Molift Smart 150 User manual

- a patient lifter from
TM09201 Molift Smart 150 English

TM09201 Molift Smart 150 English - Rev. D1/ 03/2012Page 2 of 24
IMPORTANT!
The patient lifter is only meant to be used by
qualied personnel.
The manual shall not be handed over, or
made available to, any unauthorised third
party, without a prior written consent from
Etac Supply Gjøvik. Existing laws, conventions
and agreements protects all documents. No
extract of this documentation can be re-
produced, used or transferred without pri-
or written consent from Etac Supply Gjø-
vik. Violation of these regulations may lead
to judicial repercussions and economic
responsibility. Industrial rights are reserved.
Etac Supply Gjøvik
Hadelandsveien 2
2816 Gjøvik, Norway
Teleph: ([phone] www.molift.com
Fax: [phone] [email protected]
Table of Content
General advice....................................................... 3
Explanation of symbols................................... 3
Caution.............................................................. 3
Responsibility................................................... 3
Technical description ......................................... 4
Chassis ............................................................. 4
Lifting column................................................... 4
Lifting arm with suspension............................ 4
Charger and battery ........................................ 4
Service ...................................................................... 5
Equipment and special tools........................... 5
Equipment ........................................................ 5
Special tools..................................................... 5
Fault finding............................................................ 6
Repairing.................................................................. 6
Actuator............................................................. 6
Rear castors..................................................... 7
Front castors .................................................... 7
Front castor with bracket................................ 7
Electronics (PCB) ............................................ 8
Leg mechanism / pedals ................................ 9
Suspension / O-ring in suspension ............. 10
Lifting arm, lifting column and legs ............. 10
Foam cover chassis/legs.............................. 10
Lifting column stopper....................................11
Plugs in column lock ......................................11
Finishing the job................................................. 12
Safety control ................................................. 12
Logging ........................................................... 12
Inspection Diagram after Service and
Repair ...................................................................... 13
Service: ........................................................... 13
Safety Inspection........................................... 13
Appendix A............................................................ 14
Main components .......................................... 15
Appendix B............................................................ 16
Column and lifting arm...................................17
Appendix C............................................................ 18
Chassis / leg mechanism ............................. 19
C1 Bracket with front castor......................... 19
Appendix D............................................................ 20
Battery holder / electronics .......................... 21
Appendix E............................................................ 22
Electrical Diagram ......................................... 22

Page 3 of 24
General advice
This technical manual contains important safety
instructions and information regarding the service
and repair of the lifter. Carefully read the manual in
order to be familiar with function and use, service
and repair of the lifter.
Explanation of symbols
This symbol is used to point out instructions
and information related to work place safety
where injury may occur if the information is
disregarded or ignored. Follow these instruc-
tions, be careful and attentive at all times.
This symbol indicates important information
regarding the use of the equipment. If not
taken into consideration, it may lead to dam-
age or functional defects to the lifter or other
equipment.
This symbol indicates important and useful
information. If taken into consideration, it
will help the operator of the lifter to work ef-
ficiently. It may help simplify routines and to
explain complicated facts.
Caution
When repairing the lifter, you will nd it necessary
to lift and handle heavy, long and/or sharp objects.
When disassembling and assembling the lifter you
may also nd that the stability of the lifter may be
reduced, increasing the risk of toppling the lifter or
parts falling down.
Therefore, use general caution when performing
maintenance and repairs.
The lifter must not under any circumstances
be put to use or tested with load without the
bottom cover C
27
(Appendix C, position 27)
properly in place with all bolts fastened. The
plate contributes significantly to the stiffness
of the chassis, and lifts without this plate may
cause irreparable structural damage to the
chassis.
Responsibility
Please read these operating instructions carefully
before putting the product into operation. We as-
sume no liability for damage or malfunctions re-
sulting from failure to comply with the instruc-
tions. Warranty claims must be made immediately
on detecting the defect. Remember to quote the
serial number. Consumable parts are not subject
to the warranty.
All technical information, data and instructions
for operation contained in these operating in-
structions were up-to-date at time of print and
are compiled on the basis of our experience and
to the best of our knowledge. We reserve the right
to incorporate technical modications within the
scope of further development of the product de-
scribed in this manual. No claims can be derived
from the information, illustrations or descriptions
contained in these instructions. We assume no lia-
bility for any damage or malfunction caused by op-
erating errors, non-compliance with these operat-
ing instructions or inappropriate maintenance. We
expressly point out that only genuine Etac Supply
Gjøvik spare parts and accessories approved by us
may be used. For safety reasons, the tting and
use of spare parts or accessories, which have not
been approved, and unauthorised modication or
conversion of the product, are not permitted. Etac
Supply Gjøvik will accept no liability for damages
resulting from such acts.
With the exclusion of product liability, Etac Supply
Gjøvik is liable for faults or omissions on its part
within the scope of the warranty obligations stat-
ed in the purchase contract. Claims for damages
are excluded, irrespective of the legal reason from
which such claims are derived. Only documenta-
tion belonging to the actual equipment is valid.
Any failure to comply with the safety regulations
and precautionary measures stated in these oper-
ating instructions renders the declaration of con-
formity supplied with the system in accordance
with Council Directive (93/42/EEC) concerning
medical devices invalid.

