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.

Rev 2.0/4-15 9 FLEXR-HV11DC: #35037
OPERATION
BEFORE USING THE LIFTER
The operator must determine whether the lifter is capable of performing each intended task, in
accordance with the SPECIFICATIONS and INTENDED USE sections of this INSTRUCTIONS
manual. In addition, all of the following preparations must be completed prior to lifting any load.
Taking Safety Precautions
The operator must be trained in all relevant industry and regulatory standards for the operation
of the vacuum lifter in its geographical location (eg, ASME B30.20 in the USA).
The operator must read and understand this INSTRUCTIONS manual, including all WARNINGS ,
before using the lifter. If necessary, contact Wood’s Powr-Grip or an authorized dealer for
assistance.
WARNING: Always wear appropriate personal protective equipment.
The operator must wear any personal protective equipment and take any other precautions
required to handle the load safely. Consult appropriate trade association guidelines to determine
what precautions are necessary for each type of load material.
Performing Inspections and Tests
WARNING: Always check battery energy before using lifter.
(See MAINTENANCE: BATTERY TEST)
Perform all inspections and tests required by the INSPECTION and TESTING
SCHEDULES (see MAINTENANCE). In addition, if the lifter has been in storage,
always conduct a VACUUM TEST before placing it in service (see MAINTENANCE).
CAUTION: Examine each air filter regularly, and empty when necessary.
The lifter is equipped with one or more air filters to help protect the vacuum system from
contaminants. In order for a filter to function, the operator must empty the filter bowl before
enough liquid accumulates to contact any portion of the filter element (see MAINTENANCE: AIR
FILTER MAINTENANCE).

Rev 2.0/4-15 10 FLEXR-HV11DC: #35037
TO CHANGE THE CONFIGURATION OF VACUUM PADS
The lifter can accommodate various load dimensions, depending on the position of the sliding
pad arms and movable pad mounts on the pad frame (see illustration in OPERATING FEATURES).
Move the pad arms and pad mounts inward or outward on the pad frame as needed to provide
adequate support across the load surface. The vacuum pads must be arranged symmetrically, to
keep the lifter balanced.
WARNING: Make sure all vacuum hoses are coiled or routed so they do not
become entangled, kinked or punctured.
To position a pad arm, remove the cotterless hitch pin from the arm’s sliding mount. While
making sure the vacuum hose does not get pinched, slide the arm to the desired position and
align the holes for the pin. Push the pin through the holes until the retaining ball emerges on the
far side of the arm mount. On the opposite end of the pad frame, position the second sliding
pad arm at an equal distance from the center of the
lifter.
To position each set of vacuum pads on a pad arm,
remove the cotterless hitch pins from the pad mounts,
move the pads inward or outward equal distances on the
pad arm, and secure them with the cotterless hitch pins.
Before applying the vacuum pads to a load, make sure
that all vacuum hoses are properly connected and will
not interfere with lifter operation.
TO APPLY THE PADS TO A LOAD
Powering up the Lifter
Make sure the lever on the vacuum control valve is in the center position (see TO RELEASE THE
PADS FROM THE LOAD: About Energy Conservation Mode to follow). Place the power switch in the
ON ( ) position (blue indicator light remains illuminated while power is engaged).
4
The power
switch must remain in the ON position while operating the lifter.
5
WARNING: Never turn power off while operating lifter.
Placing the power switch in the OFF ( ) position during lifter operation could result in the
release of the load and possible injury to the operator (see TO LIFT AND MOVE THE LOAD: In Case of
Power Failure to follow).
4
After the power switch is placed in the ON position, the low vacuum warning light and the vacuum pumps turn on until the
lifter attains full vacuum. Since the lifter is operating in energy conservation mode at this stage, the pumps and warning light
may subsequently turn off. However, this does not indicate that the lifter is ready to lift a load.
5
If a vacuum pump fails to function while the power switch is in the ON position, examine the circuit breaker (below power
switch) to determine whether it has interrupted the electrical circuit to the pump. Although the operator can reset the circuit
breaker, the power interruption may indicate an electrical problem that requires attention. Correct any deficiency before
resuming normal operation of the lifter (see wiring diagram provided).

