Molnar 11 Series Instruction manual

MOLNAR
4 TONNE
2 POST
CLEAR FLOOR HOIST
MODEL 2P4T- PREMIUM
Series 11
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Revision “B” May 2010

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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 outside of
Australia and New Zealand refer to local standards/regulations.
Circuit breakers should be of “D” curve type (motor start, high
inrush current ). Ratings given as a maximum for circuit & motor
protection based on DOL selection guide.
Voltage operating range: -6% to +10% of motor nameplate voltage.
Motor Voltage 240 V, operation range 225V to 264V.
Cable sizes are given as a guide only for a maximum cable length
to 30 M. Longer cable runs and in areas where supply voltage is
below motor voltage, calculation should be made to ensure Voltage
Drop will not fall below minimum operating voltage.
When installed motors must be tested under Full Load checking
Voltage at motor terminals.
Motor: 2.2Kw 240 V single phase, model CWC 3640F.
Full Load Current: 12.4 Amps
Min Cable Size: 2.5mm 2 core + earth
Circuit Breaker: 1 phase 32 Amp 10Ka
Recommended Clipsal 4CB132/10 or equivalent.
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No person should be permitted to operate the
MOLNAR CLEAR FLOOR HOIST without first
studying the operating instructions on page 6 and
safety precautions on page 10.
This Manual should be kept in a safe place and
referred to as necessary.
The installation requirements on page 23 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.
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.
When installed in tropical environments it is
advisable to raise the hoist to full height when not in
use overnight or on weekends, to minimise
condensation forming inside the cylinder which may
lead to corrosion of cylinder bore.

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CONTENTS
SPECIFICATIONS ..................................................................................................................................2
INTRODUCTION....................................................................................................................................3
INTRODUCTION....................................................................................................................................4
FLOOR REQUIREMENTS FOR MODEL 2P4T....................................................................................5
OPERATING INSTRUCTIONS..............................................................................................................6
OPERATING INSTRUCTIONS..............................................................................................................7
MAINTENANCE.....................................................................................................................................8
MAINTENANCE.....................................................................................................................................9
LUBRICATION PROCEDURES FOR MOLNAR 2 POST HOISTS.....................................................9
SAFETY PRECAUTIONS.....................................................................................................................10
FAULT CHART.....................................................................................................................................11
HYDRAULIC CYLINDER REPLACEMENT......................................................................................12
WIRING DIAGRAM.............................................................................................................................13
HYDRAULIC CIRCUIT DIAGRAM....................................................................................................14
INSTALLATION INSTRUCTIONS .....................................................................................................15
INSTALLATION INSTRUCTIONS .....................................................................................................16
INSTALLATION INSTRUCTIONS .....................................................................................................17
INSTALLATION INSTRUCTIONS .....................................................................................................17
INSTALLATION INSTRUCTIONS ...................................................................................................189
INSTALLATION INSTRUCTIONS .....................................................................................................20
INSTALLATION PROCEDURE ..........................................................................................................20
ARM LOCK PARTS LIST ....................................................................................................................21
DOOR PROTECTOR INSTALLATION PROCEDURE......................................................................22
INSTALLATION PROCEDURE ..........................................................................................................22
INSTALLATION REQUIREMENTS ...................................................................................................23
BETABITE HYDRAULICS ASSEMBLY INSTRUCTIONS ..............................................................24
CERTIFICATION..................................................................................................................................26
SPECIFICATIONS
Width between columns 2650mm
Overall width 3450mm
Overall height 3850mm
Overall length 1000mm
Maximum raised height 1900mm
Minimum lowered height 115mm
Length of lifting arms maximum 1020mm
Length of lifting arms minimum 610mm
Lifting time (working height) Approx. 30 secs
Electric motor - 3 phase, 2.2kw, 2700 rpm, 415 volts, 50 hertz
(optional) - Single phase, 2.2kw, 2850 rpm, 240 volts, 50 hertz
Hoist mass - 960kg
Wire rope - 13mm diameter 6 x 29FW(14/7+7F/1) IWRCRHOL
B1770 minimum breaking strength 107kn
Hydraulic oil - Castrol Hyspin AWH46, Shell Tellus T46,Mobil DTE
25, BP Bartran HV46 or equivalent
Capacity - 4000kg (4.0 tonnes)
The Manufacturer reserves the right to alter these features and specifications without notice.

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INTRODUCTION
Here is the MOLNAR CLEAR FLOOR HOIST, a space saving wheel-free hoist
and its many advantages.
It has been purposely designed for space saving and to give versatility and
profitability to the largest garage and smallest service station. Safe, strong,
simply built to give years of trouble-free service. The MOLNAR CLEAR
FLOOR HOIST embodies many features that make it the most up-to-date
equipment for quicker and more profitable service.
SAFE AND EFFICIENT OPERATION
Molnar Hoists use 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 together with “deadman”
controls.
INSTALLATION
The MOLNAR CLEAR FLOOR HOIST PREMIUM is fast and simple to install
only 16 expanding sleeve anchors are 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 CLEAR
FLOOR HOIST can be quickly, easily and economically re-sited.

