S vehicle Height min 30mm E PICK UP PAD LARGE Height max 80mm zd J3 Supports and stabilises _Diameter 100mm A vehicle _Height min 30mm PICK UP PAD SMALL _Height max 80mm pe OLSB 02 i i Length 1550 mm Sa z isthe more pick up Width 370 mii QUICK LIFT BEAM P Height 110mm r Length 120 mm EXT PAD Provides valuable extra Width 100mm clearance for four wheel Te ere 70mm aioz BEAM RISER STANDARD drives and vans ight mi Height max 215mm Length 120mm ExT Pap Low For vehicles with low Width 100 mm Eeataviee Height min 140mm BEAM RISER LOWERED g aise o2 PY Height max 175mm l Length 120 mm AXLE PU For stable pick up on axle Width 100 mm cradle head prevents lateral Height min 150mm astoz BEAM RISER AXLE PER MOLANA Height max 205mm J3BP Stabilises mere on beams Made from solid long Pad Height 30mm Pe BEAM PAD lasting vulcanised rubber PL92 RB Solid rubber block for Length 150mm cushioned lifting Width 100 mm RUBBER BLOCK STANDARD For use on Rubber Block Nest Height 70mm QLSB 02 PL92 RB 40 For vehicles with low Length 150mm f cle
7. Operation and TWO POST HOISTS maintenance instructions for Molnars D RA NI range of Two Post Hoists AND MAINTENANCE Molnar Hoists manufacture five Two Post Hoists together with a range of accessories made in Australia and built to the highest safety standards Intended for use in commercial workshops these hoists are designed to optimise workshop clear floor space for ease of access cleaning and freedom of movement for equipment ETS CIN zs ee AV UY CONTENTS CONTENTS KEY Overview 03 qi General warning Safety Precautions 04 lt gt Electrical hazard Operating 06 Maintenance o TERMINOLOGY Owner Maintained Procedures 08 From time to time product or process descriptions can Trouble Shooting 12 change or evolve for the purposes of clarity Reeekeories 3 cables wire ropes pulleys sheaves Warranty 14 shafts pulley pins safety lock lift pads pick up pads release lever lowering handle This is owner manual 1 of 4 of every ALLROUNDER ear Monar __ALLROUNDER INSTALLATION F SERENE Rr for Moar ALL ROUNDER Ee OPERALGNS J PARTS LIST siege of Two Post ere x oj matras rhoi ches Suey pace ci me menge SS edesignedto e mercial worksho aes pages sringand fre paes ace yor eguipme ert e a mee shor Be sde oo an As the policy of Molnar Hoists is one of continuous improvement
8. amp TIDY The work areashould be clean and tidy prior to operation to eliminate the risk of slips and trip hazards i e oil parts tools hoses etc STRUCTURE A visual inspection of the structure for anomalies that may indicate damage or deterioration Anomalies must be reported to the authorised person Only an authorised person may assess the condition of the structure The result of this assessment must be reported and recorded LOOSE OR DAMAGED PARTS A visual inspection of hoist components for anomalies that may indicate parts are damaged or loose The result of this assessment must be reported and recorded DECALS amp CONTROL MARKINGS Check to see that the hoist s decals and markings for controls are not only present but are in a good clean condition and clearly visible HYDRAULIC FLUID LEVELS Check the amount of hydraulic fluid in the system is within the correct limits PICK UP PADS Where used check condition of pick up pads to ensure they are clean the material and structure is in good condition and not excessively worn or otherwise damaged ARM LOCKS ARE FUNCTIONING CORRECTLY Maintenance DAILY FUNCTIONALINSPECTION OPERATING CONTROLS Operating controls should be tested by activating through the full range of operation UNUSUAL NOISE OR VIBRATION If during operation unusual noise or vibration is detected it must be reported and treated as a potential fault HYDRAULIC SYSTEM LEAKS After the operatio
9. arance Width 100mm RUBBERBLOCK LOW PROFILE For use on Rubber Block Nest Height 40mm QLSB 02 SLO2 NEST Length 160 mm Nest to house rubber blocks _Width 100mm ato RUBBER BLOCK NEST Height 120 mm Molnar Two Post Hoists Operation amp Maintenance Accessories 13 AUSTRALIAN MADE AND OWNED ETS aS MOLNAR HOISTS For more information please contact us or your local Molnar Representative 16 20 Coglin Street Brompton SA 5007 Australia T 08 7120 8700 FO8 8346 0097 Einfo molnarhoists com au www molnarhoists com au onwards amp upwards