Rev 2.0/4-15 11 FLEXR-HV11DC: #35037
Positioning the Lifter on the Load
Make certain that the contact surfaces of the load and all vacuum pads are free of any
contaminates that could harm the pads or prevent them from sealing against the load (see
MAINTENANCE: VACUUM PAD MAINTENANCE).
6
WARNING: To avoid accidental load release, always center lifter’s pad frame on
load.
Center the lifter’s pad frame to within 2" [5 cm] of the load center, since off-center loading could
result in a load release and possible injury to the operator, and it may also damage the lifter.
7
Make sure that all vacuum pads will fit entirely on the load’s contact surface (see
SPECIFICATIONS: Pad Spread) and that they will be loaded evenly while lifting (see
SPECIFICATIONS: Per-Pad Load Capacity). Then lower the lifter onto the load until all pads are
touching the contact surface.
Sealing the Pads against the Load
Move the lever on the vacuum control valve to the “APPLY” position: Pull upward on the lever's
knob, move the lever all the way forward (away from operator) and release it. This position
opens the lifter’s vacuum lines to the airflow created by the vacuum pumps, causing air to be
drawn immediately at the vacuum pads.
8
Apply the lifter to the load until all pads seal against it.
WARNING: Keep valve lever in “APPLY” position throughout lift.
The valve lever must remain in the “APPLY” position throughout the entire lift. Any interruption
of the vacuum flow during lifter operation could result in the release of the load and possible
injury to the operator.
Note: If a vacuum pad has been lying against a hard object (as during shipping), it may be
slightly distorted. Although initially it may be difficult to apply the pad to a load, this condition
should correct itself with continued use.
Reading the Vacuum Gauge
The vacuum gauge indicates the current vacuum level in the lifter’s vacuum system. The green
range indicates vacuum levels sufficient for lifting the maximum load weight, whereas the red
range indicates vacuum levels that are not sufficient for lifting the maximum load weight. The
gauge needle should show a sudden surge in vacuum as the vacuum pads seal against the load.
If it takes more than 5 seconds for the vacuum level to reach 5" Hg [-17 kPa], press on any pad
that has not yet sealed.
6
Since oil damages the rubber in standard pads, the load surface must be free of oil unless the lifter is equipped with optional
nitrile pads, which may be used on oily surfaces.
7
The lifter is designed to handle the maximum load weight (see SPECIFICATIONS: Maximum Load Capacity) when the load’s
center of gravity is positioned within 2" [5 cm] of the pad frame’s center point. Occasional loading deviations are permissible,
provided that the operator can maintain control of the load at all times and that the load weight is low enough to avoid damaging
the lifter.
8
To conserve battery energy and reduce the time required to apply the pads to a load, do not place the valve lever in the
“APPLY” position unless the vacuum pads are contacting the load.

