Molift Air

TM16101 Rev A 2013-11-14

Molift AirEN - Technical manual

1

Molift Air / www.molift.com

Content

General .....................................................2How to open.............................................3Disconnect battery ....................................3Molift Service Tool .....................................4Technical description .................................5Measurements ..........................................6Air Components ........................................7Spare part list ..........................................12Labels .....................................................13Battery ....................................................14Covers ....................................................15Hand control ........................................... 17Angle Sensor/Ens Sensor..........................18Suspension coupling ................................19Emergency Stop/Lowering .......................20Replacing Lifting Band .............................21Brake ......................................................22Lifting Motor/Gear House ........................23Microswitches .........................................24PCB (Printed Circut board) .......................25Electric Diagram ......................................26Trolley .....................................................27IRC (In rail charging) ................................28Propulsion ...............................................28Documenting the Service .........................29Periodic Inspection Checklist Molift Air ....30Safety checklist after Service and Repair ...31Service Log .............................................32Installation ..............................................33Notes ......................................................33

Important

This Technical Manual contains important safety instructions and information regarding the repair and service of the lifter and accessories.

Warning! This symbol indicates important information related to safety. Follow these instructions carefully.

Read User Manual before use! It is important to fully understand the content of the user manual before attempting to use the equipment.

Visit www.molift.com for download of documen-tation to ensure you have the latest version.

Conditions of Performing Service/RepairLift and transfer of a person will always pose a certain risk and only certified personnel are allowed to repair and service the equipment and accessories covered by this technical manual.

Only certified personnel are allowed to open hoist or acces-sories to perform service or repair. Risk of injury from rotating parts and electric shock.

Activate emergency stop before opening side covers. Disconnect battery before any repair or service.

When disassembling and assem-bling the lifter, take care that no cables are squeezed or damaged, this might cause malfunction.

Any Service or Repair should be documented in the service log, and verified by using the Checklist after service and repair.

English Manual

2


General

Product IdentificationThe Product labels barcode contain product ID, serial number and production date.

Transport and Operating Conditions

Transport and StorageFor long time storage it is recommended that the emergency stop button is activated (pulled out). The lifter can be stored and transported under temperatures between -25 - 70 °C.

OperatingThe lifter is designed for use at standard room temperatures (+5 to +40°C).Air Pressure: 70 - 106 kPaRelative Humidity: 15 - 93 %Following storage or transport at other tempera-tures leave the lifter in a room with a suitable temperature until it reaches a safe operating temperature.

Medical electrical equipment requires special precautions regard-ing electromagnetic compatibility (EMC). Portable or mobile radio communication equipment may affect the medical electrical equip-ment, and should be kept minimum 25 cm (10 inches) from the lifters electronics.

Battery and Service indicator

The lifter has two indicator lights.

Wrench symbol / Service lightBattery symbol / Battery light

The electrical system has a power save functionwhich will turn off the electrical system after tenminutes without activity. All lights will turn off.The system is activated when pushing one of theoperating buttons

Battery LightThe battery indicator light will illuminate and make a sound when battery level is low and the lifter requires charging. When this occurs the lifter will have sufficient power available for one full lift cycle with SWL. When battery is critically low it is only possible to lower the lifting band.

Service LightThe electronics record the loads lifted and how much the lift has been used. After a certain period of operation a signal is given to indicate that service is required.

Service light ModeNo light Power saving (Stand by)Green Ready for useYellow Order serviceRed Perform serviceRed + sound Perform service

immediatelyFlashing yellow Overheating

Service Scope

Service scopeService involves replacing the lifting band and inspection/replacement of worn parts. This must be carried out by authorised personnel.

Service is needed when the service light is red (calculated 5.000 lifts in weightclass 2), or service is required after 5 years if the service counter not has displayed red yet.

Authorised service personnel can use the Molift Service Tool to take readings of the lift’s data and number og lifts.

3


How to open

Disconnect battery

Emergency Stop

Activate emergency stop before opening side covers.

Pull to activate emergency stop. The button will come out, and hoist will stop.

Remove sidecovers

Sidecovers are snap-on and can be released by pushing down the two buttons on top of the lifter and pulling the sidecover outwards.

Sidecovers are interchangeable.

Disconnect battery before any repair or service.

1. Activate emergency stop.2. Open side cover.

3. Locate battery cable on PCB, and disconnect.

4


Molift Service Tool

Authorised service personnel can use the Molift Service Tool software to take readings of the lifters data and to log servicing work. The owner of the lift is responsible for logging service work and repairs.

Connect Service Tool Cable

1. Remove hand control cover.

2. Unplug hand control and and insert service tool cable.

3. Refer to User Manual for Molift Service Tool for instructions on how to use the Molift Service Tool software.

Service Tool Software

Molift Service Tool software can be downloaded from http://molift.hwiig.no/download, contact Etac Supply Gjøvik for user account.