TM09201 Molift Smart 150 English - Rev. D1/ 03/2012Page 4 of 24
Battery holder
The battery holder B
16
is made out of an plastic
mould in which the battery will t. In the battery
holder, you will nd the spring contacts D
13
. The
emergency switch D
9
is mounted at the side of
the battery holder, and the main PCB D
5
is placed
inside with the LED visible trough a hole in the bat-
tery holder. A button on the main PCB providing
emergency lowering is possible to access through
a hole in the battery holder.
Electronics
The electronics consists of one printed circuit
board (PCB) D
5
with remote control, emergency
stop D
9
and lowering switches, and battery and
service lights. All functions rely on the main PCB.
The control card has a counter, which registers the
number of seconds with activity. After a certain
time, it signals to activate the service light to in-
form the user that the lift needs service. An electric
emergency lowering switch is located above the
stop switch. The motor has a manual emergency
lowering function in case of a power failure.
Driving handle
The curved driving handle B
4
is pressed into the
two bushings B
7
on each side of the lifting col-
umn. The bushings have a seat for a rubber O-ring
which is glued in place with Loctite. Loctite is also
applied inside the bushing before the handle is
pressed in place.
Actuator
The lower part of the actuator B
21
is connected to
the lifting column bracket B
16
and the upper part
to the lifting arm B
25
and bracket B
22
.
Lifting arm with suspension
The lifting arm B
25
is hinged to the lifting column
through a bushing with bolt. The suspension B
29
is possible to rotate 360° - the rotation is braked by
an O-ring inside the connection.
Charger and battery
The Molift Powerpac system is a custom battery
pack built up by a 14,4 V battery pack, a charger
frame and the charger with wire.
Technical description
Chassis
The chassis A
2
, is made out of bent steel plates
coated with polyester. The chassis consists of
spread legs C
11
, C
12
the spread mechanism with
pedals C
38
, C
39
and locking mechanism for lift-
ing column with lock handle C
17
. The rear castors
(with brakes) C
5
are at the back - the wheels are
turnable and not necessary to lubricate.
Legs
The legs are attached to the chassis with a bolt
C
6
and bushings locked together with a spe-
cial fastener. A castor C
11
is mounted at the tip of
each leg (without brake) in a plastic cast moulded
bracket.
Leg spreading mechanism
The leg spreading mechanism is found inside the
chassis. The mechanism is operated by pumping
the pedals C
38
, C
39
. The movement of the pedal
will lift the brake bar C
35
and engage the sleeve
C
34
to the sprocket C
9
. This will produce a circu-
lar movement of the sprocket and a movement of
the legs via leg spreader rods C
23
connected to
the legs.
Lifting column security lock
The chassis also holds a mechanism that prevents
the lifting column to be xed in the bracket before
the legs are spread to working position. This secu-
rity device consists of a stopper C
48
held in place
by a spring connected to a bracket C
47
. As long
as the legs are in transport position, the stopper
will hit the bent end of the left leg bar and in this
way prevent the lifting column to be lowered com-
pletely into the bracket. When the legs are moved
to the minimum working position, the bent end of
the leg bar will slide away allowing the stopper to
be pushed all the way down by the lifting column.
Lifting column
On the lifting column,you will nd the battery
A
3
, battery holder with electronics B
34
, bracket
for actuator B
16
and the push/pull handle B
4
.

Page 5 of 24
Service
Molift Smart 150 has a LED on the battery holder
indicating if the lifter needs service. The LED gives
a green light when the lifter is ready for use.
The electronics logs how much the lifter is being
used, and the load it is used with. After a given
time of usage there will be given a signal that the
lifter needs service to the service LED. The LED will
rst give a yellow light, then red. Take contact with
your local service representative and order service.
If there is a sound together with the light, it means
the lifter needs service immediately.
Service lamp Status
No light Power save
Green Ready for use
Yellow Order service, lifter
still works
Red Perform service
Red + sound Perform service im-
mediately
Service consists of replacing the lifting motor and
check/replacement of worn or damaged parts.
Service and repair should be performed by au-
thorized personnel only.
Fill in and sign a copy of the checklist on next page.
The owner is responsible to ensure proper logging
and written verication of each service or repair.
Service
Equipment and special tools
Equipment
The accessories and equipment related to the dai-
ly use of the lifter - see User manual.
Special tools
Universal wrench
The majority of the external fasteners on the lifter
has a special grip which requires a special wrench.
This can be bought in any well equipped hardware
store, and we recommend models with adjustable
span.
Illustration only
Service lamp
Battery lamp

