WOOD'S POWR-GRIP P11004DC User manual

KEEP FOR FUTURE REFERENCE
INSTRUCTIONS
International Version
MODEL NUMBERS: P11004DC,
P1HV1104DC, P11104DC
SERIAL NUMBER: ___________
(please see serial label and record number here)
SINGLE-CHANNEL LIFTER
DC-VOLTAGE
READ ALL INSTRUCTIONS AND WARNINGS
BEFORE OPERATING THIS LIFTER
DESIGNED FOR THE MATERIALS HANDLING PROFESSIONAL
P.O. Box 368 –908 West Main
Laurel, MT USA 59044
phone [phone]
phone [phone]
fax [phone]

Rev 26.0/6-13 1 P1-DC: #35111
TABLE OF CONTENTS
SPECIFICATIONS............................................................................................................ 3
WARNINGS ..................................................................................................................... 4
OPERATING FEATURES................................................................................................... 5
ASSEMBLY....................................................................................................................... 6
INTENDED USE ............................................................................................................... 7
LOAD CHARACTERISTICS ............................................................................................................. 7
OPERATING ENVIRONMENT .........................................................................................................8
DISPOSAL OF THE LIFTER ............................................................................................................ 8
OPERATION .................................................................................................................... 9
BEFORE USING THE LIFTER.......................................................................................................... 9
Taking Safety Precautions ............................................................................................................................9
Performing Inspections and Tests .................................................................................................................9
TO APPLY THE PADS TO A LOAD..................................................................................................10
Positioning the Lifter on the Load ...............................................................................................................10
Sealing the Pads against the Load...............................................................................................................10
Reading the Vacuum Gauge .......................................................................................................................11
Vacuum Level on Optimal Surfaces .............................................................................................................11
Vacuum Level on Other Surfaces ................................................................................................................11
TO LIFT AND MOVE THE LOAD ....................................................................................................12
Positioning the Lift Bar ...............................................................................................................................12
Load Capacity and the Warning Light ..........................................................................................................12
Monitoring Vacuum Indicators ....................................................................................................................12
Monitoring the Low Vacuum Warning Buzzer (if applicable) ..........................................................................13
Controlling the Lifter and Load....................................................................................................................13
In Case of Power Failure ............................................................................................................................13
TO ROTATE THE LOAD EDGEWISE................................................................................................ 14
TO RELEASE THE PADS FROM THE LOAD .......................................................................................15
AFTER USING THE LIFTER..........................................................................................................16
Storing the Lifter........................................................................................................................................16

Rev 26.0/6-13 2 P1-DC: #35111
MAINTENANCE ............................................................................................................. 17
INSPECTION SCHEDULE.............................................................................................................17
Every-Lift Inspection ..................................................................................................................................17
Frequent Inspection ...................................................................................................................................17
Periodic Inspection.....................................................................................................................................17
Infrequent Use...........................................................................................................................................18
TESTING SCHEDULE..................................................................................................................18
Operational Tests.......................................................................................................................................18
Load Test ..................................................................................................................................................18
MAINTENANCE SCHEDULE..........................................................................................................19
BATTERY TEST .........................................................................................................................19
BATTERY RECHARGE .................................................................................................................19
BATTERY CHARGER TEST ...........................................................................................................20
VACUUM PAD MAINTENANCE......................................................................................................20
Friction Coefficient .....................................................................................................................................20
Inspection .................................................................................................................................................20
Cleaning ....................................................................................................................................................21
VACUUM TEST .........................................................................................................................22
AIR FILTER MAINTENANCE −SMALL ...........................................................................................23
Filter Function and Conditions Requiring Service ..........................................................................................23
Filter Service Procedures ............................................................................................................................23
VACUUM PUMP MAINTENANCE −DYNAFLO DV1032102 ...............................................................24
Replacing the Diaphragm ...........................................................................................................................24
Replacing the Gasket/Flap Valves................................................................................................................24
Replacing the Head Assembly .....................................................................................................................24
VACUUM PUMP MAINTENANCE −THOMAS 107CDC20 ..................................................................25
Replacing the Diaphragm ...........................................................................................................................25
Replacing the Intake Valve Flapper .............................................................................................................25
Replacing the Exhaust Valve Flapper and Head Gasket .................................................................................25
VACUUM SWITCH ADJUSTMENT ..................................................................................................26
Vacuum Switch Function ............................................................................................................................26
Conditions Requiring Readjustment .............................................................................................................26
Adjustment Procedure ................................................................................................................................27
REPLACEMENT PARTS LIST .......................................................................................... 28
LIMITED WARRANTY.................................................................................................... 29

