Molnar SM Series - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

The Molnar SM Series FOUR POST HOIST is an electro-hydraulic vehicle lift designed for professional use in workshops and garages. This installation manual covers the 4, 5, and 6 Tonne models, providing comprehensive instructions for safe and efficient operation, installation, and maintenance.

Function Description

The Molnar SM Series FOUR POST HOIST is primarily used for lifting vehicles to facilitate various maintenance, repair, and inspection tasks. Its four-post design provides stable and secure support for vehicles, making it suitable for a wide range of automotive services, including oil changes, tire rotations, exhaust system repairs, and undercarriage inspections. The electro-hydraulic system ensures smooth and controlled lifting and lowering operations. The hoist is designed to be installed on a hard and flat floor made with reinforced concrete, with specific requirements for concrete strength (32MPa grade) and thickness (100mm minimum). Anchor bolts (M16 x 140mm tru-bolt) are used to secure the hoist to the floor, with 16 anchor bolts required for installation.

Important Technical Specifications

The Molnar SM Series hoists come in various capacities: 4 Tonne (SM440), 5 Tonne (SM450), and 6 Tonne (SM460). These models share common electrical and environmental specifications.

Electrical Specifications:

Supply Voltage: 0.9 - 1.1 nominal supply voltage.
Source Frequency: 0.99 - 1.01 nominal frequency.
Input Voltage Tolerance: Should be ±10%.
Frequency Tolerance: Should be ±1%.
Power Supply Cable: Must be a 10A over current protector installed in the input power line.
Diameter of Power Supply Cable: 2.5 mm².
Wiring: Requires 3 active and earth wires.
Control Voltage: 24V transformer for low voltage control.

Environmental Specifications:

Ambient Temperature: 5°C - 40°C.
Altitude: Shall be at altitudes up to 1000m above mean sea level.
Relative Humidity: Not to exceed 50% at 40°C.
Atmosphere: Free from excessive dust, acid fume, corrosive gases, and salt.
Exposure to Direct Sunlight or Heat Rays: Avoid exposing the hoist to direct sunlight or heat rays, which can change the environmental temperature.
Vibration: Avoid exposing to abnormal vibration.
Electrical Equipment Storage: Electrical equipment shall withstand the effects of transportation and storage temperature within a range of -25°C to 55°C and for short periods not exceeding 24 hours at up to +70°C.

Hydraulic System:

Hydraulic Oil: 46 Weight AWH Hydraulic Oil.
Oil Capacity: 10L for SM440/SM450 and 12L for SM460.
Power Pack: The hoist is equipped with a power pack that includes a motor and rubber mounts. The hydraulic hose connects the power pack to the hoist.

Dimensions (Layout Drawings):

SM440-S & SM440-A:
- Overall Length: 5595 mm
- Platform Length: 4775 mm
- Platform Width: 4095 mm
- Post Inside: 2734 mm
- Overall Width (including posts): 3095 mm
- Ramp Length: 820 mm
SM450-A:
- Overall Length: 4600 mm (platform length)
- Platform Length: 4875 mm
- Post Inside: 2734 mm
- Overall Width (including posts): 3095 mm
- Ramp Length: 1069 mm
SM460-S & SM460-A:
- Overall Length: 5446 mm (platform length)
- Platform Length: 5241 mm
- Platform Width: 5796 mm
- Post Inside: 3010 mm
- Overall Width (including posts): 3416 mm
- Ramp Length: 1069 mm

Usage Features

The Molnar SM Series hoists are designed for ease of use and safety.