Rev 2.0/4-15 12 FLEXR-HV11DC: #35037
Vacuum Level on Optimal Surfaces
When the lifter is attached to clean, smooth, nonporous load surfaces, it should be able to
maintain a vacuum level in the green range on the vacuum gauge, except when used at high
elevations (see SPECIFICATIONS: Operating Elevation). If not, make sure the vacuum switch is
adjusted correctly (see MAINTENANCE: VACUUM SWITCH ADJUSTMENT). If the vacuum switch
cannot be adjusted to maintain a vacuum of 16" Hg [-54 kPa], perform the VACUUM TEST (see
MAINTENANCE) to determine whether there is a deficiency in the vacuum generating system.
Vacuum Level on Other Surfaces
When the lifter is attached to contaminated, rough or porous load surfaces, it may not be able to
maintain a vacuum level in the green range on the vacuum gauge, due to leakage in the seal
between the vacuum pads and the load surface.
9
In the case of contamination, thoroughly clean
the contact surfaces of the load and the vacuum pads (see MAINTENANCE: VACUUM PAD
MAINTENANCE: Cleaning), and reapply the lifter to the load. If the load has rough or porous
surfaces, the operator must conduct a test to determine whether the lifter is designed
to lift the load , as follows:
1) Make sure the lifter's vacuum generating system is functioning correctly (see MAINTENANCE:
VACUUM TEST).
2) Apply the vacuum pads to the load as previously directed.
3) After the vacuum pumps stop running, place the power switch in the OFF ( ) position.
4) Raise the load a minimal distance, to assure that it is supported by the lifter.
5) Monitor the vacuum gauge while the load is suspended for 5 minutes: The lifter must
maintain a minimum vacuum level of 10" Hg [-34 kPa] during this time. If not, the
load does not possess the characteristics required for using this lifter.
10
TO LIFT AND MOVE THE LOAD
Load Capacity and the Warning Light
A lifter’s Load Capacity is rated at a vacuum level of 16" Hg [-54 kPa] (see SPECIFICATIONS).
After the lifter has attained this level, the vacuum pumps turn off automatically, to conserve
battery energy. At the same time, the low vacuum warning light turns off, to indicate that the
lifter is ready to lift the maximum load weight.
WARNING: Never attempt to lift load while red warning light is illuminated.
Do not attempt to lift the load while the warning light is illuminated; such an attempt could result
in a load release and possible injury to the operator.
9
Contaminated loads can also cause the vacuum pumps to run frequently or continuously. Since excessive pumping quickly
reduces battery energy, the operator should clean the load when possible, to minimize pumping.
10
Certain load materials are too rough or porous to allow the lifter to form a seal which can be maintained for 5 minutes without
power. However, in geographical locations where CE Standards do not apply, it may be possible to use the lifter to lift such loads.
Contact Wood’s Powr-Grip for more information.

Rev 2.0/4-15 13 FLEXR-HV11DC: #35037
Monitoring Vacuum Indicators
The low vacuum warning light and the vacuum gauge must remain completely visible to the
operator, so that they can be monitored throughout the entire lift.
WARNING: Vacuum indicators must be visible to operator throughout entire lift.
If the vacuum system experiences leakage while the lifter is attached to the load, the vacuum
pumps turn on automatically, as required to maintain sufficient vacuum for lifting the maximum
load weight. The low vacuum warning light also turns on and remains illuminated while the
pumps are running, to signal the reduction in vacuum to the operator.
If the pumps and warning light turn on while you are lifting a load, make sure the vacuum gauge
shows a vacuum level of 16" Hg [-54 kPa] or higher. If not, move away and stay clear of the
load until it can be lowered to the ground or a stable support.
WARNING: Stay clear of any suspended load while vacuum level is lower than
16" Hg [-54 kPa].
Discontinue lifter use until the cause of the vacuum loss can be determined. If the pumps run at
intervals of ten minutes or less while the lifter is attached to clean, smooth, nonporous materials,
the leakage is likely to be in the vacuum system. In this event, perform the VACUUM TEST (see
MAINTENANCE) and inspect the vacuum pads for damage (see MAINTENANCE: VACUUM PAD
MAINTENANCE: Inspection). If the vacuum loss cannot be remedied immediately, perform
inspection and maintenance as needed to identify and correct any deficiency before resuming
normal operation of the lifter.
Controlling the Lifter and Load
When vacuum indicators show that the lifter is ready, use the
hoisting equipment to raise the lifter and load as needed to
clear any obstacles in their path. Use the control handle to keep
the lifter and load in the desired orientation while they are
suspended from the crane.
Note: Depending on the arrangement of sliding pad arms and movable pad mounts, the pad
frame may extend beyond the edges of smaller loads. When moving such loads, be careful to
avoid any obstacles to the pad frame, as well as to the load.
In Case of Power Failure
The lifter is equipped with a vacuum reserve tank, designed to maintain vacuum temporarily in
case of a power failure (ie, in battery).
WARNING: Stay clear of any suspended load in the event of a power failure.
Although the lifter is designed to support the load for at least 5 minutes without power, this
depends on many factors, including the condition of the load and the lifter’s vacuum system (see
INTENDED USE: LOAD CHARACTERISTICS and MAINTENANCE: VACUUM PAD MAINTENANCE,VACUUM
TEST). If a power failure occurs, keep all personnel clear of the suspended load until it can safely
be placed on the ground or a stable support. Correct any deficiency before resuming normal
operation of the lifter.