TM09201 Molift Smart 150 English - Rev. D1/ 03/2012Page 6 of 24
Fault finding
See User manual.
If the fault nding table in the user manual is in-
conclusive, you will have to try by method of elimi-
nation and judgement.
Repairing
Actuator
You will need:
• Loctite243
• Specialwrenchx2
• Hotairgun
Procedure:
• Raisetheliftingcol-
umn to an upright
position and - if pos-
sible - raise the lifting
arm to horizontal po-
sition.
• Loosenthebatterysupportanddisconnectthe
cable on the backside of the battery support.
Remove the wire anchorage.
• OpenspecialscrewB
14
at the lower actuator
bracket B
16
using the special wrench.
It may be necessary to heat the bolt/fastener
to disable the Loctite used when assembled.
Limit the heating to a minimum area and ap-
ply as little heat as possible to avoid uninten-
tional spreading of heat to other parts.
The actuator will come loose and may fall
down when performing the nest steps. It is
recommended to have assistance holding the
actuator, or try to secure it in other ways (i.e.
tie it with a rope) to control the action.
• OpenspecialscrewB
14
at the upper actuator
bracket B
22
using the special wrench.
• PushoutbothboltsB
15
, if necessary; tap care-
fully using a bolt with the same diameter.
• Lifttheactuatoroutandputitcarefullydown.
• Getthenewactuatorandplaceitinposition-
make sure it is placed correctly with the motor
Qty.
Bill of materials:1
Material. Commen t.
Dimension/
Draw. no.
Description.Pos.
03-279 BOM .xls

  
      
   



 

   

  

  
 

Drawing na me:
Size
Designed/Dra wn: Date: Scale:Projection:





Drawing num ber:





   








E




 







Locktite 2701.
Locktite 243.
Locktite 2701.

Locktite 2701.


F

Locktite 243.


Locktite 243.

Assembly instructions Complete upper half = 03-P06







 
C

C


Locktite 2701.
G


Electrical diagram

Page 7 of 24
housing on the same side as the battery holder.
• Pushtheboltsinplace.
• AddLoctite243onthethreadsofthespecial
screws and tighten them.
• Connectthecablefortheactuatortothecable
from battery support. Place the cable in the slot
on the back of the support and screw the bat-
tery support back on the column.
• Fastenthewireanchorage.
• Performsafetyinspection,seepage13.
Rear castors
You will need:
• Loctite243
• Specialwrenchx2
• Hotairgun
• Spanner13mm
Procedure:
• Openspecialnut(13).
It may be necessary to heat the bolt/nut to
disable the Loctite used when assembled.
Limit the heating to a minimum area and ap-
ply as little heat as possible to avoid uninten-
tional spreading of heat to other parts. If pos-
sible - use a narrow nozzle.
• Pullthecastor(5)withboltoutofthebracket.
• Preparethenewcastorbyputtingwashers(4),
bushing (2) and wall wheel (3) over the bolt.
• Placetheassemblyintothebracketandap-
ply Loctite 243 to the threads of the special nut
(13) before tightening.
Front castors
The castors on the front legs are mounted in brack-
ets made of plastic cast moulded brackets. If it is
the castor C1
10
itself that has been damaged, it is
possible to pull it of and replace it with a new one.
Front castor with bracket
Since heating of the assembly to disable the Loc-
tite will damage the bracket, it is necessary to re-
place the bracket (8) if the castor pin or special nut
(9) is damaged.
You will need:
• Poprivet4,8x16mmtool
• DrillsteelØ5mm
Procedure:
• Carefullydrilloutthepoprivets(7)attheun-
derside of the leg to release the bracket (8)
Be careful when drilling out the pop rivet. Do
not drill into the aluminium of the leg.
• Pullthebracketoutofthelegprole.
• Insertthenewbracketandverifythattherivet
holes in the bracket and prole corresponds.
• Fastenthebracketwiththepoprivets.
• Checkthatthenewcastorworksproperly.
See safety inspection on page 13.

TM09201 Molift Smart 150 English - Rev. D1/ 03/2012Page 8 of 24
Electronics (PCB)
You will need:
• Torx20screwdriver
• Allenkey5mm
• Screwdriverat
Procedure:
• CopysettingsfromoldPCBinliftertothenew
main PCB by using Molift Servicetool. See the
user manual for the Servicetool for instructions.
• Removetheconnectorforthehandcontrol
from bottom of the battery support.
• RemovethescrewsB
36
xing the battery sup-
port to the column, one on top and one in bot-
tom.
• Disconnectthecablesonthebacksideofthe
battery support.
• RemovethetwoscrewsD
10
on each side of the
battery support, and remove the label.
• Pullthethreepartsofthebatterysupportcare-
fully apart.
• Lifttheemergency
lowering extenders
from the emergency
switch on the main
PCB.Useaatscrew-
driver and push them
carefully apart.
• Push/pullthemainPCBoutofthebatterysup-
port. Take care of the extenders.
• Emergencystopbuttonmaybedetachedby
releasing the locking ring inside the battery
holder.
• Disconnectthecableconnectorformotorand
battery.
• Connectthemotorandbatteryconnectorto
the new main PCB.
• Placethetoppieceofextenderinthelower
hole in the battery support, and the two lower
pieces on the emergency lowering switch on
the PCB.
• PullthemainPCBD
5
in place in the slot in the
battery support.
• Pushtheextendersontheemergencylowering
switch, and the complete battery supports to-
gether. Make sure the PCB enters the slots.
• AssembletheholderandscrewsD
10
.

