Molnar Hoist UNIVERSAL M245-A User manual

UNIVERSAL
SERVICING
Spare Parts for Molnar Hoists
Two Post Hoist (4.5 Tonne)
M245-A

1
Contents
INTRODUCTION .......................................................................................................................................... 2
OVERVIEW .................................................................................................................................................. 3
SAFETY ....................................................................................................................................................... 4
TOOL LIST ................................................................................................................................................... 4
MATERIALS LIST ......................................................................................................................................... 5
SAFETY PRECAUTIONS ............................................................................................................................. 6
MAINTENANCE ........................................................................................................................................... 7
TECHNICIAN MAINTENANCE SCHEDULE ................................................................................................. 8
ELECTRICAL CHECK .................................................................................................................................. 9
INSTALLATION CHECK ............................................................................................................................... 9
COVER REMOVAL ...................................................................................................................................... 9
Release Cable Cover Removal ................................................................................................................. 9
Cylinder Cover Removal ........................................................................................................................... 9
CYLINDER REPLACEMENT ...................................................................................................................... 10
Cylinder Removal .................................................................................................................................... 10
Cylinder Fitting ........................................................................................................................................ 12
Bleeding Hydraulic System ..................................................................................................................... 13
BALANCE CABLE INSPECTION ............................................................................................................... 14
Balance Cable Replacement Criteria ...................................................................................................... 14
Balance Cable & Pulley Inspection Procedure ........................................................................................ 14
BALANCE CABLE ADJUSTMENT ............................................................................................................. 16
Balance Cable Adjustment Check ........................................................................................................... 16
Balance Cable Adjustment Procedure ..................................................................................................... 17
Lock Release Cable Adjustment Procedure ............................................................................................ 18
BALANCE CABLE & PULLEY REPLACEMENT ......................................................................................... 20
Balance Cable & Bottom Pulley Removal ................................................................................................ 20
New Balance Cable and Bottom Pulley Replacement ............................................................................. 20
TOP BALANCE CABLE PULLEY ............................................................................................................... 21
Top Balance Cable Pulley Replacement ................................................................................................. 21
CARRIAGE SLIDE BLOCKS ...................................................................................................................... 22
Carriage Slide Block Tracks Inspection and Lubrication .......................................................................... 22
Carriage Slide Block Replacement .......................................................................................................... 22
HYDRAULIC SYSTEM CHECK .................................................................................................................. 24

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REPLACING HYDRAULIC OIL ................................................................................................................... 24
STRUCTURAL CHECK .............................................................................................................................. 25
SAFETY OPERATION TEST ...................................................................................................................... 25
PICKUP PADS ........................................................................................................................................... 25
Pickup Pad Replacement ........................................................................................................................ 25
DOOR PROTECTORS ............................................................................................................................... 26
Door Protector Replacement ................................................................................................................... 26
MAJOR INSPECTION ................................................................................................................................ 26
TROUBLE SHOOTING ............................................................................................................................... 27
Molnar Hoists M245 ‘Universal’ Two Post Vehicle Hoist in Standard Configuration
INTRODUCTION
This Servicing Manual has been developed for the maintenance and repair of Molnar Hoists M245
‘Universal’ Two Post Vehicle Hoist.
A basic level of competency and experience handling machinery and tools is assumed of people using this
Manual.
This Manual has been laid out in a progressive format and should be read in its entirety for best preparation
prior to performing repairs or maintenance on a Molnar M245 ‘Universal” 2 Post Hoist.
As the policy of Molnar Hoists is one of continuous improvement, the manufacturer reserves the right to
change specifications without notice. Information is correct and true at time of printing.
Updated 13 February 2017

3
OVERVIEW
Technicians should familiarise themselves with the M245 shown here in Diagrams 1 & 2.
Diagram 1 – Top Down View of M245 Hoist
Diagram 2 – Isometric View of M245 Hoist
FRONT
REAR
DRIVE IN DIRECTION
CONTROL
POST
NON-CONTROL
POST
CONTROLS/
POWER PACK

