Molift Air 300 User manual

TM16101 Rev A 2013-11-14
Molift Air
EN - Technical manual

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Molift Air / www.molift.com
Content
General.....................................................2
How to open.............................................3
Disconnect battery ....................................3
Molift Service Tool.....................................4
Technical description .................................5
Measurements ..........................................6
Air Components........................................7
Spare part list..........................................12
Labels ..................................................... 13
Battery.................................................... 14
Covers ....................................................15
Hand control ........................................... 17
Angle Sensor/Ens Sensor..........................18
Suspension coupling................................19
Emergency Stop/Lowering .......................20
Replacing Lifting Band .............................21
Brake ......................................................22
Lifting Motor/Gear House ........................23
Microswitches .........................................24
PCB (Printed Circut board) .......................25
Electric Diagram ......................................26
Trolley .....................................................27
IRC (In rail charging) ................................28
Propulsion ...............................................28
Documenting the Service.........................29
Periodic Inspection Checklist Molift Air ....30
Safety checklist after Service and Repair...31
Service Log .............................................32
Installation ..............................................33
Notes ......................................................33
Important
This Technical Manual contains important safety
instructions and information regarding the repair
and service of the lifter and accessories.
Warning!
This symbol indicates important
information related to safety.
Follow these instructions carefully.
Read User Manual before use!
It is important to fully understand
the content of the user manual
before attempting to use the
equipment.
Visit www.molift.com for download of documen-
tation to ensure you have the latest version.
Conditions of Performing Service/Repair
Lift and transfer of a person will always pose
a certain risk and only certified personnel are
allowed to repair and service the equipment and
accessories covered by this technical manual.
Only certified personnel are
allowed to open hoist or acces-
sories to perform service or repair.
Risk of injury from rotating parts
and electric shock.
Activate emergency stop before
opening side covers. Disconnect
battery before any repair or
service.
When disassembling and assem-
bling the lifter, take care that no
cables are squeezed or damaged,
this might cause malfunction.
Any Service or Repair should be
documented in the service log, and
verified by using the Checklist after
service and repair.
English Manual

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Molift Air / www.molift.com
General
Product Identification
The Product labels barcode contain product ID,
serial number and production date.
Transport and Operating Conditions
Transport and Storage
For long time storage it is recommended that the
emergency stop button is activated (pulled out).
The lifter can be stored and transported under
temperatures between -25 - 70 °C.
Operating
The lifter is designed for use at standard room
temperatures (+5 to +40°C).
Air Pressure: 70 - 106 kPa
Relative Humidity: 15 - 93 %
Following storage or transport at other tempera-
tures leave the lifter in a room with a suitable
temperature until it reaches a safe operating
temperature.
Medical electrical equipment
requires special precautions regard-
ing electromagnetic compatibility
(EMC). Portable or mobile radio
communication equipment may
affect the medical electrical equip-
ment, and should be kept minimum
25 cm (10 inches) from the lifters
electronics.
Battery and Service indicator
The lifter has two indicator lights.
Wrench symbol / Service light
Battery symbol / Battery light
The electrical system has a power save function
which will turn off the electrical system after ten
minutes without activity. All lights will turn off.
The system is activated when pushing one of the
operating buttons
Battery Light
The battery indicator light will illuminate and
make a sound when battery level is low and the
lifter requires charging. When this occurs the lifter
will have sufficient power available for one full lift
cycle with SWL. When battery is critically low it is
only possible to lower the lifting band.
Service Light
The electronics record the loads lifted and how
much the lift has been used. After a certain period
of operation a signal is given to indicate that
service is required.
Service light Mode
No light Power saving (Stand by)
Green Ready for use
Yellow Order service
Red Perform service
Red + sound Perform service
immediately
Flashing yellow Overheating
Service Scope
Service scope
Service involves replacing the lifting band and
inspection/replacement of worn parts. This must
be carried out by authorised personnel.
Service is needed when the service light is red
(calculated 5.000 lifts in weightclass 2), or service
is required after 5 years if the service counter not
has displayed red yet.
Authorised service personnel can use the Molift
Service Tool to take readings of the lift’s data and
number og lifts.