Page 9 of 24
• Carefullyremoveandscrapeawayanyremains
of the old sticker before placing the new one.
• Connectthecablesonbacksideofbatterysup-
port to cables on lifter and place them in slot.
• Attachthebatterysupporttothecolumnwith
the two screws B
36
, use Loctite 243 on screws.
Make sure the cables do not get squeezed.
• Reconnectcableforhandcontrol.
• Performsafetyinspection(page13).
Leg mechanism / pedals
The leg spreading mechanism is fairly complicated
and requires experience and in depth knowledge
to repair. We recommend that a lifter with mal-
functioning leg spreading mechanism should be
sent back to the manufacturer for repair and ad-
justment.However,ifyoubelievethatthefaultis
easy to correct, i.e. to re attach a spring - open the
bottom cover C
27
and try to correct the fault. If the
problem is caused by a broken part deeper in the
mechanism, please contact the manufacturer for
advice.
Always check the leg spreading mechanism
after any repair.
• Legsdoesonlymoveinnerpositionwhencol-
umn is lifted up (transport position)
• Withcolumnmountedthelegsdoesnotmove
inside working position (parallel position)
Illustration shows lifter in working position.
Transport elastic
You will need:
• Newelastic
• Knifeorscissors
Procedure:
• Removetheliftingcolumn/-armfromthechas-
sis.
• RemovetheoldelasticB
9
by cutting it close
to the reel B
8
. Remove the reel and the old
elastic, and be careful to get out any loose parts
inside the column.
• Threadthenewelastictroughthereelandpo-
sition this in the middle.
• Threadtheendsoftheelasticthroughtheeyes
at the top of the column.
• Pushtheelasticintothecolumnandmakesure
that the ends are travelling downwards in the
column. It may help to raise the column up-
right.
• Whentheendsemergeatthebaseofthecol-
umn - verify that the ends of the elastic pass on
each side of the lower bolt in the column. If not,
this has to be corrected.
• Tightentheelasticapprox.20cmandtieathor-
ough knot.
• Releasetheknotandverifythattheelasticand
reel at the top has a tension of approx. 2 kg. If
not, pull the elastic out from the base and tie
another knot further in to pretension the elastic
some more.
• Cutofanyexcesslengthofelastic,butleaveap-
prox. 5 cm below the knot.

TM09201 Molift Smart 150 English - Rev. D1/ 03/2012Page 10 of 24
Suspension / O-ring in suspension
You will need:
• Loctite2701
• Specialtool
• Punch5mm
Procedure:
• Removethepaddingonthesuspension(41)
• Loosenthetwospecialbolts(27)withthespe-
cial tools and punch out the bolt (26).
• Removethesuspensionassemblyandremove
the plastic covers (28). Use the punch carefully
on the inside to separate the covers.
Verify that bolts or suspension are not worn or
damaged in any way. Damage to these parts
may cause a fracture in the assembly causing
serious personnel injury.
• Replacewornordamagedpartsandassemble
the suspension as reverse order, see g below.
Qty.
Bill of materials:1
Material. Comment.
Dimension/
Draw. no.
Description.Pos.
03-279 BOM.xls

 
   
   



 

  




 

Drawing name:
Size
Designed/Drawn: Date: Scale:Projection:





Drawing number:





   








E




 







Locktite 2701.
Locktite 243.
Locktite 2701.

Locktite 2701.


F

Locktite 243.


Locktite 243.

Assembly instructions Complete upper half = 03-P06







 
C

C


Locktite 2701.
G


Electrical diagram
• ApplyLoctite2701onthethreadsofthespecial
bolt(27)andtighten.
• Re-tthepadding.
• Performsafetyinspection,seepage13.
Lifting arm, lifting column and legs
If any of these parts are structurally damaged, the
entire lifter must be shipped to the manufacturer
for evaluation, control and repair. Damage to the
main structures of the lifter indicates that the lifter
has been in a situation where abnormal forces has
been applied. Such a situation can potentially in-
uencethefuturesafetyofthelifter,andshallnot
be attempted repaired by other than the manufac-
turer.
Foam cover chassis/legs
You will need:
• Newfoamcover
• Solventforremovalofglueremnants
• Expressglue
Procedure:
• Spreadlegstomaximumwidth.
• RemovetheremainoftheoldfoamcoverC
10
using a plastic scrape
Be careful when scraping in order to prevent
damage to the chassis coating.
• Washoanyremainsoffoamandglueusing
the cleaning solvent
• Drysurfaceswellandverifythatthesurfaceis
smooth and clean
• Applyglueattheendofthenewfoampartas
indicated below.
• Pressthenewfoamcoverinplacealigningthe
curve of the cover with the chassis.
• Allowthegluetosettleforawhileandthen
glue the narrow part of the foam cover to the
leg prole.
• Donotusethelifteruntilthegluehasdried-
ref. specication of the glue.
41