4
SAFETY
Always follow local safety regulations as a priority when conducting maintenance and repairs.
Personal protective equipment
Gloves
Ear & eye protection
Steel capped boots
Safety cones, warning,
signs and tape
Attention
Notes marked require
specific attention to ensure
procedure is completed
safely and correctly.
Electrician
A licensed electrician must
perform all electrical work
including power connection
and wiring.
TOOL LIST
Listed here are tools and equipment Molnar Hoists recommend for performing maintenance and repair
work on the M245 ‘Universal’ Two Post Hoists.
Standard Maintenance Tool Kit
> Flat Blade Screwdriver
> Phillips Head Screwdriver
> Metric Allen Key set
> Clamp wrench (Vice Grips)
> Rubber mallet
> Hammer
> Large Adjustable wrench
> Small Adjustable wrench
> Torque wrench with ½” drive
(minimum 155Nm torque capacity)
> Metric Spanner Set
> 9/16” open ended spanner
> Metric Socket and Ratchet Set
> Deep Series 24mm socket
> Needle-nose pliers
> External circlip pliers
> Black Texta
> 2.4 metre platform-style step ladder or an
appropriate elevated work platform
> 1200mm spirit level
> Soft, Lint-free cloth (to protect cylinder
rod)
Repairs Tool Kit
 Pry bar
 Oil funnel
 ½” drive impact gun
 27mm Spanner or Socket
 Drip Tray
 Empty oil container with min. 20 litre
capacity
 Packers (for cylinder support during
removal)
 ‘F’ Clamp
 Small Plastic Bags
 Cable Ties
 Masking Tape
Recommended Cleaning Kit
 Eye Protection
 Rubber Gloves
 Soft bristle brush
 Lint-free, soft cloths

5
MATERIALS LIST
Listed here are materials Molnar Hoists recommend for performing maintenance and repair work on the
M245 ‘Universal’ Two Post Hoists.
MATERIAL
RECOMMENDATION
Grease
High quality lithium grease with molybdenum sulphide additive
Dry Lubricant
CRC Dry Glide
Wurth HHS Dry Lube
General Lubricant
CRC Tac-2
Wurth HHS Lube
Wire Rope Lubricant
Lanotec heavy duty liquid lanolin
85-90 gear oil
Hydraulic Oil
High Quality, Anti-Wear 46 Weight (AWH 46)
NOTE: Sites in different climates may require a different weight of hydraulic
oil.
Powder Coated Surface
Cleaner
Dilute solution of mild detergent
e.g., pH-neutral liquid hand wash or dishwashing detergent in warm water.
Metal Surface Cleaner
WD-40
Degreaser
Lanotec Citra Force
Water Soluble Degreaser

6
SAFETY PRECAUTIONS
For your own safety and the safety of equipment, always take the following precautions
Failure to comply with these precautions may result in loss of load, damage to unit and/or personal injury
Servicing a Hoist must be
performed and recorded
by a competent person.
Ensure you are
authorised to service a
hoist and that you are
familiar with all aspects of
the hoist.
Cordon off work area
using safety cones or
other safety barricade.
Ensure area is clear of
any obstruction prior to
servicing.
Do not conduct
maintenance with vehicle
on hoist.
Do not try to adjust relief
valve as it has been set
at maximum operating
efficiency.
This vehicle hoist is not
designed to be used in &
around steam cleaning
nor be installed in the
open, exposed to the
elements. Hoist operated
in such conditions are not
covered by our warranty.
Do not force safety
release lever into the off
position while weight is
resting on the carriage
safety locks.
In moist conditions,
ensure moving
components are well
lubricated.
Seal and protect all
electrical components
from elements.
Clean the hoist with
warm water and non-
abrasive pH neutral
detergents. Surfaces
should be thoroughly
rinsed to remove residue.
Do not oil or grease the
lifting arm assemblies.
Do not make any
changes to safety
equipment.
Use only recommended
wire rope lubricants
Isolate hoist from power
to protect from
unintended movement
when working on internal
components, balance
cables and power
system.