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Molift Air / www.molift.com
How to open
Disconnect battery
Emergency Stop
Activate emergency stop before
opening side covers.
Pull to activate emergency stop. The button will
come out, and hoist will stop.
Remove sidecovers
Sidecovers are snap-on and can be released by
pushing down the two buttons on top of the lifter
and pulling the sidecover outwards.
Sidecovers are interchangeable.
Disconnect battery before any
repair or service.
1. Activate emergency stop.
2. Open side cover.
3. Locate battery cable on PCB, and disconnect.

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Molift Air / www.molift.com
Molift Service Tool
Authorised service personnel can use the Molift
Service Tool software to take readings of the lifters
data and to log servicing work. The owner of the
lift is responsible for logging service work and
repairs.
Connect Service Tool Cable
1. Remove hand control cover.
2. Unplug hand control and and insert service
tool cable.
3. Refer to User Manual for Molift Service Tool for
instructions on how to use the Molift Service
Tool software.
Service Tool Software
Molift Service Tool software can be downloaded
from http://molift.hwiig.no/download, contact Etac
Supply Gjøvik for user account.
Article no.
1299 011 Molift Service Tool 4
1299016 Molift Service Tool 4 (Lite Upgrade)
1299015 Molift Service Tool 4 (Lite)
1299002 Cable for Molift Service Tool (13 pin
DIN - USB)

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Molift Air / www.molift.com
Technical description
The motor for raising and lowering is of the 24 V
DC (direct current) type fitted with a worm gear
and 24V DC Brake.
The trolley is directly connected to the gearhouse,
and the gearhouse is loadbearing.
The lifter is programmed with a maximum current
limit for lifting motor. It prevents the lifter from
lifting more than SWL.
Sensors/Microswitches
• End/Angle: Activated if band angle to steep, or
band completely in.
• Band Slack: Activated if band is not in contact
with the guiding drum. This occurs if no
weight is applied to lifting band, or band is
completely out.
• Drum size: The switch is activated by a trigger
arm when more than half of the lifting band
is out, approx. 150 cm/60 inches. When the
micro switch is activated it reduces the maxi-
mum current limit. The current limit prevents
the lifter from lifting more than SWL. More
band on the drum gives higher torque and the
motor will require more current to lift max load
when drum is full of band, and less current
when drum is empty.
Variant Matrix Lifter/Trolley
Standard Molift Rail:
Article no. Lifter Trolley
2501205 Molift Air 205 2520000 Basic Trolley
2501300 Molift Air 300 2520000 Basic Trolley
2501210 Molift Air 205 Propulsion 2500103 Trolley Propulsion
2501310 Molift Air 300 Propulsion 2500103 Trolley Propulsion
2501215 Molift Air 205 IRC 2520002 Trolley IRC
2501315 Molift Air 300 IRC 2520002 Trolley IRC
2501220 Molift Air 205 IRC Propulsion 2520006 Trolley IRC Propulsion
2501320 Molift Air 300 IRC Propulsion 2520006 Trolley IRC Propulsion
Trolley for other Rail Systems:
2520001 Trolley Basic Type G+I
2520004 Trolley Basic Type L+N
2520005 Trolley Basic Type M

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Molift Air / www.molift.com
Measurements
Art.no Type / Size H2 W2 L2
1830003 2 point Small 120 -340
1830002 2 point Medium 120 -440
1830001 2 Point Large 120 -540
1830012 4 point Small 210 300 340
18 30 011 4 point Medium 220 300 440
1830010 4 point Large 240 360 540
1530006 4 point X-Large 240 380 640
All measurements in mm.
W1
A
F
CSP
B
D
E
C
C
C
L1 H1
Dimensions:
L x W x H (Length, Width, Height without trolley)
360 x 190 x 195 mm
A(Hoisting Range)
300 mm
B(Minimum distance from ceiling to CSP)
345 mm
C(Basic Trolley wheel to connection point lifter)
see table under
D(Hoist height from connection point to CSP)
249 mm
E(Wheeltrack inside rail to under rail H62)
10 mm
F (C+D+H2-E= Total height from rail to connection
point for sling)
Art.no Type / Size C
2520000 Basic Trolley 29,6
2500103 Trolley Propulsion 72,6
2520006 Trolley IRC Propulsion 72,6
2520002 Trolley IRC 29,6
All measurements in mm.