Article no. 1299011 Molift Service Tool 41299016 Molift Service Tool 4 (Lite Upgrade)1299015 Molift Service Tool 4 (Lite)1299002 Cable for Molift Service Tool (13 pin

DIN - USB)

5


Technical description

The motor for raising and lowering is of the 24 V DC (direct current) type fitted with a worm gear and 24V DC Brake.The trolley is directly connected to the gearhouse, and the gearhouse is loadbearing.

The lifter is programmed with a maximum current limit for lifting motor. It prevents the lifter from lifting more than SWL.

Sensors/Microswitches

• End/Angle: Activated if band angle to steep, or band completely in.

• Band Slack: Activated if band is not in contact with the guiding drum. This occurs if no weight is applied to lifting band, or band is completely out.

• Drum size: The switch is activated by a trigger arm when more than half of the lifting band is out, approx. 150 cm/60 inches. When the micro switch is activated it reduces the maxi-mum current limit. The current limit prevents the lifter from lifting more than SWL. More band on the drum gives higher torque and the motor will require more current to lift max load when drum is full of band, and less current when drum is empty.

Variant Matrix Lifter/Trolley

Standard Molift Rail:

Article no. Lifter Trolley2501205 Molift Air 205 2520000 Basic Trolley2501300 Molift Air 300 2520000 Basic Trolley2501210 Molift Air 205 Propulsion 2500103 Trolley Propulsion2501310 Molift Air 300 Propulsion 2500103 Trolley Propulsion2501215 Molift Air 205 IRC 2520002 Trolley IRC2501315 Molift Air 300 IRC 2520002 Trolley IRC2501220 Molift Air 205 IRC Propulsion 2520006 Trolley IRC Propulsion2501320 Molift Air 300 IRC Propulsion 2520006 Trolley IRC Propulsion

Trolley for other Rail Systems:2520001 Trolley Basic Type G+I2520004 Trolley Basic Type L+N2520005 Trolley Basic Type M

6


Measurements

Art.no Type / Size H2 W2 L21830003 2 point Small 120 - 3401830002 2 point Medium 120 - 4401830001 2 Point Large 120 - 5401830012 4 point Small 210 300 3401830011 4 point Medium 220 300 4401830010 4 point Large 240 360 5401530006 4 point X-Large 240 380 640All measurements in mm.

W1

A

F

CSP

BD

E

C

C

C

L1 H1

Dimensions:L x W x H (Length, Width, Height without trolley) 360 x 190 x 195 mm A (Hoisting Range) 300 mmB (Minimum distance from ceiling to CSP) 345 mmC (Basic Trolley wheel to connection point lifter)

see table underD (Hoist height from connection point to CSP) 249 mmE (Wheeltrack inside rail to under rail H62) 10 mmF (C+D+H2-E= Total height from rail to connection point for sling)

Art.no Type / Size C2520000 Basic Trolley 29,62500103 Trolley Propulsion 72,62520006 Trolley IRC Propulsion 72,62520002 Trolley IRC 29,6All measurements in mm.

7


Air Basic ExplodedDrawing 20-001Rev. K

Air Components

8


2500000 AIR BASIC

Pos Article no. Description1 2510001 Motor Assy2 2510000 Lower Cover3 2510002 Emegency Lowering Switch4 2520112 Main PCB Molift Air5 1101588 Rope6 1101587 Knob Red (Rope End)7 2510003 Emergency Stop Knob8 2510004 Upper Cover9 2510005 Side Cover10 2510023 Battery 26,4V NiMh11 2510006 Offlead Angle Sensor12 2510007 Micro Switch13 2510008 Bottom plate14 2510035 Label. Emergency Stop15 1100303 Label: Safety Check16 2510060 Label: Battery & Service17 1220308 Screw, Socket Head Cap18 0620134 Self-adhesive Cable-clip19 1220330 Screw, Reform20 0620133 Self-adhesive Cable-clip21 2510009 Cable no.4 Sensor22 2510010 Cable No.3 PCB-DIN-ED23 2510077 Quick Release for suspension24 2510025 Cable no. 2, Emergency Stop25 2510026 Cable no. 5, Emergency Stop26 2510027 Cable no. 6, Emergency Stop27 2510028 Battery Lock28 2510061 Cover Handcontrol29 2510041 Quick Release Unit30 2510084 Removed31 2510079 Emergency Lowering32 1310133 Screw, Ejot PT-screw, KB 4033 2510074 Cable no. 3, Emergency Stop34 1101562 Screw, Socket Head Cap35 2510099 PVC-pipe36 2510012 Carboard Box37 2510092 Inlay no. 3 Carboard Box38 2510093 Inlay no. 4 Carboard Box39 2510032 Inlay no. 1 Carboard Box40 2510137 6-kant nøkkel 90-grader41 2510136 6-kant nøkkel rett