7
MAINTENANCE
Requirements of the Operator to keep the vehicle hoist in safe, good working order and maintain warranty.
Owner Maintenance Schedule
It is the Hoists Owner’s responsibility and Duty of care to maintain the hoist.
This must be recorded and retained.
Pre-Operational
Monthly
6 Monthly
Visual Inspections
> Access and Clearance
> Work area clean & tidy
> Structure
> Loose or damaged parts
> Decals & control markings
> Pick-up pads
> Hydraulic fluid levels
Functional Inspections
> Full operation cycle of hoist
> Operating controls
> Carriage locks
> Arm locks
> Unusual noise or vibration
Check Accessories
Visual Inspections
> Flooring
> Anchor bolts
> Structural alignment
> Structural integrity
> Visual appearance
> Operation manual
> Displayed notices
> Compliant Clearance
> Pick-up pads
> Balance cables
> Hydraulic System Leaks
> Pulleys
Functional Inspections
> Lubrication
> Isolation switch
> Limit switch
Check Accessories
Visual Inspections
> Oil leaks from cylinders
> Oil leaks from pipe joints
Functional Inspections
> Installation check
Note: Service intervals are based on an average operation of 8 lifts per day, 5 days per week, 50 weeks per
year (2,000 cycles). If operation cycles are more frequent, the service and inspection frequency should
reviewed and set at an appropriate level with your Technician. The intervals shown are the minimum time
periods for inspections.

8
TECHNICIAN MAINTENANCE SCHEDULE (detailed in the Service Manual)
Requirements of the Service Technician to keep the vehicle hoist in safe, good working order and maintain
warranty.
Service and safety inspections on the hoist must be performed by a competent person.
This must be recorded and maintained.
In the first 6 Weeks
Every Year
Every 2 Years
Every 10 Years
> Replace the
hydraulic oil
> Readjust the balance
cables
> Safety operation test
> Balance cable
inspection,
adjustment and
lubrication
> Lubricate pulleys
> Lifting arms & pivot
pins
> Pick-up pads
> Hydraulic oil and
system
> Electrical controls
and limit switch
> Structural & general
check
> Accessories
condition
In addition to regular
Yearly tasks
> Replace the
hydraulic oil
> Clean tank and filter
In addition to regular
Yearly and 2 Yearly
tasks, a Major
Inspection is required.
Remove and Inspect
> Balance Cables
> Locking Toggles
> Arm Lock
Components
Replace
> Balance cable
pulleys
> Carriage Slide Block
> Pick-up pad rubbers
The first oil change
should occur within the
first 6 weeks of operation
to keep the hydraulic
system in good working
condition.
Although recommended,
this is not mandatory.
If the yearly service and
safety inspection is not
performed, the warranty
is null and void.
To keep the hydraulic
system in good working
condition, oil changes
are required every 2
years or 4,000 cycles.
After 10 years of service,
remove the balance
cables from the hoist,
clean and inspect them
to ascertain
serviceability, replace if
required. If the hoist is in
a high working or
extreme environment,
the balance cables
should be replaced.
Note: Service intervals are based on an average operation of 8 lifts per day, 5 days per week, 50 weeks per
year (2,000 cycles). If operation cycles are more frequent, the service and inspection frequency should
reviewed and set at an appropriate level with your Technician. The intervals shown are the minimum time
periods for inspections.

9
ELECTRICAL CHECK
Electrical repairs should be performed by a qualified, licensed electrician.
The isolation switch for the hoist should be in safe and easy reach of the operator.
1. Isolate hoist from electrical power.
2. Check that there is no exposed wiring on the hoist.
3. Check that the raise button, motor and contactor box are all secure and in good condition.
4. Reconnect hoist to power and check raise button, motor and limit switch are functioning correctly.
INSTALLATION CHECK
Footing should be repaired if there are cracks in the concrete near the hoist.
1. Check condition of concrete
2. Check anchor bolts are tight and in good condition.
3. Check posts are vertical in both planes and any shimming is secure and in good condition.
COVER REMOVAL
Release Cable Cover Removal
1. Remove black knob from end of lock release lever by unscrewing.
2. Loosen the screws securing the Release Cable Covers then remove them by lifting up and away
from the post.
3. If performing maintenance with covers off, refit black knob to end of lock release lever.
Cylinder Cover Removal
Gloves are recommended for handling cylinder covers.
Do not raise hoist past 1st lock without cylinder covers fitted;
cylinder covers secure the cylinders in correct position for operation.
To avoid damaging cylinder cover screws, do not use powered screwdrivers.
Top Cylinder Cover Removal
1. Set the hoist onto the first lock.
2. Loosen cylinder cover securing screws located at the top of the top cover.
3. While holding the cylinder cover, remove securing screws located at the bottom of the top cover.
4. The top cover should be easily removed by sliding down off the securing screws.
5. To avoid losing screws, refit the screws after cover has been removed.
Bottom Cylinder Cover Removal
1. Set the hoist onto the first lock.
2. Loosen cylinder cover securing screws located at the bottom of the bottom cover.
3. While holding the cylinder cover, remove securing screws located at the top of the bottom cover.
4. The bottom cover should be easily removed by sliding up off the securing screws and out from the
carriage.
5. To avoid losing screws, refit the screws after cover has been removed.