Rev 26.0/6-13 3 P1-DC: #35111
SPECIFICATIONS
Description:
Designed for use with a crane or other hoisting equipment, P1-04DC lifters employ vacuum to
hold a load for lifting, and they provide manual 180° rotation and manual 90° tilt movements
for load manipulation.
Model Number:
P11004DC
P1HV1104DC
P11104DC
Vacuum Pads:1
(Four, standard rubber, with #60 filter screen)
10" [25 cm] nom. diameter,
concave (Model G0750)
10" [25 cm] nom. diameter,
lipped (Model HV11)
11" [28 cm] nom. diameter,
lipped (Model G3370)
Maximum Pad Spread:
49" x 10"
50" x 11"
51" x 12"
(to outer edges)
[1245 mm x 254 mm]
[1270 mm x 280 mm]
[1295 mm x 305 mm]
Load Capacity:
(rated at 16" Hg [-54 kPa] on clean, smooth, nonporous flat surfaces2)
Per-Pad:
150 lbs [68 kg]
150 lbs [68 kg]
175 lbs [80 kg]
Maximum:
600 lbs [270 kg]
600 lbs [270 kg]
700 lbs [320 kg]
Lifter Weight:
65 lbs [30 kg]
74 lbs [34 kg]
70 lbs [32 kg]
Power Source:
12 volts DC, 10 amps (with Thomas pump) or 3 amps (with Dynaflo pump)
Battery Capacity:
7 amp-hours
Rotation Capability:
Manual, 180°, with automatic locking at each ¼ revolution (when desired)
Tilt Capability:
Manual, 90°, with automatic locking in vertical position
Vacuum Pump:
Diaphragm type, 1 SCFM [28 liters/minute] nominal airflow
Vacuum Reserve Tank:
Vacuum reservoir helps prevent immediate vacuum loss in case of power failure and extends
battery life by reducing pump cycles required to maintain vacuum.
Vacuum Gauge:
Dial gauge indicates current vacuum level in positive inches of Hg and negative kPa.
Low Vacuum Warning
Light:
Red light is energized until vacuum level is sufficient to lift maximum load weight (higher than
16" Hg [-54 kPa]) and whenever vacuum loss causes pump to re-engage.
Low Vacuum Warning
Buzzer (if applicable):
Maximum Alarm Volume = 103 dBA at 2 ft [60 cm]. While lifter is powered up, audible alarm
warns the operator whenever vacuum is not sufficient for lifting the maximum load weight.
Options:
See separate instructions about optional features.
Operating Elevation:
Maximum = 6000 feet [1828 meters]
Operating Temperatures:
32° to 104° F [0° to 40° C]
Service Life:
This lifter is designed to have a service life of at least 20,000 lifting cycles, when used and
maintained as intended. Vacuum pads, filter elements and other wear-out items are
excluded; see MAINTENANCE and REPLACEMENT PARTS LIST for more information. For the
DISPOSAL OF THE LIFTER after its service life, see INTENDED USE.
ASME Standard BTH-1:
Design Category "B", Service Class "0" (see www.powrgrip.com for more information)
!!-CE-!! Note: This symbol appears in the INSTRUCTIONS manual only when requirements of a CE Standard are different
from requirements of other standards that also apply to this vacuum lifter. CE requirements are mandatory in geographical
areas where CE Standards apply, but may be optional in other locations.
1Available with optional closed-cell foam rings for rough or textured surfaces (Model P1HV11F04DCO), as well as low-marking
rubber for materials susceptible to marking (see REPLACEMENTS PARTS LIST).
2Load Capacity is based on a friction coefficient of 1; see MAINTENANCE: VACUUM PAD MAINTENANCE: Friction Coefficient for
additional information.