42 2510205 Plate IP sealing43 2510206 Plate IP sealing small44 2510207 Cable no. 7, Emergency Stop

2501205 AIR 205

Article no. Description2500000 Air Basic2510080 Prod. Label 2 Molift Air 2052510044 Label Molift Air 2052017002 Hand Control 2 button w/charg

2501300 AIR 300

Article no. Description2500000 Air Basic2510078 Prod. Label 2 Molift Air 3002510011 Label Molift Air 3002017002 Hand Control 2 button w/charg

2501210 AIR PROPULSION 205

Article no. Description2500000 Air Basic2510072 Propulsion Cable2510080 Prod. Label 2 Molift Air 2052510044 Label Molift Air 2052019004 Hand Control 4 button w/charg1310144 Contact1310145 Contact Cover0420121 Cable0620133 Sel-adhessive Cable Clip

2501310 AIR PROPULSION 300

Article no. Description2500000 Air Basic2510072 Propulsion Cable2510078 Prod. Label 2 Molift Air 3002510011 Label Molift Air 3002019004 Hand Control 4 button w/charg1310144 Contact1310145 Contact Cover420121 Cable0620133 Self-adhessive cable Clip

9


Air IRC Basic ExplodedDrawing 20-012Rev. E

10


2500001 AIR IRC BASIC

Pos Article no. Description1 2510001 Motor Assy2 2510000 Lower Cover3 2510002 Emegency Lowering Switch4 2510112 Main PCB (High trac)5 1101588 Rope6 1101587 Knob Red (Rope End)7 2510003 Emergency Stop Knob8 2510004 Upper Cover9 2510005 Side Cover10 2510023 Battery 26,4V NiMh11 2510006 Offlead Angle Sensor12 2510007 Micro Switch13 2510008 Bottom plate14 2510035 Label. Emergency Stop15 1100303 Label: Safety Check16 2510060 Label: Battery & Service17 1220308 Screw, Socket Head Cap18 0620134 Self-adhesive Cable-clip19 1220330 Screw, Reform20 0620133 Self-adhesive Cable-clip21 2510009 Cable no.4 Sensor22 2510010 Cable No.3 PCB-DIN-ED23 2510077 Quick Release for suspension24 2510025 Cable no. 2, Emergency Stop25 2510026 Cable no. 5, Emergency Stop26 2510027 Cable no. 6, Emergency Stop27 2510028 Battery Lock28 2510061 Cover Handcontrol29 2510041 Quick Release Unit30 2510079 Emergency Lowering31 1310133 Screw, Ejot PT-screw, KB 4032 2510074 Cable no. 3, Emergency Stop33 1101562 Screw, Socket Head Cap34 2510099 PVC-pipe35 2510012 Carboard Box36 2510092 Inlay no. 3 Carboard Box37 2510093 Inlay no. 4 Carboard Box38 2510032 Inlay no. 1 Carboard Box39 2510137 6-kant nøkkel 90-grader40 2510136 6-kant nøkkel rett41 2510147 AIR IRC-Unit42 2010205 Cable no. 7, Emergency Stop

43 2010206 Plate IP sealing44 2010207 Plate IP sealing small

2501215 AIR IRC 205

Article no. Description2500001 Air Basic IRC 2510080 Prod. Label 2 Molift Air 2052510044 Label Molift Air 2050440002 Hand Control 2 buttons

2501315 AIR IRC 300

Article no. Description2500001 Air Basic IRC2510078 Prod. Label 2 Molift Air 3002510011 Label Molift Air 3000440002 Hand Control 2 button

2501220 AIR IRC PROPULSION 205

Article no. Description2500001 Air Basic IRC2510072 Propulsion Cable2510080 Prod. Label 2 Molift Air 2052510044 Label Molift Air 2052018004 Hand Controll 4 button1310144 Contact1310145 Contact Cover0420121 Cable0620133 Self-adhessive Cable Clip

2501320 AIR IRC PROPULSION 300

Article no. Description2500001 Air Basic IRC2510072 Propulsion Cable2510078 Prod. Label 2 Molift Air 3002510011 Label Molift Air 3002018004 Hand Control 4 button1310144 Contact1310145 Contact Cover0420121 Cable0620133 Sef-adhessive Cable Clip

11


Air Motor ExplodedDrawing 20-011Rev. D

2510001 Motor Assy Molift Air

Pos Article no. Description1 Gear Box2 0920072 Molex Plug3 0920078 Molex Crimp Socket4 Connector5 Contact Cover6 1220116 Microswitch7 Screw, Slottet Cheese Head8 Spring Perch9 1410134 Screw, Socket Head cap

10 1220194 Extension Spring11 1220155 Axle for Guiding Drum12 1220158 Guiding Drum13 1220313 Circlip14 Axle15 1410134 Screw, Socket Head Cap16 Trigger Arm17 Screw, Socket Head Cap18 Hexagon sleeve19 1431011 Set Screw20 Constrictor

12


Spare part list

Recommended spare parts to keep in stock for Service personnel.

