WPG FLEXR Series User manual

KEEP FOR FUTURE REFERENCE
INSTRUCTIONS
International Version
MODEL NUMBERS: FLEXR4HV11DC,
FLEXR6HV11DC
SERIAL NUMBER: ___________
(please see serial label and record number here)
FLEXR SERIES FLAT LIFTER
WITH SLIDING ARMS
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 2.0/4-15 1 FLEXR-HV11DC: #35037
TABLE OF CONTENTS
TABLE OF CONTENTS ...................................................................................................... 1
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 CHANGE THE CONFIGURATION OF VACUUM PADS ............................................................ 10
TO APPLY THE PADS TO A LOAD ........................................................................................ 10
Powering up the Lifter................................................................................................................................10
Positioning the Lifter on the Load ...............................................................................................................11
Sealing the Pads against the Load...............................................................................................................11
Reading the Vacuum Gauge .......................................................................................................................11
Vacuum Level on Optimal Surfaces .............................................................................................................12
Vacuum Level on Other Surfaces ................................................................................................................12
TO LIFT AND MOVE THE LOAD........................................................................................... 12
Load Capacity and the Warning Light ..........................................................................................................12
Monitoring Vacuum Indicators ....................................................................................................................13
Controlling the Lifter and Load....................................................................................................................13
In Case of Power Failure ............................................................................................................................13
TO RELEASE THE PADS FROM THE LOAD .............................................................................. 14
About Energy Conservation Mode ...............................................................................................................14
AFTER USING THE LIFTER ................................................................................................ 15
Storing the Lifter........................................................................................................................................15
MAINTENANCE.............................................................................................................. 16
INSPECTION SCHEDULE ................................................................................................... 16
Every-Lift Inspection ..................................................................................................................................16
Frequent Inspection ...................................................................................................................................16
Periodic Inspection ....................................................................................................................................16
Infrequent Use ..........................................................................................................................................17
TESTING SCHEDULE ........................................................................................................ 17
Operational Tests.......................................................................................................................................17
Load Test ..................................................................................................................................................17

Rev 2.0/4-15 2 FLEXR-HV11DC: #35037
MAINTENANCE SCHEDULE ................................................................................................ 17
BATTERY TEST ............................................................................................................... 18
BATTERY RECHARGE ....................................................................................................... 19
VACUUM PAD MAINTENANCE............................................................................................ 20
Friction Coefficient .....................................................................................................................................20
Inspection .................................................................................................................................................20
Cleaning ....................................................................................................................................................20
VACUUM TEST ............................................................................................................... 21
AIR FILTER MAINTENANCE −LARGE ................................................................................. 22
Filter Function and Conditions Requiring Service ..........................................................................................22
Filter Service Procedures ............................................................................................................................22
VACUUM PUMP MAINTENANCE −DYNAFLO DV1032102..................................................... 23
Replacing the Diaphragm ...........................................................................................................................23
Replacing the Gasket/Flap Valves................................................................................................................23
Replacing the Head Assembly .....................................................................................................................23
VACUUM PUMP MAINTENANCE ―THOMAS 2907CDC22/12................................................ 24
Replacing a Diaphragm (1) .........................................................................................................................24
Replacing an Intake Valve Flapper (6) .........................................................................................................24
Replacing a Set of Exhaust Valve Flappers (9 & 10) and a Head Gasket (12) .................................................24
VACUUM SWITCH ADJUSTMENT ........................................................................................ 25
Vacuum Switch Function ............................................................................................................................25
Conditions Requiring Readjustment .............................................................................................................25
Adjustment Procedure ................................................................................................................................26
LIMITED WARRANTY.................................................................................................... 27
REPLACEMENT PARTS LIST .......................................................................................... 28

Rev 2.0/4-15 3 FLEXR-HV11DC: #35037
SPECIFICATIONS
Description:
Designed for use with a crane or other hoisting equipment, the FLEXR-
HV11DC lifters employ vacuum to hold a load for lifting in the flat orientation.
Model Number:
FLEXR4HV11DC (w/4 Vacuum Pads)
FLEXR6HV11DC (w/6 Vacuum Pads)
Load Capacity:
(rated at 16" Hg [-54 kPa] on clean, smooth, nonporous flat surfaces1)
Per-Pad:
300 lbs [136 kg]
300 lbs [136 kg]
Maximum:
1200 lbs [545 kg]
1500 lbs [680 kg]
Lifter Weight:
160 lbs [73 kg]
185 lbs [84 kg]
Power Source:
12 volts DC, 26 amps
Battery Capacity:
26 amp-hours
Vacuum Pads:2
10" [25 cm] nominal diameter, lipped (Model HV11), 55 standard rubber,
spring-mounted (¾" [20 mm] travel), with #60 filter screen
Pad Spread:
(to outer edges)
Maximum:
41" x 70¼" [1041 x 1784 mm]
Minimum:
23" x 54¼" [584 x 1378 mm]
Vacuum Pumps:
2 diaphragm type, 1 SCFM [28 liters/minute] nominal airflow or
1 diaphragm type, 3 SCFM [85 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
pumps to re-engage.
Options:
See separate instructions about optional features.
Operating Elevation:
Maximum = 7000 ft [2133 m]
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.wpg.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.
1
Load Capacity is based on a friction coefficient of 1; see MAINTENANCE: VACUUM PAD MAINTENANCE: Friction Coefficient for
additional information.
2
Options include oil-resistant vacuum pads and pads with closed-cell foam rings for use on rough or textured surfaces.

Rev 2.0/4-15 4 FLEXR-HV11DC: #35037
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).

Rev 2.0/4-15 5 FLEXR-HV11DC: #35037
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 FLEXR6HV11DC shown.
1 LIFT SPOOL
7 MOVABLE PAD MOUNT
14 BATTERY GAUGE
2 CONTROL HANDLE
8 VACUUM RESERVE TANK
15 Enclosure with VACUUM SWITCH
3VACUUM CONTROL VALVE
9 SLIDING PAD ARM
16 POWER SWITCH
4Enclosure with BATTERY
10 AIR FILTER
17 VACUUM GAUGE
5BATTERY CHARGER
11 BATTERY TEST BUTTON
18 PARKING STAND/CONTROL HANDLE
6 VACUUM PAD
12 LOW VACUUM WARNING LIGHT
19 VACUUM PUMP(S)
13 PAD FRAME

Rev 2.0/4-15 6 FLEXR-HV11DC: #35037
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).
WARNING: Hoisting equipment hook must be fitted with restraining latch to
prevent lift spool from slipping off under any circumstances.
Attach the hoisting equipment hook to the lift spool and 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. Now the lifter is operational.
4) Perform Operational and Load Tests for the lifter as directed in MAINTENANCE: TESTING
SCHEDULE.

Rev 2.0/4-15 7 FLEXR-HV11DC: #35037
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.
3
To 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).
• 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.
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.
3
Lifters 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 2.0/4-15 8 FLEXR-HV11DC: #35037
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:
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.