Rev 26.0/6-13 4 P1-DC: #35111
WARNINGS
Powr-Grip is pleased to offer the most reliable vacuum lifters available.
Despite the high degree of security provided by this product, certain
precautions must be observed to protect the operator and others.
Always wear personal protective equipment that is appropriate for the material being handled.
Follow trade association guidelines.
Always operate the lifter under conditions approved for its design (see INTENDED USE:
OPERATING ENVIRONMENT).
Never operate a lifter that is damaged, malfunctioning, or missing parts.
Never operate a lifter if the sealing edge of any vacuum pad is cut or otherwise damaged.
Never remove or obscure warning labels.
Never operate a lifter if the Load Capacity or any warning appears to be missing or obscured.
Always make certain the contact surfaces of the load and all vacuum pads are clean prior to
applying the pads (see MAINTENANCE: VACUUM PAD MAINTENANCE).
Never exceed the Load Capacity or attempt to lift loads the lifter is not designed for (see
INTENDED USE: LOAD CHARACTERISTICS).
Never attempt to lift cracked or broken glass with this lifter.
Always position the vacuum pads correctly on the load prior to lifting (see OPERATION: TO APPLY
THE PADS TO A LOAD).
Never lift a load when any vacuum indicator shows inadequate vacuum.
Never touch the vacuum release controls during a lift. This may result in loss of vacuum and
release of the load.
Never allow people to ride on the lifter or the load being lifted.
Never lift a load higher than necessary or leave suspended loads unattended.
Never lift a load over people.
Always keep other personnel far enough away from the lifter to avoid injury in the event of an
unexpected load release.
Always place the power control in the inactive position and, when possible, disconnect the
power source before opening any enclosure on the lifter. (Only applicable to powered lifters)
Always remember that modifications to the lifter may compromise its safety. Wood’s Powr-Grip
cannot be responsible for the safety of a lifter that has been modified by the customer. For
consultation, contact Wood's Powr-Grip (see LIMITED WARRANTY).
Never disengage both the rotation latch and the tilt latch at the same time.

Rev 26.0/6-13 5 P1-DC: #35111
OPERATING FEATURES
Note: Components featured in the following instructions for assembling, operating or
maintaining the vacuum lifter are underlined on their first appearance in each section.
Standard P11104DC shown.
7 Enclosure with VACUUM PUMP,
1 LIFT BAIL
VACUUM SWITCH, and LOW VACUUM
13 VALVE HANDLE
2 LIFT BAR
WARNING BUZZER (if applicable)
14 BATTERY GAUGE
3 INSTRUCTIONS CANISTER
8 BATTERY TEST BUTTON
15 ROTATION RELEASE
LEVER
4 VACUUM RESERVE TANK
9 LOW VACUUM WARNING LIGHT
16 BATTERY CHARGER
5 PAD CHANNEL
10 VACUUM GAUGE
17 TILT RELEASE LEVER
6 BATTERY
11 CONTROL HANDLES
18 VACUUM PAD
12 AIR FILTER

Rev 26.0/6-13 6 P1-DC: #35111
ASSEMBLY
1) Open the shipping container and remove all materials for restraining or protecting the vacuum
lifter. Save the container for use whenever the lifter is transported.
2) Suspend the lifter from a crane as follows: Select hoisting equipment (crane and hoist, when
applicable) rated to carry the maximum load weight plus the lifter weight (see
SPECIFICATIONS: Maximum Load Capacity and Lifter Weight).
Note: Any application of the lifter must conform to all statutory or regulatory standards that
relate to the hoisting equipment when used in its geographical location (eg, relevant OSHA
standards in the USA).
Disengage the tilt latch (see OPERATION: TO TILT THE LOAD) and raise the lift bar to a vertical
orientation. Then attach the hoisting equipment hook to the lift bail.
WARNING: Hoisting equipment hook must be fitted with restraining latch to
prevent lift bail from slipping off under any circumstances.
Note: Some hoisting equipment hooks could interfere with an upright load that extends
beyond the lifter's pad channel. If the load would contact the hook during lifter operation,
the operator must prevent this by attaching a sling (or other rigging that does not interfere
with the load) between the hook and the lift bail.
WARNING: Any sling used must be rated to carry maximum load weight plus
lifter weight.
Use the hoisting equipment to raise the lifter out of the shipping container. Be careful to
avoid damaging any vacuum pads. Remove the pad covers and save them for use whenever
the lifter is stored.
3) Connect the electrical connectors uniting the battery to the battery charger and the vacuum
generating system. The lifter is now operational.
4) Perform Operational and Load Tests for the lifter as directed in MAINTENANCE: TESTING
SCHEDULE.