Article no.1240100 Charger Nomad/AIR2510023 Battery 26,4 V NiMH Molift Air2510063 Lifting Belt Molift Air2017002 Hand Control 2 buttons with charg-

ing probes2510005 Side Cover2510004 Upper Cover2510008 Bottom plate2510007 Micro Switch2510008 Bottom plate2510006 Offlead Angle Sensor2520112 Main PCB Molift Air1810010 Quick Release Pin Suspension2510028 Battery Lock2510061 Cover Handcontrol1130120 Cap Ø321101588 4mm red Polyester/cotton cord1101587 Knob Red (Cord End)2510003 Emergency Stop Knob2510002 Emegency Lowering Switch2510099 Tube 6/8mm red Length 40 cm2510145 Brake 24V DC2510137 6-kant nøkkel 90-grader2510136 6-kant nøkkel rett2510001 Motor Assy Molift Air2510041 Quick release unit2510077 Quick release for alu suspension2510035 Label emergency stop/lowering2510060 Label Service/battery2510079 Label emergency lowering1220194 Extension Spring1220116 Microswitch2510146 Hexagon sleeve1431011 Set Screw

13


Labels

Labels

Pos Article no. Description1 2510035 Emergency stop/lowering2 2510060 Service/battery3 2510079 Manual Emergency lowering4 1100303 Safety Check (Periodic control)5 1100306 Month/year (Periodic control)6 2510044 Cover label 205

6 2510011 Cover label 3007 2510080 Main label 2057 2510078 Main label 3008 N/A Serial number label

NB!! Contact Etac Supply Gjøvik for barcode label with article and serial number when replacing main label.

CONTROL

12 Month

25 1 3 8

7

6

6

4 5

83

7

1

2

6

4

14


Battery

Molift Air has a 26.4 V NiMH battery pack. The battery has a life expectancy of approx. 500 charge cycles.

x2

Batteries must be fully charged and depleted completely a couple of times before it achieves full capac-ity. Also follow this procedure if the lifter has not been in use for a long period (3-4 weeks)

Charging batteriesThe lifter is charged through the Hand control or In-rail charging. Charge time 0-100% 3-8 hours.

Charger LightDescription of charger light on battery charger unit:

Charger light ModeYellow Ready for use, no bat-

tery connectedYellow InitializationRed Fast ChargeGreen/Yellow Top-off chargeGreen Trickle chargeRed/Green Error

Change battery

1. Activate emergency stop2. Open both sidecovers3. Disconnect battery power cable and temp

sensor from PCB

4. Use 5mm Hex key and remove screw from battery holder.

5. Push the battery out from the back side.6. Release cables from cableclips and remove

battery.7. Install new battery in reverse order.

Used batteries must be disposed of as special waste according to local rules and regulations. Do not dispose in general waste

Check after installation

Deactivate emergency stop (push button back in). The lifter makes a sound and service light is on.

Perform and fill out Safety checklist after service and repair

Battery Parts

Article no.

2510023 Battery 26.4 V NiMH2510028 Battery Lock

Battery

15


Covers

The lifter has 6 covers. 2 identical side covers, Hand control cover, Bottom plate, Upper cover and lower cover.

Remove Side covers

Sidecovers are snap-on and can be released by pushing down the two buttons on top of the lifter and pulling the sidecover outwards.

Remove Hand control cover

Unscrew both screws (Torx 20) and remove cover.

Remove Upper cover

Remove both sidecovers, disconnect battery

Push in Quick release button for trolley, and remove the M2,5 setscrew. (1,3mm hex key)Setscrew is glued with Loctite 243, and must be glued when remounted.

Disassemble the Quick release button, unscrew the parts by hand.

Remove the 4 screws (Torx 20) in each corner and lift of the cover.

16


Remove Bottom Plate

The bottom cover are locked with snap hooks. Open sidecover to access the snap hooks, and push them out from inside.

Change Lower cover

1. Remove Sidecovers, disconnect battery2. Release all cables from cable clips.3. Remove battery clamp (hex key 5mm) and

battery.4. Remove hand control cover and hand control.5. Remove suspension coupling.6. Remove bottom plate.7. Remove Remove Emergency stop relay and

button.8. Remove Angle sensor plastic part, and micro

switch.9. Remove the 2 screws from PCB (Torx 20)

10. Remove the 4 Screws (hex key 4mm) from motor/gear house holding the lower cover, 2 screws on each side.

11. Remove the 4 screws (Torx 20) in each corner of the lower cover

12. Cut the wire for angle sensor micro switch.

13. Cut the wire for LED lights and remove cover.14. Pull wires for Led lights and microswitch

through the new cover, and solder wires. Use heat shrink tube to isolatee on all wires.