Page 11 of 24
Lifting column stopper
You will need:
• Specialpoprivets4x8,5mmandtool
• DrillsteelØ5mm
• Newparts
Procedure:
• Removetheliftingcolumnfromthechassis.
• CarefullydrilloutthepoprivetsC
46
at the back
of the chassis
Be careful when drilling out the pop rivet. Do
not drill into the chassis.
• RemovebracketC
47
and stopper C
48
.
• Replacedamagedparts.
• Pushtheassemblyintotheliftingcolumn
bracket and verify that the holes in the bracket
correspond with the holes in the chassis.
• Fastenthebracketwiththepoprivets.
Always check the leg spreading mechanism
after any repair.
• Legsdoesonlymoveinnerpositionwhencol-
umn is lifted up (transport position)
• Withcolumnmountedthelegsdoesnotmove
inside parallel position (in working position)
Illustration shows lifter in working position.
Plugs in column lock
You will need:
• Drillsteel3mmand6,1mm
• NewnylonplugsC
17.2
Procedure:
• Drilla3mmpilotholeintheremainingnylon.
Be careful when drilling out the nylon. Do not
damage the lock itself.
• Carefullydrillouttheremainingnylonwiththe
6,1 mm drill steel and clean the hole.
• Press/gentlytapthenewnylonpluginplace.
• Thenewplugmaybetoolongandmayhaveto
be trimmed using a sharp knife to t.

TM09201 Molift Smart 150 English - Rev. D1/ 03/2012Page 12 of 24
Finishing the job
Safety control
Any repair or replacement of parts requires a safe-
ty control afterwards. The procedure of control is
described in the checklist on next page. The owner
of the lifter is responsible for keeping a copy of the
checklist, lled in and signed by authorized service
representative.
Please make copies of this and next page! Serial number of lifter:___________________________
Date Description of fault Repair Date/sign.
Logging
Use the table below for logging of repair and work
done on the lifter. Write down a short description
of the incident in the appropriate interval. This will
enable the owner and service partner to see pre-
vious history for the lifter and in that way maybe
making future fault nding and repairs easier. It
is also possible to save information about service
and repair when using the service tool.

Page 13 of 24
Inspection Diagram after Service and Repair
MOLIFT Smart 150
Service:
Checked service lamp if service is necessary: YES (yellow or red light) / NO (green light)
Use Molift Servicetool and read the lifters data - check number of lifts left before service: _____________________
Service is completed : - Replaced lifting motor/actuator. Worn or damaged parts, or malfunctioning parts, are re-
placed. See description for parts replacement.
Service light was reset using Molift Servicetool. N.B.: The service light must ONLY be reset after completed service!
Perform safety inspection after service.
Safety Inspection
The lift has been visually checked for damages, malfunction and deformation, and it is in order. Checked that lifting
column is properly fastened to chassis, and that the lifter has no loose parts.
Checked that mounting of column works correct. With legs in outer position (working position), it is possible to run
the column up and down easily, and the column falls in place in the base. With lifter in transport position it is not
possible to leave the column in upright position (it falls down when pushing slightly)
Checked that remote control works and that wire and socket for remote control are undamaged.
Checked that the lifter functions correctly and runs without load all the way up and down without abnormal noise.
Checked that end stop works. Repeated test with a load of approx. 100 kg.
The suspension and lifting arm are checked visually for damage, play and deformations. The suspension shall be
turned 360° with some friction. If no defects or malfunctions are discovered, the suspension shall be tested with
maximum load (150 kg). Run the lift up and down 2 - 3 times and turn the suspension 360° around 2 - 3 times with
maximum load. Perform a new visual control; damage, play and deformations as described above. Any damaged
parts must be repaired or replaced and the test is performed once more until the lift performs correctly.
Checked that the leg spreading mechanism functions properly. Tested with maximum load. Veried that the legs do
not move beyond inner and outer limits (working position) when operated with load. The legs does not move inside
parallel positions (or working position) with column mounted.
Checked that emergency stop and lowering (electric and manual) are working correctly.
Service light is green and batteries are suciently charged.
Marked lift with safety sticker with month/year and certicate number for completed safety inspection. Inspecting
person must sign safety sticker and this diagram.
Inspection, repair and service should be done by a person certied by, or on behalf of Etac Supply Gjø-
vik. Always complete below:
Client:________________________________ Serial number of lifter:_______________________________
Date: ________________________________ Signature:_________________________________________

Page 14 of 24 TM09201 Molift Smart 150 English - Rev. D1/ 03/2012
Appendix A
Pos. Part. no.. Appendix Description
0920008 Molift Smart 150
1 0920080 Appendix B Upper half assembly, Molift Smart 150
2 0920083 Appendix C Chassis assembly, Molift Smart 150
3 0541000 Battery NiMH 2,2 Ah 14,4 V
4 1340100 Charger NiMH/NiCd
5 0920057 Appendix D Battery support w electronics
6 0920084 Appendix E Suspension complete
7 0920084 Appendix F Electrical diagram Molift Smart 150