10. eand m arm locks A i E m E Molnar Two Post Hoists Operation amp Maintenance Wire Ropes ANNUALLY If the 12 monthly service and safety inspection is not performed the warranty is null and void Safety operation test Wire rope safety test Check carriage rollers Lubricate pulleys Lift arms pivot pins pick up pads Hydraulic oil and system Electrical controls and travel limits Structural amp general check Accessory conditions 7 2 YEARLY To keep the hydraulic system pump seals valves in good working condition oil changes are required every two years to ensure any degraded or contaminated oil is cleaned out of the system M Replace hydraulic oil M Clean tank and filter He B 0 10 YEARLY After 10 years of service remove Wire Ropes and pulleys from hoist Clean and inspect to ascertain serviceability replace if required It is recommended that pulley bushes be replaced at this time If the hoist is in a high working or extreme environment the Wire Ropes should also be replaced Mi Replace pulley bushes Mi Replace wear pads M Replace pick up pads E Wire Ropes amp pulley removal and inspection Maintenance TTAR W OWNER MAINTAINED DAILY VISUAL INSPECTION ACCESS amp CLEARANCE Ensure there are no obstructions around the hoist or vehicles when on the hoist that could prevent operators working safely on and around the hoist and vehicle WORK AREA CLEAN
11. efore commencing work at any height Lock Lever Molnar Two Post Hoists Operation amp Maintenance zs TIAN W MAINTENANCE OWNER MAINTAINED described in this Manual ki It is the Hoist Owner s responsibility and Duty of Care to maintain the hoist This must be recorded and retained D DAILY M Visual Access amp clearance Inspection Workareaclean amp tidy Structure Loose or damaged parts Decals amp control markings Hydraulic fluid levels Pick up pads M Functional Operating controls Inspection Safety mechanism Unusual noise or vibration Hydraulic system leaks MM Check Accessories MONTHLY E isolation points Flooring Anchor bolts Structural alignment Structural integrity E Visual appearance Compliant clearance Safety mechanism Pick up pads Limit switches Wire ropes Check accessories Lubrication Pulleys Displayed notices Six MONTHLY Additional checks on top of Monthly check E Oil leaks from cylinder MH Oilleaks at pipe joints E Anchor bolts SERVICE PROFESSIONAL described in Service Manual ki Service and safety inspection on the hoist must be performed by a competent person This must be recorded and retained AFTER 6 WEEKS The first oil change should occur within the first three months of operation to remove any contaminants flushed through the system m E change the hydraulic oil a M readjust longcabl
12. er tracks can be heavily lubricated as the qi Wire ropes must be inspected by a COMPETENT person Wire ropes should be replaced by an authorised service agent Maintenance outer tracks are fully covered by the Hoist covers 4 Lubricate the safety mechanism and linkages with spray lubricant Check operation by raising and lowering 10 Molnar Two Post Hoists Operation amp Maintenance TIAN f Y OWNER MAINTAINED MONTHLY CHECK SWIVEL ARMS 1 Wear Pads gt Raise hoist to waist height gt Check free play in carriages by rocking the carriages sideways There should be 1 2mm of movement gt If there is excessive movement side wear pads will need to be replaced 2 ArmExtension gt Pullarms out to ensure that Extension stops are in place amp gt gt If arms pull out of the carriage or do not pull out at all arms will need to be replaced 3 Auto Arm Lock gt Check that there isn t excessive vertical movement at the Arm Lock gt Check that the circlip on the pivot pin isin place gt Check that the split pin is still in place in the pivot pin gt Raise the Lift Rod and disengage lock mechanism to check smooth movement of arms f as gt Raise the Lift Rod position arm in normal operating position release lift rod and apply side force to the arm Ensure the lock remains engaged gt Visually inspect that the locking teeth are in good condition gt L
13. lle Wi h control post bottom pulle i KE if pulleys are not rotating freely pulleys must be removed inspected replaced by an authorised service agent Maintenance a aa W AY OWNER MAINTAINED MONTHLY WIRE ROPE INSPECTION 1 Loosen the 4 M6 bolts securing the covers to the posts lift and remove 2 Visually inspect wire ropes for wear corrosion deformities and fractures with the hoist fully lowered 3 Repeat with the hoist fully raised MONTHLY LUBRICATION PROCEDURES 1 Wipe grease or lubricant from gt outer roller tracks gt inner roller tracks side wear tracks on both posts with acloth ki if any damage is found to the wire ropes contact an authorised service agent for further investigation Wire rope must be replaced if A Atany point the visible number of broken wires exceeds 7 wires in 78mm length of rope or 14 wires in 390mm length of rope B Thenumber of broken wires is likely to exceed the above measure by the next service B Astrandof wire is broken c Arope has been physically damaged by crushing or deforming D Ifthere are any inconsistent areas If inconsistency is found it should be replaced or referred to a wire rope specialist for inspection 2 Applylubricant to gt inside roller tracks gt side wear tracks on both posts with Dry Spray Lubricant 3 Grease Outer Roller Tracks with Marine grade wheel bearing grease Outer roll