15. Glue led indicators to lower cover and insert angle sensor microswitch in slot.

16. Remount all parts as described (pt. 1-11) in reverse order.


Make sure all covers are attached properly and there are no loose parts.

Run the lifter, and pull band sideways to activate angle sensor. The lifter should stop lifting when angle sensor activates.


Cover Parts

Article no.2510005 Side Cover Tegn. (20-104)2510004 Upper Cover Tegn. (20-101)2510000 Lower cover Tegn (20-102)2510008 Bottom plate Tegn. (20-103)2510061 Hand control cover (20-136)

Led lights2510007 Microbryter Series 1050 Wlfa

35-830-55

17


Hand control

Hand control

The Hand control has 2 buttons for lifting and lowering, or 4 buttons if the hoist is equipped with propulsion. The Hand control has an indica-tor light that will illuminate when battery level is low and the lifter requires charging

The Hand control has four charging probes on the back for charing through wall mounted charger, or no probes if lifter has In Rail Charging (IRC).

Hand Control Clip

Hand control clip is snap on and can be replaced by lifting snap hook (use a plastic pry tool) and push clip downwards.

Hand control with four charging probes.

Remove Hand control

1. Unscrew both screws (Torx 20) and remove cover

2. Unplug hand control

Install Hand control

1. Connect hand control

2. Attach cover and tighten both screws properly (Torx 20)


All buttons and functions are working The cover shall function as a cabel clamp.

Pull the hand control cable slightly to makes sure the cover is properly fastened.


Hand Control Parts

Article no.2510061 Cover Handcontrol2017002 Hand Control 2 buttons w/charging2019004 Hand Control 4 buttons w/charging0440002 Hand Control 2 buttons

Hand Control 4 buttons0440004 Replaceable hook for Molift hand

controls

18


Angle Sensor / End sensor

The hoist has a directional safety feature that prevents lifting if angle on lifting band is to steep.

>30˚

If the hoist doesn’t respond to Hand control “up” button, it might be because lifting band angle is to steep, or lifting band is twisted and sensor is activated.

This sensor also detects the end of the band, and stops the lifter when the band is driven all the way in.

Change angle sensor plastic part

1. Open sidecover and disconnect battery2. Remove bottom (see “Bottom Plate” page 16)3. Remove suspension coupling (see “Suspension

coupling page 19)

4. Change angle sensor plastic part, make sure to install it the correct way (chamfered edges in center facing up).

Change angle sensor microswitch

1. Open sidecover and disconnect battery2. Remove bottom cover (see “Remove bottom

plate” page 16)

3. Use a plyer to pull the broken microswitch out, or push it out from the inside of the lifter.

4. Cut the wires, and pull the wires out through the hole.

5. Solder the wires to the microswitch on the outside and use heat shrink tube to isolatee.

6. Push the microswitch into the hole to lock it in place.

7. Mount bottom plate.


Run the lifter, and pull band sideways to activate angle sensor. The lifter should stop lifting when angle sensor activates.

Drive the band completely in. The sensor should aktivate and lifter stop running when the band is driven all the way in.


Angle sensor Parts

Article no. 2510006 Angle sensor plastic part2510007 Microbryter Series 1050 Wlfa

35-830-55

19


Suspension coupling

Change suspension coupling

1. Pull of the plastic cap2. Push the bolt out3. Pull the band out4. Remount in reverse order

Checklist after installation

Make sure cap is properly fastened and doesn’t slide of.

Make sure the sviwel rotates freely


Suspension Coupling Parts

Article no. 1810010 Quick Release Pin Suspension1130120 Cap Ø322510077 Quick release coupling

20


Emergency Stop/Lowering

Remove Emergency stop relay and button

1. Activate emergency stop2. Remove both side covers and disconnect

battery3. Remove battery clamp (hex key 5mm) and

battery.

4. To access the relay with standard tool it is nec-essary to remove screws holding gear/motor to lower cover, and remove microswitch.

5. Remove nut and washers from emergency stop relay with 14mm wrench.

6. Disconnect wires and remove the relay and the button.

Emergency Stop/Lowering Parts

Article no. 1101588 4 mm red Polyester/cotton cord1101587 Knob red (Cord End)2510003 Emergency Stop Knob2510002 Emergency Lowering Switch2510099 Tube 6/8 mm red Length 40 cm


Activate emergency stop by pulling cord. Make sure it is not possible to run lifter with emergency stop activated.

Pull and hold cord. Electric emergency lowering should start.


21


Replacing Lifting Band

Remove lifting band

1. Run the lifter until the lifting band is run out completely. Pull the band while pushing down button (the band must be tensioned or band slack sensor activates)

2. Open sidecover3. Remove lid from gear house by removing 4

screws (PH2) to access the drum.