Page 15 of 24
A
Main components
5
6
3
2
1
7
4

Page 16 of 24 TM09201 Molift Smart 150 English - Rev. D1/ 03/2012
Appendix B
Pos. No Part no. Description
1 1 0920512
Bolt for lifting column bracket 2 pcs, set
incl pos 32
2 10 0920216 Rivet nut
3 1 0920320 Label: user manual Smart
4 2 0910107 Push bar
5 2 0920201 Screw M8x80 DIN912 Elzn
6 4 0232103 Spirol Ø3x8
7 4 0920519 Push bar sleeve mounted
8 1 0910166 Reel (for elastic)
9 1 0910174 Elastic, color black
10 2 0920214 Tubular rivet
11 1 0910209 Strengthening plate for column
12 1 0910160 Sleeve for column
13 2 1150414 Lock nut DIN 985 M8 Elzn
14 4 0910158 Screw, special, M6, incl in pos 21
15 2 0910159 Bolt for actuator, incl in pos 21
16 1 0910109 Lower actuator bracket
17 8 0920202 Screw, button head M6x25 ISO7380
18 1 0910113 Suspension parking hoop
19 1 1310306 Label, Part no
20 1 0910119 Plug for column
21 1 0920506
Actuator Linak LA 34, including pos 14
and 15
22 1 0910108 Upper actuator bracket
23 2 0910181 Flanged bearing
24 2 0910197 Plastic cover, column
25 1 0910124 Lifting arm for Linak
26 1 0910161 Bolt lifting arm
27 2 0910152 Bolt, special M8
28 2 0910196 Plastic cover, arm/suspension
29 1 10099 Suspension complete
30 1 0210305 Label, slinglabel
31 1 0210309 Label, SWL 150 kg
32 4 Push nut 10 mm, incl in pos 1
33 1 0910127 Smart column
34 1 0920057 Battery support
35 1 0440002 Hand control, 2 button
36 2 0220120 Screw M6x20 DIN912 8.8 Elzn
37 1 0920119 Stretch relief 6,4 mm
38 1 0540508 Screw 4,5x13 DIN7981C Elzn
39 2 0920010 Label Molift Smart
40 1 0920084 El. diagram Smart 150 (see app. F)
41 1 0910150 Padding suspension Smart

Page 17 of 24
Column and lifting arm
B
Qty.
Bill of materials:1
Material. Comment.
Dimension/
Draw. no.
Description.Pos.
03-279 BOM.xls

 
   
   



 

  




 

Drawing name:
Size
Designed/Drawn: Date: Scale:Projection:





Drawing number:





   








E




 







Locktite 2701.
Locktite 243.
Locktite 2701.

Locktite 2701.


F

Locktite 243.


Locktite 243.

Assembly instructions Complete upper half = 03-P06







 
C

C


Locktite 2701.
G


Electrical diagram
Qty.
Bill of materials:1
Material. Comment.
Dimension/
Draw. no.
Description.Pos.
03-279 BOM.xls

 
   
   



 

  




 

Drawing name:
Size
Designed/Drawn: Date: Scale:Projection:





Drawing number:





   








E




 







Locktite 2701.
Locktite 243.
Locktite 2701.

Locktite 2701.


F

Locktite 243.


Locktite 243.

Assembly instructions Complete upper half = 03-P06







 
C

C


Locktite 2701.
G


Electrical diagram
41

Page 18 of 24 TM09201 Molift Smart 150 English - Rev. D1/ 03/2012
Appendix C
Pos. No Art. no.. Description
1 1 0920009 Chassis machined / painted
2 2 0910155 Wallwheel sleeve
3 2 0910154 Wallwheel
4 4 1120312 Fender washer HB140 Ø10
5 2 0920108 Wheel 75mm w/brake
6 2 0910151 Bolt for leg
7 2 1120320 Washer HB140 Ø10,5xØ30x2,5
8 2 1120506 Screw, button head M8x10 ISO7380
9 1 Sprocket, see pos 52
10 2 0920071 Foam cover for chassis
11 1 0920510 Right leg complete - see below
12 1 0920511 Left leg complete - see below
13 2 0910153 Nut, special M10
14 4 0910152 Nut, special M8
15 2 0910190 O-ring DIN3770 Ø10x5
16 1 0910157 Bolt for column lock
17 1 0920513 Column lock set Smart, incl pos 14,15,16
17.1 1 0920518 Eccentric lock mounted, incl pos 17.2
17.2 2 0920213 Plastic pin Ø6,2, column lock
18 1 0220310 Label, security check
19 1 0920303 Decal: leg spreading
20 1 0920301 Label, Molift Smart 3D
21 2 0920517 Plate, Polyethylene mounted
22 1 Needle bearing, see pos 52
23 1
Leg spreader rods Smart 150, see pos
52
24 2 Support disc, see pos 52
25 3
Washer, plane Ø8,4x18x1,25, see pos
52
26 2 Nut, hex thin M8 ISO4035, see pos 52
27 1 0910201 Bottom cover
28 9 0920208 Washer Nordlock Ø6,5/10,8x1,8
29 10 0220119 Screw, buttonhead M6x10 ISO7380
30 1 0220121 Washer Ø6.4 ISO703/DIN9021
31 1 1310307 Label, controlled date/sign
32 1 0220309 Label, Authorized personnell only
33 1 Sleeve for cogwheel, see pos 52
34 2 Guide sleeve, see pos 52
35 1 Brakebar, Molift Smart, see pos 52
36 2 0920222
Spring, Extension with O-ring, see pos
52
37
38 1 0920508 Pedal assy right, Smart, Set
39 1 0920509 Pedal assy left, Smart, Set
40 2 0220118 Washer neoprene Ø22x5,5x3,5
41 3 0920223 Extension spring SF-DF 1x8x18
42 2 0920209 Screw DIN912 M8x65 Elzn
43 2 1150414 Nut, lock DIN985 M8 Elzn
44 2 0228125 Nut, lock DIN985 M6 Elzn
45 1 0920306 Label Molift Smart 150
Pos. No Art. no.. Description
46 2 0920058
Rivet 4,8x10 DIN7337 ST A2/A2, see
pos 52
47 1 0920089
Bracket leg stopper Smart 150, see pos
52
48 1 0920088 Leg stopper Smart 150, see pos 52
49 1 0421135 Decal: ID no
50 1
Screw ISO4017 M8x25 8.8 EL, see pos
52
51 2 0920232 Lock clamp Smart
52 0920521
Leg mechanism set Smart 150, incl pos
9, 22, 23, 24, 25, 26, 33, 34, 35, 36, 41,
44, 46, 47, 48, 50
C1 0920502 Bracket with front castor
1 2 Washer, fender Ø10xØ25x1,5
7 2 Rivet dowel 4,8x18 TIDA 4818TP
8 1 Wheel bracket
9 1 Nut, special M10
10 1 0920107 Wheel Ø75 without brake