Rev 2.0/4-15 14 FLEXR-HV11DC: #35037
TO RELEASE THE PADS FROM THE LOAD
WARNING: Load must be fully supported before releasing vacuum pads.
When the load is at rest and fully supported, move the lever on the vacuum control valve to the
“RELEASE” position: Pull upward on the lever's knob, move the lever all the way back (towards
operator) and then release it. This forces air into the vacuum pads, quickly breaking the vacuum
seal. After the pads have disengaged completely from the load, move the lifter away. Then
place the lifter in energy conservation mode as directed in the following discussion.
About Energy Conservation Mode
The lifter's vacuum control valve features a neutral position, designed to conserve battery energy
between lifts. To utilize this feature, pull upward on the lever's knob, move the lever to the
center position and then release it. Placing the valve lever in the center position closes off the
vacuum line that connects the vacuum pads to the vacuum generating system. As a result,
sufficient vacuum builds up in the line to turn off the low vacuum warning light and the vacuum
pumps before the lifter is applied to another load. This reduces the amount of battery energy
needed to power the pumps and warning light.
WARNING: Never move valve lever to center position while lifter is supporting
load.
Energy conservation mode may only be used when the lifter is not supporting a load. The
operator must never move the valve lever to the center position while the lifter is supporting a
load, because this could result in a load release and possible injury to the operator.

Rev 2.0/4-15 15 FLEXR-HV11DC: #35037
AFTER USING THE LIFTER
Place the power switch in the OFF ( ) position (blue indicator light shuts off when power is off).
CAUTION: Do not set the lifter against any surfaces which could soil or damage the
vacuum pads.
Use the hoisting equipment to gently lower the lifter onto a stable support; then detach the
hoisting equipment hook from the lift spool.
If the lifter is transported to another location, use the original shipping container and secure the
lifter so as to protect the vacuum pads and all other components from damage while in transit.
Storing the Lifter
Use the covers supplied to keep the vacuum pads clean.
!!–CE–!! In accordance with CE Standard EN 13155, the lifter is designed to rest on relatively
horizontal surfaces without tipping over. To store the lifter in this way, set the lifter with the
pads facing downward on a clean, smooth, flat surface.
Charge the battery completely when placing it in storage and at six-month intervals thereafter
(see MAINTENANCE: BATTERY RECHARGE). After charging the battery, disconnect the electrical
connectors uniting the battery to the battery charger and to the vacuum generating system, in
order to minimize power drainage. Preferred temperatures for storing the battery are 32° to 70°
Fahrenheit [0° to 21° Celsius]. Higher temperatures require the battery to be charged more
frequently. Storage at temperatures above 100° Fahrenheit [38° Celsius] should be avoided.

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MAINTENANCE
WARNING: Always make sure battery is disconnected before servicing lifter.
Note: One or more wiring diagrams are provided in the final section of this INSTRUCTIONS
manual for reference when servicing the lifter or trouble-shooting a deficiency.
INSPECTION SCHEDULE
Perform inspections routinely, according to the following frequency schedule:
Every-Lift Inspection
• Examine the vacuum pads and load surface for contamination or debris (see VACUUM PAD
MAINTENANCE to follow).
• Examine the vacuum pads, controls and indicators for visual damage (see VACUUM PAD
MAINTENANCE to follow).
• Test the battery for adequate charge (see BATTERY TEST to follow).
If a battery’s charge appears to be inadequate, charge and retest the battery (see BATTERY
RECHARGE to follow). If any other deficiency is detected during the inspection, correct it before
using the lifter and perform the Frequent Inspection to follow.
Frequent Inspection
( following every 20-40 hours’ use; or whenever lifter is out of service for 1 month or more )
• Examine the lifter’s structure for visual damage.
• Examine the vacuum system (including vacuum pads, fittings and hoses) for visual damage.
• Examine the air filter for conditions requiring service (see AIR FILTER MAINTENANCE to follow).
•Perform the VACUUM TEST to follow.
• Check for unusual vibrations or noises while operating the lifter.
If any deficiency is detected during the inspection, correct it before using the lifter and perform
the Periodic Inspection to follow.
Periodic Inspection
( following every 250-500 hours’ use; or whenever lifter is out of service for 1 year or more )
• Examine the entire lifter for external evidence of looseness, excessive wear, deformation,
cracks, excessive corrosion, dents to structural or functional components, cuts, or any
deficiency which might constitute a hazard.
• Inspect all parts of the electrical system for damage, wear or contamination that could
constitute a hazard, in compliance with all local codes and regulatory standards that are
relevant for the geographical region.
CAUTION: Be sure to use appropriate cleaning methods for each type of electrical
component, as specified by codes and standards. Improper cleaning
can damage components.