4. Run lifter and position bolt at approx 15° to the right. (5 o’clock)

5. Activate emergency stop6. Disconnect battery

7. Remove bolt with Large flat screwdriver.

8. Pull out the lifting band

Install new Lifting Band

1. Insert new lifting band. Make sure band is inserted on th correct side of the guiding drum.

2. Align lifting band with hole, and insert bolt. Tighten the bolt properly.

3. Mount the lid (4 PH2 screws with washer).4. Reconnect battery and mount the side cover.5. Push UP button on handcontrol to drive band

in on the drum.


Run the lifting band in and out completely, make sure band goes up when pushing up button.

Test lifter with one lifting cycle with SWL.


Lifting Band Parts

Article no. 2510063 Lifting Band Molift Air

22


Brake

Change brake

1. Open both sidecovers2. Disconnect battery3. Remove batteryclamp (hex key 5mm) and take

out battery4. Remove both hex keys5. Loosen setscrew (hex key 2,5mm) to remove

sleeve from brake

6. Remove both screws holding the brake (hex key 3mm)

7. Disconnect the wire from PCB8. Remove and change the brake. Remount in

reverse order.


Test the electric emergency lowering Test lifter with one lifting cycle with SWL,

the brake should not slip


Lifting Band Parts

Article no. 2510145 Brake 24V DC

23


Lifting Motor/Gear House

Remove lifting motor/gearhouse.

1. Activate emergency stop2. Remove both side covers3. Disconnect Battery power cable and tempera-

ture sensor, remove battery clamp.4. Disconnect Power cable to motor from PCB.5. Remove both Quick release buttons for trolley.

6. Remove the 4 screws (Torx 20) in each corner of the upper cover

7. Remove both microswitches (2x PZ1 screws on both microswitches).

8. Remove the 4 Pan Head Screws (Hex key 4mm) from motor/gear house holding the lower cover, 2 screws on each side motor gear unit.

9. Dismantle suspension coupling and lifting motor can be removed.

10. Install new motor/gear in reverse order.

Change Brake

1. Activate emergency stop2. Remove both side covers3. Disconnect battery4. Remove set screw on Hexagon sleeve and pull

it off.5. Unscrew bolts holding brake and replace the

brake.6. Assemble in reverse order.

Parts

Article no. 2510001 Motor/Gear Molift Air1220194 Extension Spring 0,5x8x252510145 Brake 24V DC2510137 Allen Key Hex Socket 6mm2510136 Allen Key Hex Straight 6mm x 1002510146 Hexagon sleeve1431011 Set screw DIN 914 M4x6 Elzn


All buttons and functions are working Run the lifter, and pull band sideways to

activate angle sensor. The lifter should stop lifting when angle sensor activates.


24


Microswitches

Left- Micro switch Band Slack sensor If band is not tight this switch disables band in/up function. This also works as endstop when lifting band is completely out.

Right- Micro switch drum sensor This sensor register the amount of band on drum (on=”small drum” off=”large drum”).

Change Microswitch

Same procedure for both microswitches:1. Activate emergency stop2. Open sidecover3. Disconnect battery power cable4. Cut both wires close to microswitch.5. Remove both screws and replace the

microswitch.

6. Remember to use the gasket when mounting the new microswitch.

7. Solder the wires to the microswitch and use heat shrink on both wires tube to isolatee.


Microswitch for band slack: It should not be possible to drive lifting band out if the button is NOT activated/pushed in. Test up/down with no load, it should not be possible.

Drive the band completely out, the lifter should stop when band is completely out.

Microswitch for drum sensor: Use Molift Service tool, and the the function “Live Data”. Look the sensor with value “large drum” or “small drum”. Push microswitch button to see if data changes.


Microswitches

Article no.1220116 Microswitch 35-724-35 Elfa

25


PCB (Printed Circut board)

The lifter has a PCB (Printed Circut board).

1. Battery cable2. Motor Cable3. Temperature battery4. Brake5. Emergency lowering6. DIN 13 contact (Hand control)7. LED/DIN8. Sensors9. 20 Amp fuse10. TES (to Emergency stop)11. EDT (Emergency detect)12. FES (From Emergency stop)13. Propulsion motor

Refer to electric diagram for more details.

