Related Manuals for Molnar M245-A
Summary of Contents for Molnar M245-A
- Page 1 UNIVERSAL Spare Parts for Molnar Hoists Two Post Hoist (4.5 Tonne) SERVICING M245-A...
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Page 2: Table Of Contents
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 ......................... -
Page 3: Introduction
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. -
Page 4: Overview
OVERVIEW Technicians should familiarise themselves with the M245 shown here in Diagrams 1 & 2. FRONT CONTROLS/ POWER PACK CONTROL NON-CONTROL POST POST REAR Diagram 1 – Top Down View of M245 Hoist Diagram 2 – Isometric View of M245 Hoist... -
Page 5: Safety
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 Repairs Tool Kit >... -
Page 6: Materials List
MATERIALS LIST Listed here are materials Molnar Hoists recommend for performing maintenance and repair work on the M245 ‘Universal’ Two Post Hoists. RECOMMENDATION MATERIAL High quality lithium grease with molybdenum sulphide additive Grease CRC Dry Glide Dry Lubricant Wurth HHS Dry Lube... -
Page 7: Safety Precautions
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 Cordon off work area performed and recorded using safety cones or by a competent person. -
Page 8: Maintenance
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... -
Page 9: Technician Maintenance Schedule
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. -
Page 10: Electrical Check
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. -
Page 11: Cylinder Replacement
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. - Page 12 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 Diagram 9 – Bar covered with Diagram 10 – Removing Cylinder End Cap O-Ring Soft Cloth used to support End Cap with Circlip Pliers...
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Page 13: Cylinder Fitting
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 17 – Cylinder Diagram 18 – Cylinder Diagram 16 – Attaching Diagram 15 – Hand fitting incorrectly aligned to correctly aligned New Hydraulic Fitting... -
Page 14: Bleeding Hydraulic System
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. -
Page 15: Balance Cable Inspection
BALANCE CABLE INSPECTION Balance Cable Replacement Criteria Balance Cables (Wire Ropes) shall be replaced immediately if in any area of the cable; Wire breaks exceed 4 wires within 48mm (Refer to Diagrams 19 & 20), Wire breaks exceed 10wires within 240mm (Refer to Diagrams 19 & 20), or There is break in a single strand (Refer to Diagram 19), or Is severely corroded, worn or damaged (Refer to Diagrams 21 &... - Page 16 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.
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Page 17: Balance Cable Adjustment
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. -
Page 18: Balance Cable Adjustment Procedure
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 29 - 2mm Allen Key on Diagram 30 - 90mm Extension Diagram 28 - 90mm Extension Non-Control Side for High with and without clearance under Carriage for Cable... -
Page 19: Lock Release Cable Adjustment Procedure
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 Diagram 33 - Adjusting... - Page 20 Diagram 35 - Trimming Excess Lock Release Diagram 34 - Gauging the clamping of the Lock Cable Release Cable with 1.5mm Allen Key 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.
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Page 21: Balance Cable & Pulley Replacement
BALANCE CABLE & PULLEY REPLACEMENT Balance Cable & Bottom Pulley Removal Do not operate hoist without balance cables. Refer to Diagram 36 (Balance Cable Layout) and Diagram 2 (Isometric View of M245 Hoist) 1. Raise the hoist and lock on first lock position. 2. -
Page 22: Top Balance Cable Pulley
a. Run through the correct area of the carriage b. Run over the correct pulleys c. Correctly seated in the pulleys d. Not twisted around the cylinder. 8. Conduct Balance Cable Adjustment procedure. 9. Replace cylinder covers. TOP BALANCE CABLE PULLEY When disassembling and reassembling the hydraulic fittings, first mark an alignment point on both sides of the fitting. -
Page 23: Carriage Slide Blocks
14. Refit Cylinders, Balance Cables and Lock Release Cable. 15. Reactivate power supply for hoist. 16. Adjust balance cables, lock release cable and bleed hydraulic system. 17. Refit all covers and lower hoist to ground CARRIAGE SLIDE BLOCKS Carriage Slide Block Tracks Inspection and Lubrication When cleaning Carriage Slide Block Tracks, refer Diagram 38, inspect for signs of wearing or scraping inside posts. - Page 24 *NOTE: Incoming power wiring disconnection to be performed by a Qualified Electrician only. 6. Unbolt anchor bolts and lower post to ground. Take care to not damage the thread of the anchor bolts and use an eye bolt through the lifting point hole on the post. 7.
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Page 25: Hydraulic System Check
HYDRAULIC SYSTEM CHECK 1. Lower hoist to ground. 2. Check level of hydraulic fluid in tank using dip stick if an accurate visual determination not possible. 3. Check all external hydraulic oil pipe connections for tightness and wipe clean with cloth while making note of any hydraulic oil found around fittings or power unit. -
Page 26: Structural Check
STRUCTURAL CHECK 1. Check for corrosion, distortion, crack welds or any damage or deterioration to the hoist structural components. Replace faulty components. 2. Check all bolts, screws and fasteners are tight starting from the arms and working up to the overhead beam assembly. -
Page 27: Door Protectors
DOOR PROTECTORS Check door protectors are clean and in good condition, replace if necessary. Door Protector Replacement 1. To remove door protectors, push tube vertically upwards and pivot bottom of tube away from carriage so tube is at approximately 30 degrees from carriage, then pull the tube down and away from the top door protector retaining bracket. -
Page 28: Trouble Shooting
Lubricate Release Lever Pivot Hoist not staying up Contaminated Oil blocking Change Oil valves Faulty Valve Contact Molnar Hoists Locks Not Engaging Contact Molnar Hoists Low hydraulic oil level Check Oil Level and check for leaks; top up Hoist will not lift to oil. - Page 29 Loose fittings Tighten fittings Oil Leaks Faulty fittings Replace fittings Leaking Hydraulic Cylinder Contact Molnar Hoists Incorrect Phase wiring Change rotation of motor# Motor runs but will not lift Release Lever Sticking Lubricate Release Lever Pivot Hoist overloaded...
- Page 30 For more information, please contact us or your local Molnar Representative 16-20 Coglin Street Brompton SA 5007 Australia T 08 7120 8700 F 08 8346 0097 E info@molnarhoists.com.au www.molnarhoists.com.au onwards & upwards...
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