Page 19 of 24
Chassis / leg mechanism
C
Rev. Description: Date/Sign. Approved:
A Released for production 18.11.2008 MHL
B Changed item no 22.10.2009 TÅB MHL
C Re moved pos 11. (0920239) 03.11.2009 TÅB MHL
Complete Bottom Chasis 2006
1:10
Size
Designed/Drawn: Date: Scale:
Drawing name:
Projection:
tes
03-269
A3
Left Leg Complete
Drawing number:
18/11-2008
Molift Smart
6
B
3
42
4
2
5
77
10
9
8
1
Add Locktite 243
1
Add Locktite 243
C
Bill of materials:
1
Material.
Comment.
Dimension/
Draw. no.
Description. Qty.
Pos.
03-284 BOM.xls
18
10
2019
8
6
5
4
3
2
1
13
14
7
15
Loctite
243.
Loctite
243.
1716
12 11
B
B
C
51 51
E
27
25
26
32
28
30
29
33
44
47
48
1
46
21
22
23
9
24
24
34 35
31
41
40
36
50
39
38
42
43
B
B
B
1:10
Loctite
243.
Loctite
2701.
Assembly instructions Chassis= 03-P05
E
Removed pos 45 and 49.
EO 122/2010
19.11.2010 RVS TÅB
D Ref. EO 6/2010 08.01.2010/TES TÅB
C
Added pos 51 clamp. Moved from
leg
03.11.2009 TÅB MHL
B
New chassis and leg stopper Re
numbered all
19.10.2009 TÅB MHL
A Released for production 10.09.2009RVS MHL
Rev. Description: Date/Sign. Approved:
39
1
Complete bottom
chassis 2006 03-269
38
1
Complete bottom
chassis 2006 03-268
37
1
03-267
36
1
03-266
35
1
Label ID no 13-232
34
1
ISO 4015 - M8 x 30 x
22-N
33
2
Support disc 03-233
32
1
03-252
31
1
Leg Stopper 03-289 AISI 304
30
1
Bracket leg
stopper 03-290 AISI 304
29
2
0920211
28
1
Label 0920306
27
2
DIN EN ISO 7040 -
M6 - N
26
2
ISO 7040-M8-N
25
2
DIN 912 M8 x 65 ---
28N
24
2
Ø5,5/22x3,5
0220118 Neoprene
skive
23
2
Button head
ISO 7380 - M8 x 30 ---
30N
22
3
0920223
21
2
03-271
20
1
03-199
19
2
hylse for bremsestag
18
1
03-185
17
1
Only authorized
personell label 13-218
16
1
Art. and id no. 13-217
15
1
Washer DIN 9021 - 6.4
14
10
ISO 7380 - M8 x 20 ---
20N
13
9
Ø6,5/10,8x1,8
0920208 Nordlock
Lock Washer 6mm
12
1
03-115
11
2
Hexagon Thin Nut ISO
- 4035 - M5 - N
10
3
Washer, plane
0920227 Plan skive
ø8,4x18x1,25
9
1
Sprocket 03-232
8
1
Leg spreader rods
SMART 150 03-291
7
1
0232107
6
2
03-254
5
1
0920301 Decal, Molift
Smart
4
1
03-168 leg spread
3
1
03-168 leg attract
2
1
Label safety check 03-258-A
1
1
Chassis welded
SMART 150 03-293
Pos.
Boks
eksplodert/QTY.
Description
Dimension/
Draw. no. Material: Comment:
Molift Smart
Assembly
Drawing name:
10/9-20009
Drawing number:
Chassis Smart 150
A2
03-284
1:5
RVS
Projection:
Scale:
Date:
Designed/Drawn:
Size
Bill of materials:
1
Material.
Comment.
Dimension/
Draw. no.
Description. Qty.
Pos.
03-284 BOM.xls
18
10
2019
8
6
5
4
3
2
1
13
14
7
15
Loctite
243.
Loctite
243.
1716
12 11
B
B
C
51 51
E
27
25
26
32
28
30
29
33
44
47
48
1
46
21
22
23
9
24
24
34 35
31
41
40
36
50
39
38
42
43
B
B
B
1:10
Loctite
243.
Loctite
2701.
Assembly instructions Chassis= 03-P05
E
Removed pos 45 and 49.
EO 122/2010
19.11.2010 RVS TÅB
D Ref. EO 6/2010 08.01.2010/TES TÅB
C
Added pos 51 clamp. Moved from
leg
03.11.2009 TÅB MHL
B
New chassis and leg stopper Re
numbered all
19.10.2009 TÅB MHL
A Released for production 10.09.2009RVS MHL
Rev. Description: Date/Sign. Approved:
39
1
Complete bottom
chassis 2006 03-269
38
1
Complete bottom
chassis 2006 03-268
37
1
03-267
36
1
03-266
35
1
Label ID no 13-232
34
1
ISO 4015 - M8 x 30 x
22-N
33
2
Support disc 03-233
32
1
03-252
31
1
Leg Stopper 03-289 AISI 304
30
1
Bracket leg
stopper 03-290 AISI 304
29
2
0920211
28
1
Label 0920306
27
2
DIN EN ISO 7040 -
M6 - N
26
2
ISO 7040-M8-N
25
2
DIN 912 M8 x 65 ---
28N
24
2
Ø5,5/22x3,5
0220118 Neoprene
skive
23
2
Button head
ISO 7380 - M8 x 30 ---
30N
22
3
0920223
21
2
03-271
20
1
03-199
19
2
hylse for bremsestag
18
1
03-185
17
1
Only authorized
personell label 13-218
16
1
Art. and id no. 13-217
15
1
Washer DIN 9021 - 6.4
14
10
ISO 7380 - M8 x 20 ---
20N
13
9
Ø6,5/10,8x1,8
0920208 Nordlock
Lock Washer 6mm
12
1
03-115
11
2
Hexagon Thin Nut ISO
- 4035 - M5 - N
10
3
Washer, plane
0920227 Plan skive
ø8,4x18x1,25
9
1
Sprocket 03-232
8
1
Leg spreader rods
SMART 150 03-291
7
1
0232107
6
2
03-254
5
1
0920301 Decal, Molift
Smart
4
1
03-168 leg spread
3
1
03-168 leg attract
2
1
Label safety check 03-258-A
1
1
Chassis welded
SMART 150 03-293
Pos.
Boks
eksplodert/QTY.
Description
Dimension/
Draw. no. Material: Comment:
Molift Smart
Assembly
Drawing name:
10/9-20009
Drawing number:
Chassis Smart 150
A2
03-284
1:5
RVS
Projection:
Scale:
Date:
Designed/Drawn:
Size
C1 Bracket with front castor
40
( 19,60 )
135
58,50
2
2
1
Rev. Description: Date/Sign. Approved:
A Released For Production 30.09.2008/TES MHL
Size
Designed/Drawn:
Date:
Scale:
Projection:
tes
1:2
03-252
A4
Eccentric Lock Mounted
Drawing number:
30/09-2008
Drawing name:
Complete bottom Chassis
Molift Smart
17
17.2
17.2