Remove PCB

1. Open sidecover, disconnect battery

2. Remove hand control cover and disconnect hand control

3. Disconnect all wires attached to the PCB

4. Remove both screws (T20) at bottom of PCB.5. Flip the PCB out

Install new PCB

1. Molift Service Tool must be used to copy set-tings from old Card to the new card.

2. Use molift Service tool and install factory set-tings to PCB. Refer to User Manual for Molift Service Tool.

3. Disconnect all cables. Remove old PCB, and mount new PCB in lifter.


All buttons and functions are working


PCB Parts

Article no. 2520112 PCB

49 10

11

12

13

1

3

5

2

7

8

6

26


Electric Diagram

Mot

or 1

Mot

or 2

1

2

3

1 "N

orm

al d

rift"

posit

ion

2 "E

mer

genc

y st

op" p

ositi

on3"

Emer

genc

y lo

wer

ing"

pos

ition

12

6 5 478

9134

+ -

T2 T1Ba

ttery

Brake

3 bu

tton

emer

genc

y sw

itch

P1Battery

Emg low

Motor 1Brake

1 2

+ - Gnd

Din

cont

act

Temp2

Dru

msiz

eEn

d/a

ngle

Slac

kSe

nsor

s

11

12

23

23

3

NC

NO

NC

C

C

C

4568

4

56 8

8

Serv

ice

led

Batte

ry le

d

2 17810

85

P10

P3

P2

P8

P4P5

P1P6

P9

71415 13

Charging +

Temp BTemp A

Cha

rgin

g - (

7)

5

FES ED

T (E

MG

det

ect)

TE

S

(to

EMG

stop

)

52 33

74

69

++

+

8

(Fro

m E

MG

stop

)

D9 3

Motor 2

Rese

tt ch

arge

r (3)

Charging+ color white

Charging - color black

Resett charg color white

Temp A color blackTemp B color black

IRC

cha

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27


Trolley

Change wheels

Wheels are held in place by a circlip. Remove with cirlcip plyer to change wheels.Axle is locked in place (centered) with Loctite 2701.

Wheels

Article no. 1109514 Wheel1120706 Circlip DIN 471 ø10x11120705 Roller Bearing1109515 Axle


Make sure wheels are rolling freely and circlip is properly fastened.

28


IRC (In rail charging)

Propulsion

If the lifter is equipped with IRC (In rail charging) it has a trolley with a cable connected to a contact in the upper cover. The charger unit is mounted inside the lifter, and the hand control has no charging probes. The rail system must also be equipped with in rail charging.

In-Rail Charging Parts

Article no. 2510147 AIR IRC-Unit2520002 Trolley IRC0440002 Hand Control 2 buttons

Hand Control 4 buttonsContact

If the lifter is equipped with propulsion, it has trol-ley with a motor connected to the lifter through a contact in the upper cover. The hand control has 4 buttons.

Propulsion Parts

Article no. 1101241 Green label1101242 Yellow label2500103 Trolley Propulsion Air2520006 Trolley IRC Propulsion Air

Handcontrol 4 buttons2019004 Hand Control 4 buttons w/charging2510072 Propulsion Cable

1310144 Contact1310145 Contact Cover0420121 Cable0620133 Sel-adhessive Cable Clip

2520002 Trolley IRC

2520006 Trolley IRC Propulsion Air

29


Periodic inspection of the hoist should be undertaken at least once a year to ensure that the device operate properly and safely.

Service is needed when the service light is red or service is required after 5 years if the service counter not has displayed red yet.

Periodic inspection Checklist

When performing a periodic inspection, the inspector shall fill out the inspection report for Molift Air. The reports should be retained by the person(s) responsible for servicing the hoist. If the inspection reveals defects and damages, the owner shall be notified and a Non-conformity report should be sent to Etac.

In the event of damage that jeop-ardizes the safety of the patient, the hoist shall immediately be taken out of service and marked clearly with “out of order” and shall not be used until the hoist is repaired

When periodic inspection is completed the inspector shall mark the hoist with a sticker on the control label showing the date when periodic inspection is performed. The control label can be found on the inside of the Side cover, and this will then indicate when next service should be performed.

CONTROL

12 Month

Mark label with month and year of inspection

Any Service or Repair should be documented in the service log, and verified by using the Checklist after service and repair.

Checklist after Service and Repair

Use the checklist to verify that the hoist is properly installed and can operate correctly and safely be-fore use. Document the job by signing the Service Log.

Service Log

The service manual has a table for logging of repair and work done on the lifter. Write down a short description of the incident in the appropriate interval. This will enable the owner and service partner to see previous history for the lifter and in that way maybe making future fault finding and repairs easier.

Documenting the Service

30

Molift Air / www.molift.com Molift Air / www.molift.com

Periodic Inspection Checklist Molift AirIn accordance with ISO:10535 2006 Annex B.

Article no.:...........................................................................................Serial no.:...........................................................................................Production Year:...........................................................................................Owner:...........................................................................................Sling serial number:...........................................................................................

Sling Inspected separately and is not included in this inspection.

Situation of use: Home Institution (type of institution):

Hospital Nursing home Other

Service light indicator

Service not required when service light indicator displays green and if hoist is under 5 years old

Service light displays green Hoist is less then 5 years old

Physical examination

Test FUNCTION and check for wear. All checkpoints must be checked of to approve lifter for further use.