Installation Process: The installation involves several key steps:
1. Preparation: Ensure the concrete floor meets specifications.
2. Layout: Place the main parts (platforms and transverse beams) on the appropriate position in reference to the layout diagram.
3. Assembling Transverse Beam for Platforms: Take the pins fixing guide block, pull out the pins, and take out the transverse beam pulleys. Remove wood pieces inside the platform, cut cable ties, and pull out the large black conduit, tightening the nut to the side of the platform. Connect lock cables into each end of the transverse beams.
4. Cable Arrangement: Put the control platform cable and control end transverse beam cable through the end of the platform, pulling out each cable. Ensure cables are positioned correctly. Fix nuts on each end of the cables to protect the thread from damage. Start with the non-control end transverse beam, bringing the cables through the ends of the transverse beam and reassembling the pulleys in the reverse order. Attach the platforms to the non-control transverse beam. Install the front wheel stop on each platform. Move to the control transverse beam, bringing cables through the ends and reassemble the transverse beam pulleys. Attach the rear of the platforms to the control transverse beam.
5. Assembling the Lock Rails and Posts: Square up the assembled transverse beam and platform to ensure square and level. Place the lock rails through the transverse beam ends and locate in the hole at the bottom of the posts. Set up the posts, maintaining the space of approx. 45-60mm between the fixing plate of the top of the post and the lock rail bracket. Fasten 2 (a) nuts (16mm) as shown in the figure below, fasten the upper nut clockwise and the lower nut counter clockwise, maintaining approx. space to the lock rail for 45-60mm (guideline only). Fasten 2 (b) nuts (11.5mm) each to opposite direction, maintaining 2-3 threads (3mm) between the nuts. Fix (c) nut tight to the lock rail.
6. Shimming and Leveling: Shim the posts as required, drill concrete holes, and install anchor bolts, fastening the nuts lightly. Shim up baseplates so that posts are vertical. Adjust baseplate surface to be in contact with the floor. Molnar recommends at least 50% surface to floor contact, especially in the middle of the baseplate, which must be in contact with the floor or shimmed. Set the posts so that guide blocks lightly contact and hold the posts when lifting up/down the platforms. Adjust vertically and level the 4 posts and then tighten the anchor nuts. Raise the platform to the first or second lock position and recheck platform levels.
7. Limit Switch and Cable Installation: Attach the limit switch to the bracket and assemble to the lock rail. Ensure the bracket is tightly fitted to the lock rail and doesn't slide up or down. Install the cable end through the hole in the top of the post plate and fasten both nuts. Attach the conduit holder bracket, air regulator, and control box to the post. Attach the black conduit end to the holder bracket.
8. Power Pack and Wiring: Mount the red power pack mounting plate to the post. Attach the motor mount and rubber mounts to the power pack and attach to the post. Remove tank and fill with hydraulic oil. Connect the hydraulic hose to the power pack. Install the 4 top post covers. Attach the 24V transformer to its cover and then to the top of the control post. Connect the main plate conduit tube and the control panel cable with the connection cable (purple) and assemble the power pack tank cover.
9. Final Leveling: For the final leveling of the platforms, raise the platforms to the 4th from bottom lock position and then press the lock button. Pull the cables in each of the 4 posts evenly and tighten the cable end bolts with a spanner. Recheck the levels with the heaviest vehicle available (under the hoist capacity).
10. Run-up Ramps: Assemble the run-up ramps and lift into position on the platforms and slide the pins through and fit circlips.
Safety Features:
- Before Commencing Operation: Inspect system components, control, emergency stop, and safety equipment for condition and correct function.
- Locking Mechanism: The hoist features a locking mechanism to secure the platforms at various heights, preventing accidental lowering.
- Emergency Stop: An emergency stop button is present on the control panel for immediate shutdown.
- Limit Switch: A limit switch is installed to prevent over-raising of the hoist.
- Cable Arrangement: Proper cable arrangement and tension are crucial for safe operation. Nuts on the cables protect threads from damage.
- Leveling: Regular checking and adjustment of platform levels are essential for safe vehicle support.

Maintenance Features

Regular maintenance is critical for the longevity and safe operation of the Molnar SM Series hoists.

Greasing: The pulley pins require greasing. Refer to page 15 of the manual for detailed instructions.
Cable Lubrication: Lubricate the cylinder rod.
Cable Adjustment: To avoid cable clamps rubbing the cables, adjust and angle the cable clamps as shown below and keep separated by approx. 10cm.
Pre-Operation Checks: Before commencing operation, inspect system components, control, emergency stop, and safety equipment for condition and correct function.
Periodic Checks:
- Legal Clearances: Ensure legal clearances around the hoist are maintained.
- Floor Suitability: Verify that the floor is suitable and within manufactures specifications.
- Cables, Pulleys, and Hoses: Check for any damage.
- Pulleys/Pins: All pulleys/pins must be greased. (Transverse beam and platform pulleys).
- Safety Devices: Limit switches and controls must be checked for correct operation.
- Hydraulic System: Check for leaks and ensure it is free at time of installation.
- Load Testing: Hoist must be tested without and with load as per manufactures specifications.
- Lubrication: Hoist must have been lubricated and adjusted as per manufactures specifications.
- Log Book: Log book use has been explained to owner/operator and initial details completed.
- Client Representative: The client representative must have been shown and instructed in the correct operation and maintenance of the hoist.
Grease Application: By this stage of the installation, ensure that grease has been applied to all pulleys on the hoist. This includes the four transverse beam pulleys as well as the front and rear pairs of pulleys under the platform. (Pulley pins are supplied with grease nipples for easy greasing). This should be performed every 6 months.
Tightening Cables: Turn on the hoist and raise up the hoist and press the locking switch to tighten the cable. (Raise the hoist to the position comfortable to work under the platform). Fasten the cable clamp on the cylinder fixing cable and the drive plate. Clamps must be tight, retighten again at the end of the installation.

The Molnar SM Series FOUR POST HOIST is a robust and reliable lifting solution, provided that all installation, operation, and maintenance guidelines are strictly followed. The detailed manual ensures that users have all the necessary information to safely and effectively utilize this equipment.