Rev 26.0/6-13 7 P1-DC: #35111
INTENDED USE
LOAD CHARACTERISTICS
WARNING: This lifter is NOT intended for lifting hazardous materials, such as
explosives or radioactive substances.
The operator must verify that the lifter is intended to handle each load, in accordance with the
following requirements:
• The load must not exceed the maximum allowable weight specified under Load Capacity (see
SPECIFICATIONS).
• The load must be a single piece of nonporous or semiporous material with a flat and relatively
smooth contact surface.3To determine whether the load is too porous or rough, perform the
test under Vacuum Level on Other Surfaces (see OPERATION: TO APPLY THE PADS TO A LOAD).
• The load's contact surface must be suitable for obtaining a friction coefficient of 1 with the
lifter's vacuum pads (see MAINTENANCE: VACUUM PAD MAINTENANCE: Friction Coefficient), as
verified by a friction test. If necessary, contact Wood's Powr-Grip for help in conducting a
friction test.
• In order to avoid damaging the vacuum pads, the load's surface temperature must not exceed
the allowable Operating Temperatures (see SPECIFICATIONS). However, if such an
application cannot be avoided, Wood's Powr-Grip does offer a heat-resistant rubber
compound and other solutions which may enable you to lift loads with higher surface
temperatures. Contact Wood’s Powr-Grip or an authorized dealer for more information.
•While the minimum length and width of the load are determined by the Pad Spread (see
SPECIFICATIONS), the maximum length and width are determined by the allowable
overhang, or the amount of load material that can extend sideways beyond the vacuum pads
without breaking or otherwise being damaged.
The allowable overhang depends on the kind of load material being lifted, the thickness of the
material, and the angle at which it is handled (if any). Since materials such as glass, stone or
sheet metal each have different physical properties, the allowable overhang must be
evaluated separately for each type of load. If necessary, contact Wood’s Powr-Grip or an
authorized dealer for help in determining the recommended overhang in a specific situation.
• 1" [2.5 cm] is the maximum allowable thickness of loads at the maximum weight (see
SPECIFICATIONS: Load Capacity). However, allowable thickness increases as load weight
decreases. If necessary, contact Wood’s Powr-Grip for help in determining the maximum
thickness permitted when handling any specific load.
Note: Vacuum pads can stain or deform load surfaces with light colors or soft coatings. The
operator should test such surfaces for detrimental effects before using the lifter on them.
3Lifters that feature concave vacuum pads can also attach to some kinds of curved loads. Since curvature affects the lifting
capacity, contact Wood’s Powr-Grip for help in determining the Load Capacity for a particular curved load.

Rev 26.0/6-13 8 P1-DC: #35111
OPERATING ENVIRONMENT
The operator must determine whether the lifter is intended to be used in each work environment,
in accordance with the following restrictions:
WARNING: Never use lifter in dangerous environments.
• This lifter is not intended for use in any environment that is inherently dangerous to the
operator or likely to compromise the lifter's ability to function. Environments containing
explosives, caustic chemicals and other dangerous substances must be avoided when using
the lifter.
• The lifter's work environment is limited by the Operating Elevation and Operating Temperatures
indicated in SPECIFICATIONS.
• The lifter's work environment must be free of metal particles or any other contaminates that
could damage lifter components through airborne contact or any other means of transmission
in the environment. If such contaminates cause a vacuum pump failure, they could result in a
load release and possible injury to the operator or others nearby.
WARNING: Environmental contaminates could result in vacuum pump failure.
• Using the lifter in wet environments may require the operator to take special precautions:
Moisture on contact surfaces of the load or vacuum pads diminishes the lifter’s slip resistance,
thereby reducing the lifting capacity (see MAINTENANCE: VACUUM PAD MAINTENANCE: Friction
Coefficient).
WARNING: Moisture reduces slip resistance of vacuum pads.
Although the lifter's exterior surfaces can tolerate some exposure to water vapor, they are not
designed to be water-tight. Submerging the lifter or using it in rain may damage lifter
components; these and similar conditions must be avoided.
• !!-CE-!! If the lifter is employed in a construction area, CE Standard EN 13155 requires the
use of a secondary positive holding device, such as a sling system, designed to support the
load in case of a vacuum system failure.
WARNING: Where CE Standards apply, secondary positive holding device is
required for lifting loads in construction zones.
DISPOSAL OF THE LIFTER
After the vacuum lifter has reached the end of its service life, you must dispose of the lifter in
compliance with all local codes and regulatory standards that are relevant for the geographical
region.
Note: This lifter is equipped with a battery, which may be subject to special disposal regulations.