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Molift Air / www.molift.com
Air Basic
Exploded
Drawing
20-001
Rev. K
Air Components

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Molift Air / www.molift.com
2500000 AIR BASIC
Pos Article no. Description
12510001 Motor Assy
22510000 Lower Cover
32510002 Emegency Lowering Switch
42520112 Main PCB Molift Air
511015 8 8 Rope
61101587 Knob Red (Rope End)
72510003 Emergency Stop Knob
82510004 Upper Cover
92510005 Side Cover
10 2510023 Battery 26,4V NiMh
11 2510006 Offlead Angle Sensor
12 2510007 Micro Switch
13 2510008 Bottom plate
14 2510035 Label. Emergency Stop
15 1100303 Label: Safety Check
16 2510060 Label: Battery & Service
17 1220308 Screw, Socket Head Cap
18 0620134 Self-adhesive Cable-clip
19 1220330 Screw, Reform
20 0620133 Self-adhesive Cable-clip
21 2510009 Cable no.4 Sensor
22 2510010 Cable No.3 PCB-DIN-ED
23 2510077 Quick Release for suspension
24 2510025 Cable no. 2, Emergency Stop
25 2510026 Cable no. 5, Emergency Stop
26 2510027 Cable no. 6, Emergency Stop
27 2510028 Battery Lock
28 2510061 Cover Handcontrol
29 2510041 Quick Release Unit
30 2510084 Removed
31 2510079 Emergency Lowering
32 1310133 Screw, Ejot PT-screw, KB 40
33 2510074 Cable no. 3, Emergency Stop
34 1101562 Screw, Socket Head Cap
35 2510099 P V C- p i p e
36 2510012 Carboard Box
37 2510092 Inlay no. 3 Carboard Box
38 2510093 Inlay no. 4 Carboard Box
39 2510032 Inlay no. 1 Carboard Box
40 2510137 6-kant nøkkel 90-grader
41 2510136 6-kant nøkkel rett
42 2510205 Plate IP sealing
43 2510206 Plate IP sealing small
44 2510207 Cable no. 7, Emergency Stop
2501205 AIR 205
Article no. Description
2500000 Air Basic
2510080 Prod. Label 2 Molift Air 205
2510044 Label Molift Air 205
2017002 Hand Control 2 button w/charg
2501300 AIR 300
Article no. Description
2500000 Air Basic
2510078 Prod. Label 2 Molift Air 300
2510 011 Label Molift Air 300
2017002 Hand Control 2 button w/charg
2501210 AIR PROPULSION 205
Article no. Description
2500000 Air Basic
2510072 Propulsion Cable
2510080 Prod. Label 2 Molift Air 205
2510044 Label Molift Air 205
2019004 Hand Control 4 button w/charg
1310144 Contact
1310145 Contact Cover
0420121 Cable
0620133 Sel-adhessive Cable Clip
2501310 AIR PROPULSION 300
Article no. Description
2500000 Air Basic
2510072 Propulsion Cable
2510078 Prod. Label 2 Molift Air 300
2510 011 Label Molift Air 300
2019004 Hand Control 4 button w/charg
1310144 Contact
1310145 Contact Cover
420121 Cable
0620133 Self-adhessive cable Clip

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Molift Air / www.molift.com
Air IRC Basic
Exploded
Drawing
20-012
Rev. E

