Molnar 3585 User manual

Molnar Engineering Pty. Ltd
Installation
Operation
Maintenance
Instructions
MOLNAR
Four Post
Hoist Models:
3585 & 4488

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 ofAustralia & 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 240V Operation range 225V to 264V.
Cable sizes are given as a guide only for a maximum
cable length to 30m. Longest cable runs and in area
where supply voltage is belowmotor 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 240V Single phase model CWC3640F
Full Load Current 12.4Amps
Min Cable Size 2.5mm 2 core + earth
Circuit Breaker 1 phase 32 Amp 10kA
Recommended Clipsal 4CB132/10 or equivalent

Page 1
No person should be permitted to operate
the MOLNAR FOUR-POST HOIST without first
studying the operating instructions on page
5 and safety precautions on page 4.
This manual should be kept in a safe place
and referred to as necessary.
The installation requirements on page 24
must be completed and the certificate
on the inside back cover must be signed
by the installer. The guarantee card must
be completed and returned to MOLNAR
ENGINEERING PTY. LTD.
In tropical and steam cleaning conditions to
prevent rust in the cylinder raise the hoist to
full height and leave it there when not in use
overnight and on weekends.
This vehicle hoist is not designed to be used
for steam cleaning nor to be installed in
the open exposed to the elements. Vehicle
hoists installed under such conditions are not
covered by our guarantee.

Page 2
OPTIONS
As industry leaders in the manufacture of 2 and 4 post vehicle hoists,
Molnar Engineering Pty Ltd have applied this same knowledge to the JB 87
Hydraulic Jacking Beam.
The unit is for use in conjunction with a ramp 4 post hoist and has been
specially designed to provide versatility and ease-of-operation for a wheel
free system.
FEATURES
•Low profile in the parked position.
• Vertical travel of pumping handle provides for ease of vehicle
lifting.
• Support pads and adjustable slide arms and saddles provide
for all types of vehicles and lifting operations.
•Body end rollers allow for non-jamming travel along ramps.
•Large knurled handle permits easy gripping for valve control.
SPECIFICATIONS
Specifications
Capacity 2000 kg
Minimum Height 75 mm
Lifting Travel 280mm
Maximum
saddle spacing 1250 mm
Net Weight 78 kg
Fittings 2Support Pads
2Saddles
MOLNAR JB 87
Molnar Jacking Beam
OPTIONAL
EXT PAD
Suitable for
Molnar Jacking
Beam

Page 3
CONTENTS
Page No.
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Foreward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 5
Setting up the hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 6
Floor Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13
Layout of wire ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General layout of locking mechanism.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Betabite HydraulicsAssembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Replacement parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fault Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 22
DripTray Inspection and Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Wheels Free Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 24
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Page 4
FOREWORD
SAFETY PRECAUTIONS
SERVICE AND MAINTENANCE OF THE HOIST IS THE
RESPONSIBILITY OF THE OWNER

Page 5
OPERATING INSTRUCTIONS

Page 6
SETTING UP THE CAR HOIST

Page 7
FLOOR REQUIREMENTS
The floor should be a reinforced concrete slab with Compressive strength of minimum 25Mpa.
Reinforcement wire diameter 6mm x 200mm x 200mm square mesh F42 grade.
Minimum thickness of 100mm.
For a successful installation, it is important that the floor is flat and level at the points where the posts
are bolted to the floor.
Maximum level differences are referred to in Figure 4.
FIGURE 2
When the floor slope is greater than the recommended difference (Figure 4) the four post foundation
plates must be levelled by either:
ALOCAL LEVELLING BY MEANS OF CONCRETE FOUNDATION BLOCKS
BBY SUITABLE PACKING UNDER POST FOUNDATION PLATES
Figure 4A shows the recommeded concrete foundation blocks.
FIGURE 3
Adrive-on angle that is too acute (as illustrated) isto be avoided, asthis condition can cause damage to
the underside of vehicles.

Page 8

Page 9
INSTALLATION OF THE HOIST
"FLOOR REQUIREMENTS"
Remove nuts from the cable ends for assembly purposes and install
the wire ropes in the transverse beams in the following manner.

Page 10

Page 11
INSTALLATION OF HOIST
(to oil level line)