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• Keep a written record of all Periodic Inspections.
If any deficiency is detected during the inspection, correct it before using the lifter. If necessary,
return the lifter to Wood’s Powr-Grip or an authorized dealer for repair (see LIMITED
WARRANTY).
Infrequent Use
If a lifter is used less than 1 day in a 2-week period, perform the Periodic Inspection each time
before using the lifter .
TESTING SCHEDULE
Perform these tests when placing the lifter in service initially and each time following a repair or
modification . Correct any deficiency and retest before using the lifter.
Operational Tests
• Perform the VACUUM TEST to follow.
• Test all features and functions of the lifter (see OPERATING FEATURES, OPERATION and
MAINTENANCE).
Load Test
Prove that the lifter can lift 100% of its Maximum Load Capacity (see SPECIFICATIONS), using an
actual load or an equivalent simulation.
11
Employ the following method to test with an actual
load:
1) Place a test load with appropriate LOAD CHARACTERISTICS (see INTENDED USE) on a stable
support. Make sure the load is oriented in the upright position.
12
2) Apply the vacuum pads to the load as previously directed.
3) After the vacuum pump stops running, place the power switch in the OFF ( ) position.
4) Raise the load a minimal distance, to assure that it is supported by the lifter.
5) Hold the load for 5 minutes. The load must not slip or fall during this time period. If it does,
conduct a VACUUM TEST and inspect each vacuum pad as indicated under VACUUM PAD
MAINTENANCE: Inspection (see sections to follow). Correct any deficiency that is found and
retest the lifter.
Note: See MAINTENANCE topics to follow for additional directions about inspecting and testing
specific lifter components.
MAINTENANCE SCHEDULE
Unless specified elsewhere in this INSTRUCTIONS manual, the lifter does not require
maintenance on a routine basis. Instead, maintenance must be performed whenever a
deficiency is indicated by routine inspections or tests. Any maintenance warranted must be
performed before resuming normal operation of the lifter.
11
ASME Standard B30.20 requires the lifter to be tested to 125% of its Load Capacity.
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Flat Lifters are exempt from this requirement.

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BATTERY TEST
The lifter is equipped with a battery gauge to help the operator evaluate
whether the battery has adequate energy for lifting. Factors such as the
condition of the battery, the time required to execute a lift, and the
porosity of the load combine to determine how much battery energy is
needed. It is the operator’s responsibility to evaluate these
conditions and to make sure the battery has sufficient energy to
complete a lift safely. Check the battery energy before every lift and
also at the end of each day's use, to decide whether a charge is needed
(see BATTERY RECHARGE to follow).
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Never use the lifter when battery
energy registers lower than 50% (that is, when only red lights are illuminated), regardless of the
estimated energy requirement.
WARNING: Never use lifter if battery energy is lower than 50% of capacity.
When the power switch is in the ON ( ) position, the battery gauge automatically monitors the
energy level of the battery. However, the battery gauge shuts off temporarily while the vacuum
pump is running, to prevent an inaccurate reading. When the pumping cycle is completed, the
battery gauge requires a few moments to stabilize before it displays an accurate energy reading
again.
When the power switch is in the OFF ( ) position, the battery energy can be checked manually
using the battery test button. If the lifter has not been used since the battery was charged, the
battery gauge may falsely indicate an energy level that is higher than actual, due to a “surface
charge” on the battery. After the pump runs for approximately one minute, the surface charge
dissipates, allowing the operator to take an accurate energy reading.
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The battery charger must be disconnected from its AC power source in order to test the battery energy; otherwise, the energy
reading on the battery gauge would not be accurate.