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Molift Air / www.molift.com
2500001 AIR IRC BASIC
Pos Article no. Description
12510001 Motor Assy
22510000 Lower Cover
32510002 Emegency Lowering Switch
42510112 Main PCB (High trac)
511015 8 8 Rope
61101587 Knob Red (Rope End)
72510003 Emergency Stop Knob
82510004 Upper Cover
92510005 Side Cover
10 2510023 Battery 26,4V NiMh
11 2510006 Offlead Angle Sensor
12 2510007 Micro Switch
13 2510008 Bottom plate
14 2510035 Label. Emergency Stop
15 1100303 Label: Safety Check
16 2510060 Label: Battery & Service
17 1220308 Screw, Socket Head Cap
18 0620134 Self-adhesive Cable-clip
19 1220330 Screw, Reform
20 0620133 Self-adhesive Cable-clip
21 2510009 Cable no.4 Sensor
22 2510010 Cable No.3 PCB-DIN-ED
23 2510077 Quick Release for suspension
24 2510025 Cable no. 2, Emergency Stop
25 2510026 Cable no. 5, Emergency Stop
26 2510027 Cable no. 6, Emergency Stop
27 2510028 Battery Lock
28 2510061 Cover Handcontrol
29 2510041 Quick Release Unit
30 2510079 Emergency Lowering
31 1310133 Screw, Ejot PT-screw, KB 40
32 2510074 Cable no. 3, Emergency Stop
33 1101562 Screw, Socket Head Cap
34 2510099 P V C- p i p e
35 2510012 Carboard Box
36 2510092 Inlay no. 3 Carboard Box
37 2510093 Inlay no. 4 Carboard Box
38 2510032 Inlay no. 1 Carboard Box
39 2510137 6-kant nøkkel 90-grader
40 2510136 6-kant nøkkel rett
41 2510147 AIR IRC-Unit
42 2010205 Cable no. 7, Emergency Stop
43 2010206 Plate IP sealing
44 2010207 Plate IP sealing small
2501215 AIR IRC 205
Article no. Description
2500001 Air Basic IRC
2510080 Prod. Label 2 Molift Air 205
2510044 Label Molift Air 205
0440002 Hand Control 2 buttons
2501315 AIR IRC 300
Article no. Description
2500001 Air Basic IRC
2510078 Prod. Label 2 Molift Air 300
2510 011 Label Molift Air 300
0440002 Hand Control 2 button
2501220 AIR IRC PROPULSION 205
Article no. Description
2500001 Air Basic IRC
2510072 Propulsion Cable
2510080 Prod. Label 2 Molift Air 205
2510044 Label Molift Air 205
2018004 Hand Controll 4 button
1310144 Contact
1310145 Contact Cover
0420121 Cable
0620133 Self-adhessive Cable Clip
2501320 AIR IRC PROPULSION 300
Article no. Description
2500001 Air Basic IRC
2510072 Propulsion Cable
2510078 Prod. Label 2 Molift Air 300
2510 011 Label Molift Air 300
2018004 Hand Control 4 button
1310144 Contact
1310145 Contact Cover
0420121 Cable
0620133 Sef-adhessive Cable Clip

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Molift Air / www.molift.com
Air Motor
Exploded
Drawing
20-011
Rev. D
2510001 Motor Assy Molift Air
Pos Article no. Description
1Gear Box
20920072 Molex Plug
30920078 Molex Crimp Socket
4Connector
5Contact Cover
61220116 Microswitch
7 Screw, Slottet Cheese Head
8Spring Perch
91410134 Screw, Socket Head cap
10 1220194 Extension Spring
11 1220155 Axle for Guiding Drum
12 1220158 Guiding Drum
13 1220313 Circlip
14 Axle
15 1410134 Screw, Socket Head Cap
16 Trigger Arm
17 Screw, Socket Head Cap
18 Hexagon sleeve
19 1431011 Set Screw
20 Constrictor

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Molift Air / www.molift.com
Spare part list
Recommended spare parts to keep in stock for
Service personnel.
Article no.
1240100 Charger Nomad/AIR
2510023 Battery 26,4 V NiMH Molift Air
2510063 Lifting Belt Molift Air
2017002 Hand Control 2 buttons with charg-
ing probes
2510005 Side Cover
2510004 Upper Cover
2510008 Bottom plate
2510007 Micro Switch
2510008 Bottom plate
2510006 Offlead Angle Sensor
2520112 Main PCB Molift Air
1810010 Quick Release Pin Suspension
2510028 Battery Lock
2510061 Cover Handcontrol
1130120 Cap Ø32
11015 8 8 4mm red Polyester/cotton cord
1101587 Knob Red (Cord End)
2510003 Emergency Stop Knob
2510002 Emegency Lowering Switch
2510099 Tube 6/8mm red Length 40 cm
2510145 Brake 24V DC
2510137 6-kant nøkkel 90-grader
2510136 6-kant nøkkel rett
2510001 Motor Assy Molift Air
2510041 Quick release unit
2510077 Quick release for alu suspension
2510035 Label emergency stop/lowering
2510060 Label Service/battery
2510079 Label emergency lowering
1220194 Extension Spring
1220116 Microswitch
2510146 Hexagon sleeve
1431011 Set Screw