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CYLINDER REPLACEMENT
WARNING: The complete cylinder weight is
approximately 20kg, it is recommended to
obtain assistance for cylinder handling.
When disassembling and reassembling the
hydraulic fittings, first mark an alignment point
on both sides of the fitting. The fitting must be
retightened to the same torque on reassembly
to achieve correct seal.
Refer to Diagram 3
Cylinder Removal
1. Set hoist on first lock and apply ‘F’ clamp to hold
down the hydraulic release lever to drain oil from
system.
2. Isolate electrical power supply to the hoist.
3. Remove the cylinder covers
NOTE: An impact gun is required to effectively remove or refit the cylinder nyloc nut. For
this purpose, only use the impact gun by applying only in short bursts; short bursts should
only turn the nut and not the cylinder shaft, thus protecting the cylinder from damage.
Diagram 4 – Accessing
Nyloc Nut
Diagram 5 – Applying
Short Burst with Impact
Gun
Diagram 6 – Using Bag
and Ties to Contain
Hydraulic Oil Drips
Diagram 7 – Loosening
locking Grub Screw
from Cylinder End Cap
4. Using an impact gun and 27mm socket, remove the nyloc nut from the bottom of the cylinder rod.
Refer to Diagrams 4 & 5
5. Disconnect oil line that connects to the top of the cylinder and secure the end with a small plastic
bag a cable tie over the end of the oil pipe to contain any drips. Refer to Diagram 6
6. With an Allen key, loosen the 2.5mm grub screw (should not require more than 2 turns) in the
cylinder end cap located at the top of the cylinder. Rotate the cylinder to get better access to the
grub screw if required. Refer to Diagram 7
Diagram 3 – Hydraulic Fittings
Reassembly with Position Marking

11
NOTE: When removing or refitting the cylinder end cap, ensure the O-ring is maintained in
position at the top of the thread. Refer to Diagram 8
Diagram 8 – Indication for Cylinder
End Cap O-Ring
Diagram 9 – Bar covered with
Soft Cloth used to support
Cylinder
Diagram 10 – Removing Cylinder
End Cap with Circlip Pliers
7. Place wedge/packers between the top of the carriage and the underside of the cylinder barrel to
support the weight of the cylinder. Wrap the wedge with a soft, clean to protect the cylinder rod from
damage. Refer to Diagram 9
8. Hold the cylinder barrel and unscrew the cylinder end cap; it should only be hand tight but you can
use a pair of circlip pliers to loosen if too tight. Refer to Diagram 10
9. While holding the cylinder, remove the wedge/packers and allow it to slide down inside the carriage
until it comes to rest. Refer to Diagram 11
10. Refit (and secure with grub screw) the cylinder end cap and plug the cylinder oil line (use the plug
supplied with the replacement cylinder) to prevent movement of the rod when handling the cylinder.
Refer to Diagrams 12 & 13
11. Lift the cylinder up and out of the carriage. Refer to Diagram 14
Diagram 11 – Lowering
Cylinder down into the
Carriage
Diagram 12 – Cylinder
being Capped &
Plugged.
Diagram 13 – Close-
up image of fitting
plug to hydraulic
fitting.
Diagram 14 – Handling
Cylinder in/out of Carriage

