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.

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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.