14. nal check the areas of the hydraulic circuit must be inspected for leaks Evidence of fluid on the hoist can be a sign of a potential fault ACCESSORIES Accessories should undergo the same inspection as the hoist DAILY CHECK SAFETY MECHANISM 1 Raise hoist up to 200mm from floor 3 Switch LOCK lever to OFF position and ensure it remains in position 4 Lower hoist to ground to check that the safety LOCK lever resets to the ON position qi If safety mechanism does not operate properly do not operate hoist until it has been inspected by an authorised service agent Molnar Two Post Hoists Operation amp Maintenance TIAN W OWNER MAINTAINED MONTHLY INSPECTION ISOLATION POINTS Are there appropriate isolating points to allow the hoist to be safely isolated and locked out to prevent accidental or unwanted operation FLOORING Check condition of floor area where the hoist is mounted i e is not cracked or crumbling especially in the region surrounding mounting bolts ANCHOR BOLTS Check the anchor bolts are secure in the concrete the bolts are tight and are not excessively corroded or otherwise deteriorated or damaged GFZ There is significant difference between a Base Bolt and an Anchor Bolt Please familiarise yourself with the respective bolt location before adjusting or servicing bolts Base Bolts Anchor Bolts STRUCTURAL ALIGNMENT INTEGRITY Visually check the physical condition of
15. ower hoist to the ground and test the Auto Release Molnar Two Post Hoists Operation amp Maintenance 4 Pick Up Pads gt Check that pads screw up and down freely gt Check that the thread is not worn that there isn t excessive rocking gt Check that the retention washer and circlipis in place at the bottom of the pad shaft so that the pads can not screw out gt Ensure that the rubber of the padis in good condition remains pliable and soft and the groves in the Pad are visible F q ki If there is an issue with Wear Pads Arm Extensions and or Auto Arm Lock they should be inspected adjusted and or replaced by an authorised service agent Six MONTHLY CHECK OIL LEAKS 1 Check for oil leaks from cylinder Visual inspection If leaks are detected remove and replace cylinder Check for oil leaks around pipe joints at post and oil tank Visual inspection If leaks are detected tighten oil fittings a gt Hydraulicrepairs should be performed by an authorised service agent Six MONTHLY CHECK ANCHOR BOLTS 1 2 3 4 5 Rock the hoist to check for ANY movement Use aspirit level to ensure posts are vertical in both axis Visually inspect anchor bolts Tighten anchor bolts manually Check that the Shimming of the Hoist is secure and in good condition Maintenance zs AY yi U TROUBLE SHOOTING Q Knocking noise during raising or lowering Shuddering
16. under Base Asymmetric Quick Lift ki Do not attempt to operate the hoist from under vehicle Regular service and maintenance must be carried i l out as per the Maintenance requirements detailed in this Manual Failure to do so may void warranty and cause risk of injury Precautions ki Remove brake fluid spills immediately as this will damage the powder coat Clean the hoist with warm AAJ water and nonabrasive pH neutral detergents Surfaces should be thoroughly rinsed to remove residue After floor cleaning thoroughly rinse base of hoist to remove residue 4 Molnar Two Post Hoists Operation amp Maintenance TTAR jl M SAFETY PRECAUTIONS MOIST CONDITIONS qi Always use safety stands when removing or installing heavy components KTP This vehicle hoist is not designed to be used in amp around steam cleaning nor to be installed in the open exposed to the elements Hoists installed under such conditions are not covered by our guarantee lt D Do not operate if damaged In moist conditions ensure moving components are well lubricated To prevent rust in the cylinder raise the hoist to full height and leave it there when not in use overnight and on weekends Seal all electrical conduits and switches m qi Do not load or unload unless hoist is fully lowered qi Perform risk assessment before attempting to lift loaded vehicles
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