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INTRODUCTION
FOR SPEEDIER SERVICE
With the MOLNAR CLEAR FLOOR 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 CLEAR FLOOR 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.

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FLOOR REQUIREMENTS FOR MODEL 2P4T
These notes are for your guidance prior to installation.
1. It is the users responsibility to provide a satisfactory site area.
2. The floor should be a single reinforced concrete slab.
Min concrete thickness = 100mm
Min plan dimensions of 4600mm x 1800mm
Prepared base 100mm thickness of quarry rubble compacted to
95%
SL81 reinforcement mesh
Min thickness of concrete above mesh = 65mm
25Mpa concrete
3. For correct installation of the Clear Floor Hoist the floor must be flat and
level. A level tolerance between posts of 10mm is allowable. Check with
straight edge and spirit level. (Ref. Fig. 1).
4. Recommended anchor bolts are expansion sleeve type anchors 20mm
diameter with a minimum length of 82mm. Use the manufacturers
recommended installation procedures.
NOTE: Some authorities do not approve expanding type anchorage
devices.
5. If there is any doubt about the quality of the floor, a replacement slab
should be installed. Use a qualified person to design the replacement
slab.
6. No liability for any damages will be accepted should you install the hoist
on an unsuitable floor.

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OPERATING INSTRUCTIONS
1. Position vehicle central to the hoist
posts.
2. Place the four pads under the vehicle
at vehicle jack points.
3. Raise the vehicle with the hoist until
the wheels have just left the ground
and check that the load is balanced,
stable and the pads are located
correctly. If not correct lower vehicle to
the ground and reposition vehicle and
pads as necessary and check again.
4. Press starter button and raise vehicle
to required height. Do not go under
vehicle until load rests on safety.
5. When vehicle reaches maximum
height limit switch will come into
operation and stop hoist. When hoist
has stopped, pull release lever until
load rests on safety.
6. Before lifting, the safety lever should
be in the “ON” position. During lifting
with the automatic safety “ON” a
clicking sound should be noticeable,
this indicates the safety mechanism
operating. If this sound is not heard,
immediately cease using the hoist and
call an authorised service agent.
7. When the required height is reached,
stop the hoist, ensure the safety lever
is in the “ON” position and then lower
load until safety mechanism pawl
comes to rest on a ratchet tooth and
supports the load together with the
wire ropes.
8. To lower the hoist, first raise it
approximately 20mm, push the safety
lever to the “OFF” position and pull the
release lever down.

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OPERATING INSTRUCTIONS
9. If the car is to be worked on at an
intermediate level, load must be once
again secured as detailed in step 7.
10. WARNING: Do not go under the
vehicle under any circumstances while
the vehicle is being raised or lowered.

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MAINTENANCE
CHECK DAILY
1. Check safety mechanisms to see that they function properly.
2. Check arm locks are working correctly.
3. Check condition of lift pads.
CHECK MONTHLY
1. Safety mechanisms 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 roller tracks.
CHECK 3 MONTHLY
1 Check balance cables Refer point 20 of installation instructions.
CHECK 6 MONTHLY
1. State of swivel arms.
2. Oil leaks from cylinders.
3. Oil leaks at pipe joints.
4. Anchor bolts.
5. Wire ropes.
NOTE: Refer to trouble shooting chart, page 11, for fault remedies.
YEARLY
Service 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.

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MAINTENANCE
2 YEARLY
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 equivalent to 20 times the rope diameter i.e. for 13 mm
diameter rope 10 broken wires in 260mm of cable.
b. A strand of wire is broken.
c. A rope 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 suggests industrial grade silicone based aerosol type
sprays may be used (because the Hoist will be totally clean and there is no
fear of lubricant accidentally being rubbed on clothing).
Molnar Engineering suggests that the rear tracks be heavily lubricated. You
may use grease on the rear tracks because the rear tracks are fully covered
by the hoist covers.
“TAC 2” lubricant may also be used.

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SAFETY PRECAUTIONS
DON’T
1. Do not try to lift anything beyond the maximum capacity 4000Kg.
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 try 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 is 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.
13. When lifting vehicles with loads care should be paid to load distribution
and pad position as the load may become unstable with removal or fitting
of components to vehicle. If in doubt perform a risk assessment on the
vehicle before lifting.

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FAULT CHART
FAULT PROBABLE CAUSE REMEDY
Noise from rollers. Lack of lubrication on
roller tracks and roller
pins.
Lubricate roller tracks
and roller pins with
industrial grade aerosol
based silicone spray.
Noise from pulleys. Lack of lubrication on
pulley pins. Lubricate pulley pins as above.
Leakage of oil at joints. Loose fittings. Inspect the piping and
tighten joints.
Leakage of oil at top of
hydraulic cylinder. Worn / damaged piston seal in hydraulic
cylinder,
Replace piston seal and
/ or cylinder.
Hoist does not respond
to operation switch. Power supply to motor is interrupted.
Motor turning in opposite
direction.(3 phase only)
Cables either cut or
damaged.
Check main power
source. Check that
safety up stop switch is
free.
Refer to installing
electrician.
Damaged cable. Worn sheaves and
sheave pins or bushes. Replace sheaves, sheave pins and cables
and bushes.
Carriage shuddering in
lifting and lowering
mode.
Lack of lubricant on
roller tracks. Clean and re-apply lubricant on roller tracks.