Page 12

Page 13

Page 14

Page 15
INSTALLATION OF HOIST
19.P r ess the starter button on the contact box and raise the hoist slightly. If the motor
turns, but the hoist does not lift, then the motor is turning in reverse, and two phases
inthe contact box must be interchanged to reverse the direction of rotation (by an
Electrician).
20.R aise hoist approximately 200mm and remove the blocks on which the transverse
beams and platforms have been resting. Check all the hydraulic couplings to
ensure the there are no oil leaks (including hydraulic cylinder coupling).
NOTE: MAKE SURE THAT THE WIRE ROPES ARE NOT CROSSED AND THAT THEY DO NOT
FOUL ANY PART OF THE HOIST ASSEMBLY OR THEIR LIFE WILL BE SEVERELY SHORTENED.
21.L o wer the hoist to a point where the end of the transverse beam adjacent to No. 1
Post is approximately 50mm from the base plate.
22.A djust the posts so that they are square to the transverse beams and the rollers at
the ends of the beams contact the backs of the posts. Do not force the posts
against the rollers.
23.F or the hoist to function correctly, it is essential that the sides of both transverse
beams are exactly vertical. Using a spirit level, check the transverse beams at the
points indicated by the arrows in Figure 17. If the beams are out of vertical, shims
(packing X11) between the platforms and transverse beams will have to be used as
indicated in Figure 18.
24.W h en all posts are correctly positioned, secure them to the floor. 16mm x 64mm
DYNABOLT are recommended for fastening down. This may differ in some states.
25.T he posts must be exactly vertical in all planes and to each other for correct
operation of the hoist. If they are not vertical, shims must be used under the
baseplates.
26.E nsure that the locking toggles at the control ends of the transverse beams
(adjacent No.1 & No. 3 Posts) are both off. Fit the long square tube, (with the load
holding control handle in a near vertical position) by sliding the control end over the
safety-actuating square lug on the transverse beam adjacent to No. 1 Post. Bow
the tube, by pulling out at the middle of the tube and slide the other end of the
tube on the safety-actuating square lug on the transverse beam adjacent to No. 3
Post. Fit the retaining bracket to the centre of the driver’s side platform.
27.L o wer the hoist (using the lowering lever on the power unit) until the transverse
beams rest in the centering plates at the bottom of the posts. Tension the wire
ropes via the nuts in the following manner:
NOTE: In order to allow for normal wire rope stretch, it is advisable to have a car on
the hoist for this operation.
Tension the 4 wire ropes until they are just about to lift the transverse beams.
Engage the locking toggles by moving the load-holding control handle to the
horizontal position. Raise the hoist, taking note of the clicking sound made by the
locking toggles. If the four toggles all click together, the load holding is
operating correctly. If the toggles are not synchronised, appropriate adjustments
must be made. Leaving the load-holding control handle in the ON position, lower
the hoist until all locking toggles are engaged, observing when the locking toggles
engage in relation to No. 1 Post. Adjust the wire rope tension at one post at a time
until all locking toggles engage simultaneously. The platforms should be level when
all four locking toggles lock in simultaneously. When the locking toggles are
operating satisfactorily, fit the lock-nuts to the wire rope ends and tighten.

Page 16

Page 17
INSTALLATION OF HOIST
28.A djust the side rollers on the transverse beams so that they just contact the sides of
the posts.
NOTE: This is not applicable to the “WHEEL-FREE” models.
29.A djust the limit switch actuating bracket so that it clears the No. 1 Post by
approximately 2mm.
Adjust the limit switch so that the hoist automatically stops before the safety
toggle rollers reach the wire rope ends.
30.F it the run-up ramps at the drive-on end, and the wheel stops at the other end of
the platforms.
NOTE: “WHEEL-FREE” models only. Bolt the run-up ramp locating bar in position and
fit the other section of the run-up ramps. Fit the run-up ramp extensions. Fit the
two WHEEL-FREE RAILS so that they rest on the secondary transverse beams.
31.D ouble check that all wire ropes are properly seated on the pulleys, (refer layout
ofwire ropes) and that the hoist is operating correctly.
Double check that the wire ropes are not crossing each other.
FITTING OF JACK STAND AND JACKING BEAMS JB87
32.F it The Jack Stand (and Jacking Beams
“JB87”, (if purchased).
NOTE: Remove 3 of the 4 countersunk bolts
holding the secondary platform (platform
adjacent to NO. 2 and No. 4 posts) in
position. Slide the platform outwards, place
the Jack Stand (and Jacking beams) into
position. Slide the platform into the original
position.
Re-bolt the platform with the 3 countersunk bolts.
33.Clean the hoist of anti-corrosion spray.
FITTING OF DRIP TRAY 44880DRPT
34.(1). Raise hoist to normal working height, engage safety locks and lower until hoist
isjust resting on the safety locks.
(2). Orientate Drip Tray so the Support Tabs are on the top and slide Drip Tray over
the top of the Ramp Brace Strap. Refer to Figure 21 on page 23, steps 1, 2 &3.
(3). Locate Drip Tray in the cavity created by the inside edges of the ramp, the
Ramp Brace Strap and the Cylinder Support Strap. Refer to steps 4 & 5.
(4). Push down on the Support Tabs to ensure the bottom of the drip tray protrudes
slightly below the bottom of the Straps. Refer to step 6. It is important that the
top of the Drip Tray is pushed down as low as possible for there is little clearance
from the top of the Straps and the bottom of the Cable Block. The Drip Tray is in
danger of being crushed by the Cable Block if the top of the Drip Tray is too high.
(5).Check Drip Tray clearance by slowly lowering the hoist until Cable Block travels
over the area of the Drip Tray. If the Cable Block touches the Drip Tray repeat
step 4.
(6). Installation is complete.

Page 18
LAYOUT OF WIRE ROPES