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Molift Air / www.molift.com
Labels
Labels
Pos Article no. Description
1 2510035 Emergency stop/lowering
2 2510060 Service/battery
3 2510079 Manual Emergency lowering
4 1100303 Safety Check (Periodic control)
5 1100306 Month/year (Periodic control)
62510044 Cover label 205
62510 011 Cover label 300
72510080 Main label 205
72510078 Main label 300
8N/A Serial number label
NB!! Contact Etac Supply Gjøvik for barcode label
with article and serial number when replacing
main label.
CONTROL
12 Month
2
5 1 38
7
6
6
45
8
3
7
1
2
6
4

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Molift Air / www.molift.com
Battery
Molift Air has a 26.4 V NiMH battery pack. The
battery has a life expectancy of approx. 500
charge cycles.
x2
Batteries must be fully charged and
depleted completely a couple of
times before it achieves full capac-
ity. Also follow this procedure if
the lifter has not been in use for a
long period (3-4 weeks)
Charging batteries
The lifter is charged through the Hand control or
In-rail charging. Charge time 0-100% 3-8 hours.
Charger Light
Description of charger light on battery charger
unit:
Charger light Mode
Yellow Ready for use, no bat-
tery connected
Yellow Initialization
Red Fast Charge
Green/ Yellow Top-off charge
Green Trickle charge
Red/Green Error
Change battery
1. Activate emergency stop
2. Open both sidecovers
3. Disconnect battery power cable and temp
sensor from PCB
4. Use 5mm Hex key and remove screw from
battery holder.
5. Push the battery out from the back side.
6. Release cables from cableclips and remove
battery.
7. Install new battery in reverse order.
Used batteries must be disposed
of as special waste according to
local rules and regulations. Do not
dispose in general waste
Check after installation
Deactivate emergency stop (push button
back in). The lifter makes a sound and
service light is on.
Perform and fill out Safety checklist
after service and repair
Battery Parts
Article no.
2510023 Battery 26.4 V NiMH
2510028 Battery Lock
Battery

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Molift Air / www.molift.com
Covers
The lifter has 6 covers. 2 identical side covers,
Hand control cover, Bottom plate, Upper cover and
lower cover.
Remove Side covers
Sidecovers are snap-on and can be released by
pushing down the two buttons on top of the lifter
and pulling the sidecover outwards.
Remove Hand control cover
Unscrew both screws (Torx 20) and remove cover.
Remove Upper cover
Remove both sidecovers, disconnect battery
Push in Quick release button for trolley, and
remove the M2,5 setscrew. (1,3mm hex key)
Setscrew is glued with Loctite 243, and must be
glued when remounted.
Disassemble the Quick release button, unscrew
the parts by hand.
Remove the 4 screws (Torx 20) in each corner and
lift of the cover.

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Molift Air / www.molift.com
Remove Bottom Plate
The bottom cover are locked with snap hooks.
Open sidecover to access the snap hooks, and
push them out from inside.
Change Lower cover
1. Remove Sidecovers, disconnect battery
2. Release all cables from cable clips.
3. Remove battery clamp (hex key 5mm) and
battery.
4. Remove hand control cover and hand control.
5. Remove suspension coupling.
6. Remove bottom plate.
7. Remove Remove Emergency stop relay and
button.
8. Remove Angle sensor plastic part, and micro
switch.
9. Remove the 2 screws from PCB (Torx 20)
10. Remove the 4 Screws (hex key 4mm) from
motor/gear house holding the lower cover, 2
screws on each side.
11. Remove the 4 screws (Torx 20) in each corner
of the lower cover
12. Cut the wire for angle sensor micro switch.
13. Cut the wire for LED lights and remove cover.
14. Pull wires for Led lights and microswitch
through the new cover, and solder wires. Use
heat shrink tube to isolatee on all wires.
15. Glue led indicators to lower cover and insert
angle sensor microswitch in slot.
16. Remount all parts as described (pt. 1-11) in
reverse order.
Check after installation
Make sure all covers are attached properly
and there are no loose parts.
Run the lifter, and pull band sideways to
activate angle sensor. The lifter should stop
lifting when angle sensor activates.
Perform and fill out Safety checklist
after service and repair
Cover Parts
Article no.
2510005 Side Cover Tegn. (20-104)
2510004 Upper Cover Tegn. (20-101)
2510000 Lower cover Tegn (20-102)
2510008 Bottom plate Tegn. (20-103)
2510061 Hand control cover (20-136)
Led lights
2510007 Microbryter Series 1050 Wlfa
35-830-55