Perform 1 lifting cycle with SWL. Brake shall not slip when loaded with SWL Emergency stop Electrical Emergency lowering Handcontrol (buttons, strain relief, hook,

battery indicator) Suspension coupling (change of suspension,

QR pin, rotation and swivel funktion) Both Quick release couplings (connect to

trolley) Angle sensor (pull band sideways) Charger/Battery Accessories (t.ex: Scale, Propulsion, IRC):

...........................................................................................

...........................................................................................

Visual examination

Visual examination of load bear-ing structure to make sure there is no damage, cracks, frays or deformation. All checkpoints must be checked of to approve lifter for further use.

Product labels Plastic covers Hand control Gearhouse (pay special attention to lifting

ears, remove upper cover) Cables and other electronics. Lifting band Suspension coupling Suspension (especially composite hooks)

Performed by

Periodic inspection should be performed by a person who is certified by Etac education.

Date/Place:...........................................................................................Signature:...........................................................................................Etac Molift Service ID (6 digits):...........................................................................................

Approved without faults Approved after repair. Lifter is marked with “out of order” and

sent for repair. Hoist is not eligible for repair and taken out

of service.

If periodic inspection reveals any defect, wear or other damage that jeopardizes the safety of the patient it may not be used until the deficiency has been eliminated. Defects and damages should be reported back to the manufacturer for action in a non-conformity report (NCR).

The owner is notified NCR report sent to Etac, [email protected]

Non conformity report can be obtained from www.molift.com or by request, [email protected].

PI16101 Rev A 2013-10-22

31


Safety checklist after Service and Repair

Article no.:...........................................................................................Serial no.:...........................................................................................Production Year:...........................................................................................Owner:...........................................................................................Number of lifts to next service:...........................................................................................

Physical examination

Test FUNCTION and check for wear. All checkpoints must be checked of to approve lifter for further use.

Perform 6 lifts with SWL at 6 random points in rail system

Brake shall not slip when loaded with SWL Emergency stop Electrical Emergency lowering Handcontrol (buttons, strain relief, hook,

battery indicator) Suspension coupling (change of suspension,

QR pin, rotation and swivel funktion) Both Quick release couplings (connect to

trolley) Angle sensor (pull band sideways) Charger/Battery Accessories (t.ex: Scale, Propulsion, IRC):

...........................................................................................

...........................................................................................

The hoist is marked with Safe Working Load (SWL), this shall not exceed rail systems SWL capacity.

SWL on hoist does not exceed rail systems SWL capacity

Visual examination

Visual examination of load bear-ing structure to make sure there is no damage, cracks, frays or deformation. All checkpoints must be checked of to approve lifter for further use.

Product labels Plastic covers Hand control Gearhouse (pay special attention to lifting

ears, remove upper cover) Cables and other electronics. Lifting band Suspension coupling Suspension (especially composite hooks)

Performed by

Periodic inspection should be performed by a person who is certified by Etac education.

Date/Place:...........................................................................................Signature:...........................................................................................Etac Molift Service ID (6 digits):...........................................................................................

32


Service Log

Periodic inspection and Service/Repair logbook.

Defects and damage of importance to the safety of the hoist which have occurred between inspections and have already lead to corrective actions should be entered in the logbook. A record of the date of inspection of the hoist and inspection result should be noted in the logbook together with the signature of the inspector.

Date Description of fault Type of repair Date/Signature or ID no.

33


Installation

Assembly and installationThe hoist is marked with Safe Working Load (SWL), this should not exceed rail systems SWL capacity.

The rail system can only be installed by certified personnel inn accordance with applicable installa-tion instructions.

Do not start using hoist before completing control according to checklist after installation.

Trolley installation

Mounting trolley in rail system

Remove End stop and insert Trolley into rail. Mount end stop, and make sure it is securely fastened

Make sure end stops are mounted in all ends of the Rail system before using the hoist!

Lifter installation

Mounting of Lifter on trolley. No tools required. The lifter has two connection points.

Connect one point first. Push button all the way in, and place lifter in connection point on trolley. Release button and make sure it is clearly show-ing green before connecting the next point.

Make sure both connection point buttons completely return and clearly show green after installation.

Checklist after installation

Use this checklist to verify that the hoist is properly installed and can operate correctly and safely before use.

End stops on rail are installed after mounting of trolley

Make sure that the hoist is properly fastened to the rail and that the lift does not have any loose parts.

Perform one lift with normal load (60-80 kg) Make sure battery is fully charged.

34


Notes

Etac ASEtac Supply GjøvikHadelandsveien 2, 2816 Gjøvik, NorwayTel +47 4000 [email protected] www.molift.com

Find your distributorvisit www.molift.com

Documents

Molift Air