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HYDRAULIC CYLINDER REPLACEMENT
Procedure
1. Turn off power and isolate the hoist.
Disconnect power cables from the hoist (only to be performed by a
licensed electrician).
2. Remove post covers and cable cover.
3. Make sure both carriages are fully lowered. Disconnect balance cables
on both carriages.
4. Disconnect top limit switch. Slide conduit into right hand post to expose
cable connectors. Disconnect the cable connectors for the top limit
switch in the top cross beam. Disconnect hydraulic lines at top of post
and remove.
5. Remove balance cables.
6. Remove the top cross beam.
7. Remove pulley assemblies from the top of the posts.
8. Disconnect conduit from the T-piece junction, and withdraw the two
white top limit switch wires from conduit.
9. If removing right hand side cylinder disconnect hydraulic pipe from the
cylinder at the power pack and gently push it back until it sits inside the
post to ensure it does not snag when removed from post. Then remove
the power pack from the right hand post.
10. Unbolt posts and lay down with the exposed sheaves facing upwards.
11. Disconnect twin cables from carriage and remove pulley assembly from
the top of the cylinder.
12. Disconnect cylinder locater at the top of the cylinder and disconnect pipe
locater. Ensure hydraulic pipe disconnected is inside the post (refer to
step 8) and then slide cylinder/pipe out of post.
13. 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-honed or replaced.
14. Reassemble in reverse order.

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WIRING DIAGRAM

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HYDRAULIC CIRCUIT DIAGRAM

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INSTALLATION INSTRUCTIONS

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INSTALLATION INSTRUCTIONS
1. Position hoist to installation position on two bearers with packing legs
approximately 20-50mm above the ground.
2. Remove packing legs.
NOTE: The packing legs securing bolts (3 per side) are to be fitted into
the base plates of the posts. The leftover packing nuts and bolt from
each side are to be discarded.
3. Remove wooden crates. Open crates and lay out contents.
4. Remove lifting arms.
5. Cut straps holding posts and remove wooden protectors from posts.
6. Swing out top of both posts, horizontally anti-clockwise right hand post
first and place on wooden blocks. Refer figure 2.
7. Remove balance cables from inside each post. “Top end”.
8. Pull conduit through the hole on the face of right hand post.
9. Remove pulleys from support beam brackets NOTE: 1 Bracket has hole
for conduit must go to motor post. Fit brackets to posts. Fit balance cable
through brackets and refit pulleys ensuring shims are fitted correctly to
side of pulleys.
10. Ensure cable is tightly seated in sheave groove at the bottom end of
both posts whilst raising posts into upright position.
11. Check cable positions when each post is in upright position.
12. Position right hand post and bolt down one outside fastening lug.
Recommended anchor bolts are expansion sleeve type anchors 20mm
diameter with a minimum length of 82mm.
13. Position left hand post 2650mm from right hand post then repeat step
11.
14. Place top cross beam on top of beam support brackets. Refer figure 4.
Secure each side with bolts provided.
15. Check distance between bottoms of posts is 2650mm.
16. Check posts are square to each other, adjust accordingly.
17. Check that posts are vertical. Shim as required under frame of base.
18. Bolt left hand and right hand posts down.

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INSTALLATION INSTRUCTIONS
19. Fit the cable to the opposite side pulley assembly and locate pulley
assembly onto the top of the post. Ensure cables are not crossed over
through top beam.
20. Fit balance cables loosely to the carriages
21. Cut the straps marked “DO NOT CUT THIS STRAP UNTIL THE POST IS
IN AN UPRIGHT BOLTED-DOWN POSITION”.
22. Place power pack on motor post. Feed limit switch wires through conduit
in post, connect at top. Refer figure 4.
23. Connect hydraulic pipe leading from the cylinder. Ensure all hydraulic
fittings are tight. Connect oil pipe between both posts. See page 24 for
Betabite Hydraulics assembly instructions, refer figure 10.
24. Attach limit switch activating bar to the top crossbeam. Refer figure 6&7.
FIG 7

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INSTALLATION INSTRUCTIONS
25. Pour oil into the tank. Oil to be filled through breather vent. Connect
power (only to be performed by a licensed electrician).
26. IMPORTANT. Check that all cables are seated correctly in pulley
grooves.
27. Adjust Balance cables.
Step1:Raise hoist manually to waist height, lower on to safety
locks.
Step 2: Make sure the left carriage is locked in at the same
height as the right carriage. It may be necessary to loosen the
balance cables in order to set carriages at same level,
Step 3: Tighten the nut on the right hand carriage until the safety
toggle has risen 10-13mm above the tooth.
Step 4: Tighten the nut on the left hand carriage until the safety
toggle on the right hand carriage lowers back down to the safety
tooth. Then give one full turn extra.
Note: For a new installation this process should be repeated
after the first 3 months of use, as the cables would have
stretched and bedded in. (refer to Figure 5).
28.
Cable
Nut
FIG
5