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Cylinder Fitting
Cylinder Fitting is almost the same process as the Cylinder Removal process in reverse. Please familiarise
yourself with the cylinder removal process before continuing.
Diagram 15 – Hand fitting
Nyloc Nut
Diagram 16 – Attaching
New Hydraulic Fitting
Diagram 17 – Cylinder
incorrectly aligned to
Carriage
Diagram 18 – Cylinder
correctly aligned
square with Carriage
1. Ensure to plug the cylinder oil line (plug should be supplied with the cylinder) this will prevent
movement of the rod when handling the cylinder. Refer to Diagrams 12 & 13
2. Remove the nyloc nut from the end of the cylinder rod, and fit rod end down into the centre of the
carriage. Refer to Diagram 14
3. By hand, start the nyloc nut onto the cylinder piston rod end. Refer to Diagram 15
4. Continue to tighten with 27mm socket and impact gun used in short bursts until nut is firmly
tightened.
5. Loosen off nyloc nut by a ½ turn to allow some clearance for movement of the cylinder.
6. Loosen the 2.5 mm locking grub screw (max. 2 turns) and remove the cylinder end cap. Refer to
Diagram 7
7. Remove the plug from cylinder oil line.
8. Pull the cylinder barrel up and feed through the hole in the top plate at the top of the post, then while
holding the cylinder barrel, place wedge/packers between the top of the carriage and bottom of the
cylinder barrel. Refer to Diagram 9
9. Refit the cylinder end cap (firmly hand tighten) to the cylinder barrel and secure by tightening the
2.5mm locking grub screw.
NOTE: When removing or refitting the cylinder end cap, ensure the O-ring is maintained in
position at the top of the thread. Refer to Diagram 8
NOTE: When reassembling hydraulic fittings, re-apply the same torque, do not overtighten.
10. Connect the oil line to the new cylinder, firmly hand tighten, then using spanners, tighten a further
1/2 turn exactly. Refer to Diagram 16. If reassembling, the fittings should return to the same torque;
this can be achieved by marking the fittings for alignment. Refer to Diagram 3
11. Ensure the cylinder is positioned with brackets square to the carriage. Refer to Diagrams 17 & 18
12. Clean up any oil that has leaked onto the floor or the hoist. Make sure to check and clean inside the
post, under the carriage.
13. Remove wedge/packers under cylinder barrel and fit the bottom cylinder cover only.
14. Remove ‘F’ Clamp and reconnect electrical power supply to the hoist.
15. Complete bleeding of hydraulic system before fitting top cylinder cover.

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Bleeding Hydraulic System
1. Ensure top cylinder cover(s) are removed.
2. Ensure the cylinder(s) is positioned with brackets square to the carriage. Refer to Diagrams 17 & 18
3. Raise the hoist 50mm and then lower hoist to ground but continue to hold down release lever for a
further 90 seconds to clear air from system.
4. Check oil level, and;
a. Top up oil if required, or;
b. Change oil if replacing cylinder or power pack components.
5. Run hoist through 3 full cycles unloaded each time holding down the release lever for a further 30
seconds after lowering to ground.
6. Check cylinder oil line connections for leaks. If a leak is found, retighten fitting, wipe clean and
repeat steps 1-6
7. Refit top cylinder cover(s) and check operation by running the hoist through 3 cycles loaded with a
vehicle.

14
BALANCE CABLE INSPECTION
Balance Cable Replacement Criteria
Balance Cables (Wire Ropes) shall be replaced immediately if in any area of the cable;
A. Wire breaks exceed 4 wires within 48mm (Refer to Diagrams 19 & 20),
B. Wire breaks exceed 10wires within 240mm (Refer to Diagrams 19 & 20), or
C. There is break in a single strand (Refer to Diagram 19), or
D. Is severely corroded, worn or damaged (Refer to Diagrams 21 & 22), or
E. Expected to exceed any of the above replacement criteria before the next service.
Diagram 19 – Wire Rope Construction Diagram 20 – Wire Rope Wire Breaks
Diagram 21 – Wire Rope Wear Diagram 22 – Kink or Crush Damage
Balance Cable & Pulley Inspection Procedure
Please make note of the precautions before starting the
inspections.
To inspect the balance cables and pulleys the
tension on the cables must be released to
enable these items to be correctly inspected
and lubricated.
Use gloves when handling Wire Ropes to
avoid injury from broken wires.
To properly assess wire ropes, you must bend
them to expose any broken wires, refer to
Diagram 23. Give special attention to the
sections that run over the pulleys; check both
the inner and outer running areas of these
sections.
Diagram 23 – Bending Wire Ropes
to Expose Broken Wires