Page 20 of 24 TM09201 Molift Smart 150 English - Rev. D1/ 03/2012
Appendix D
Pos. No Art. no. Description
1 1 0920063 Upper mould Battery support Smart
2
3 1 0920064 Middle mould Battery support Smart
4 1 0920065 Lower mould Battery support Smart
5 1 1320112 Main PCB
6 1 1310122 Membrane Battery holder
7 1 1310136 End piece, Cap
8 1 0220307 Label emergency stop
9 1 0920114 Emergency stop switch
10 2 0920066 Plastic screw PT 1452 40x40
11 2 0920094 Circlip DIN 6799 6mm
12 1 0920067 Emergency stop extender
13 2 0920068 Spring Ø7/Ø6x17 thread Ø5
14 1 0920069 Molex plug 44441-2003 Smart
15 1 0920072 Molex plug 44441-2002 Smart
16
17
18 1 0920075 Cable red L=300 mm
19 1 0920076 Cable black L=300 mm
20 1 0920077 Mec extender 6mm 2S06 Smart
21 2 0920078 Molex crimp Socket 43375-0001
22 1 0920079 Mec extender 7mm 2S07 Smart
23 2 0421142 Cable clip male 6,3x0,8x1,5 Insulated
24 2 0421143 Cable clip female 6,3x0,8x1,5 Insulated
25 1 0920092 Battery cable (+) red Smart
26 1 0920093 Battery cable (-) black Smart