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Molift Air / www.molift.com
Hand control
Hand control
The Hand control has 2 buttons for lifting and
lowering, or 4 buttons if the hoist is equipped
with propulsion. The Hand control has an indica-
tor light that will illuminate when battery level is
low and the lifter requires charging
The Hand control has four charging probes on the
back for charing through wall mounted charger, or
no probes if lifter has In Rail Charging (IRC).
Hand Control Clip
Hand control clip is snap on and can be replaced
by lifting snap hook (use a plastic pry tool) and
push clip downwards.
Hand control with four charging probes.
Remove Hand control
1. Unscrew both screws (Torx 20) and remove
cover
2. Unplug hand control
Install Hand control
1. Connect hand control
2. Attach cover and tighten both screws properly
(Torx 20)
Check after installation
All buttons and functions are working
The cover shall function as a cabel clamp.
Pull the hand control cable slightly to makes
sure the cover is properly fastened.
Perform and fill out Safety checklist
after service and repair
Hand Control Parts
Article no.
2510061 Cover Handcontrol
2017002 Hand Control 2 buttons w/charging
2019004 Hand Control 4 buttons w/charging
0440002 Hand Control 2 buttons
Hand Control 4 buttons
0440004 Replaceable hook for Molift hand
controls

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Molift Air / www.molift.com
Angle Sensor / End sensor
The hoist has a directional safety feature that
prevents lifting if angle on lifting band is to steep.
>30˚
If the hoist doesn’t respond to Hand control “up”
button, it might be because lifting band angle is
to steep, or lifting band is twisted and sensor is
activated.
This sensor also detects the end of the band, and
stops the lifter when the band is driven all the way
in.
Change angle sensor plastic part
1. Open sidecover and disconnect battery
2. Remove bottom (see “Bottom Plate” page 16)
3. Remove suspension coupling (see “Suspension
coupling page 19)
4. Change angle sensor plastic part, make sure to
install it the correct way (chamfered edges in
center facing up).
Change angle sensor microswitch
1. Open sidecover and disconnect battery
2. Remove bottom cover (see “Remove bottom
plate” page 16)
3. Use a plyer to pull the broken microswitch out,
or push it out from the inside of the lifter.
4. Cut the wires, and pull the wires out through
the hole.
5. Solder the wires to the microswitch on the
outside and use heat shrink tube to isolatee.
6. Push the microswitch into the hole to lock it in
place.
7. Mount bottom plate.
Check after installation
Run the lifter, and pull band sideways to
activate angle sensor. The lifter should stop
lifting when angle sensor activates.
Drive the band completely in. The sensor
should aktivate and lifter stop running
when the band is driven all the way in.
Perform and fill out Safety checklist
after service and repair
Angle sensor Parts
Article no.
2510006 Angle sensor plastic part
2510007 Microbryter Series 1050 Wlfa
35-830-55

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Molift Air / www.molift.com
Suspension coupling
Change suspension coupling
1. Pull of the plastic cap
2. Push the bolt out
3. Pull the band out
4. Remount in reverse order
Checklist after installation
Make sure cap is properly fastened and
doesn’t slide of.
Make sure the sviwel rotates freely
Perform and fill out Safety checklist
after service and repair
Suspension Coupling Parts
Article no.
1810010 Quick Release Pin Suspension
1130120 Cap Ø32
2510077 Quick release coupling