15
When working on the cable ends, protect the exposed
cylinder rod by thickly wrapping a soft cloth around
the tools used. If the cylinder rod is damaged it may
lead to damage of cylinder seals and cause the
cylinder to leak. Avoid contacting the cylinder where
possible. Refer to Diagram 24
1. Set hoist on first lock and hold down the release lever for 10
seconds to ensure the load is on the locks.
2. Remove all cylinder covers.
3. Measure and note the amount of thread protrusion of the
top cable end located at the top of each carriage. Refer to
Diagram 25
4. If top cable end thread protrusion is less than 40mm, go to
step 5, if greater than 40mm, follow these steps;
a. Loosen off the nut until the top of the nut is level with
the top of the top cable end thread on both sides.
b. Remove the bottom pulley from both posts and note
orientation of pulley. Refer to Diagram 26
c. Pull the bottom cable end down from the bottom of
each carriage and wind each nut on a further 25mm.
Refer to Diagram 27
d. Clean old grease from bottom pulleys and bottom pulley pins then re-grease.
e. With the cables seated in the grooves, refit the bottom pulleys on both posts ensuring the
small shoulder is facing towards the post (away from circlip) when refitting.
Diagram 25 - Top Cable End
Thread Protrusion
Diagram 26 - Bottom Pulley
Secured with Circlip
Diagram 27 - Bottom Cable End
Adjustment
5. Starting at the control post, then repeat for non-control post:
Use a 9/16” open ended spanner to hold the balance cable end inside the top of the carriage safety
rack. Use a 24mm deep socket with ratchet to loosen the cable nut till the top of the nut is just level
with the end of the cable. Avoid contacting the cylinder rod with the tools. Refer to Diagram 24
6. On all accessible sections of balance cables, clean dirt and old lubricant if necessary, inspect for
damage by ‘reverse bending’ (bending 90 degrees in opposite directions) the cables to expose any
broken wires and then lubricate with Wire Rope lubricant.
7. Inspect all balance cable pulleys (per side there are 2 top, 1 bottom) for;
a. wear in the groove, and
Diagram 24 – Cable End
Adjustment with Soft Cloth Covered
Tools to protect Cylinder

16
b. internal diameter wear by examining the amount of clearance on the shafts.
8. Lubricate the top balance cable pulley shafts with general spray lubricant.
9. Refit all top cylinder covers and ensure the cylinder brackets are square to the carriage.
10. Lock hoist at top position and hold down the release lever for 10 seconds to ensure the load is on
the locks.
11. On previously inaccessible sections of balance cables, clean dirt and old lubricant if necessary,
inspect and then lubricate with Wire Rope lubricant.
12. Check all balance cables are correctly seated in pulley grooves then conduct balance cable
adjustment procedure.
13. Refit bottom cylinder covers.
14. Lower hoist to ground.
BALANCE CABLE ADJUSTMENT
Follow balance cable adjustment procedure to ensure correct tension; if balance cables are
not correctly adjusted, damage to hoist, vehicles, equipment or personnel could occur.
Balance Cable Adjustment Check
1. Remove the Cable Covers
2. While raising the hoist,
listen and observe the lock
engagement.
The locks should engage
and release in unison, if
not, tighten the top balance
cable end on the carriage
that is running “higher“ or
complete the Balance
Cable Adjustment
Procedure.
3. Ensure that the Lock
Release cable is tensioned
correctly or perform the
Lock Release Cable
Adjustment Procedure.
4. Replace Cable Covers

17
Balance Cable Adjustment Procedure
1. Set hoist onto first lock and remove the bottom cylinder covers from both posts.
2. Raise the hoist 100mm.
Diagram 28 - 90mm Extension
under Carriage for Cable
adjustment
Diagram 29 - 2mm Allen Key on
Non-Control Side for High
Configuration Cable adjustment
Diagram 30 - 90mm Extension
with and without clearance
3. Take 2 x 90mm pad extensions, place 1 between the carriage and base plate on each post. Refer to
Diagram 28
For units in the High configuration (4040mm Overall Height), add a 2mm Allen Key on top of
the Pad Extension on the Non-Control Side only. Refer to Diagram 29
4. Lower the hoist until carriages are just sitting on the extensions so they cannot be removed. Refer
to Diagram 30
a. For units in the High configuration (4040mm Overall Height), add a 2mm Allen Key on top of
the Pad Extension on the Control Side only to allow for the extra length cable adjustment.
Refer to Diagram 29
5. On the control side, hold the top cable end at the top of the carriage with 9/16” spanner and tighten
the cable Nyloc nut with 24 mm Deep Socket or Spanner until the non-control carriage has raised
just enough that the pad extension could be removed. Refer to Diagram 30
a. For units in the High configuration (4040mm Overall Height), remove the 2mm Allen Key at
this point.
6. On the non-control side, hold the hold the top cable end with 9/16” spanner and tighten the cable
Nyloc nut until the non-control carriage lowers back onto the pad extension just so much that the
pad extension cannot be removed.
7. If top cable end thread protrusion is less than 40mm, go to step 5, if greater than 40mm, follow
these steps;
a. Loosen off the nut until the top of the nut is level with the top of the top cable end thread on
both sides.
b. Remove the bottom pulley from both posts and note orientation of pulley. Refer to Diagram
26
c. Pull the bottom cable end down from the bottom of each carriage and wind each nut on a
further 25mm. Refer to Diagram 27
d. Clean old grease from bottom pulleys and bottom pulley pins then re-grease.
e. With the cables seated in the grooves, refit the bottom pulleys on both posts ensuring the
small shoulder is facing towards the post (away from circlip) when refitting.

18
f. Restart Balance Cable Adjustment procedure.
8. Raise the hoist 50mm and replace 90mm Pad Extensions.
9. Perform Balance Cable Adjustment check.
10. Set hoist onto first lock and replace the bottom cylinder covers from both posts
11. Lower hoist to ground and perform Lock Release Cable adjustment.
Lock Release Cable Adjustment Procedure
Diagram 31 -Checking Lock
Disengagement
Diagram 32 - Checking Lock
Release Cable Tension
Diagram 33 - Adjusting
Lock Release Cable
Tension
1. Remove the Release Cable Covers.
2. Raise the hoist off the locks.
3. Lubricate the locking toggle pivots and lock release cable pulley shafts then check they all pivot
freely.
4. Check the return springs are in good condition and positively engage locking toggles.
5. Hold down the lock release lever fully and compare the disengagement of the non-control lock to
the control side. The non-control side lock should retract as much or more than the control side,
Refer to Diagram 31, if not go to Step 8.
6. Set hoist onto first lock and hold down the hydraulic release lever for 10 seconds.
7. Check the tension of the lock release cable. Refer to Diagram 31
a. If loose, go to Step 8.
b. If tight, go to Step 12
8. Loosen off the clamping nut on the non-control side lock. Refer to Diagram 33

19
Diagram 34 - Gauging the clamping of the Lock
Release Cable with 1.5mm Allen Key
Diagram 35 - Trimming Excess Lock Release
Cable
Do not overtighten the clamping nuts on locks, damage to lock release cables may occur.
The spacing between washers should be 1.5mm. It is recommended to use a 1.5mm Allen
Key to gauge the correct spacing as shown in Diagram 34
9. Pull the cable down tight and hold while re-tightening. Refer to Diagram 33
10. Check correct spacing of clamping washers on lock using 1.5mm Allen Key and adjust if necessary.
11. Raise hoist off locks and recheck the movement of the non-control lock when holding down the lock
release lever. Repeat process with more tension on cable if disengagement is insufficient.
12. Trim any excess lock release cable that hangs below the cable cover bracket. Refer to Diagram 35
13. Run a light coating of cable lubricant over the length of the lock release cable.
14. Perform balance cable check.
15. Replace cable covers and lower hoist to ground.