WPG MRT411LDC3 User manual

Rev 4.0/7-20 MRT4-DC3: #35068AUS1
INTENDED FOR USE BY SKILLED
PROFESSIONALS • READ AND
UNDERSTAND BEFORE OPERATING
OPERATING
INSTRUCTIONS 908 W. Main • P.O. Box 368
Laurel, MT USA 59044
800-548-7341 (phone)
406-628-8231 (phone)
406-628-8354 (fax)
www.WPG.com
Record serial number in blank space above (to locate, see serial
label on the product).
MANUAL
ROTATOR/TILTER,
DC-VOLTAGE WITH
INTELLI-GRIP® TECHNOLOGY
Model numbers: MRT411LDC3 (shown),
MRT49DC3, MRT4HV11DC3
KEEP FOR FUTURE REFERENCE

MRT4-DC3: #35068AUS Rev 4.0/7-202

Rev 4.0/7-20 MRT4-DC3: #35068AUS1
SPECIFICATIONS .....................................................................................3
SAFETY...................................................................................................5
OPERATING FEATURES............................................................................6
ASSEMBLY..............................................................................................7
TOCHANGE THE PAD FRAME CONFIGURATION ..................................................9
Installing/Removing Extension Arms and Repositioning Vacuum Pads ............................10
Using Secondary Rotation Stops .......................................................................................11
INTENDED USE .....................................................................................12
LOAD CHARACTERISTICS...............................................................................12
OPERATING ENVIRONMENT..........................................................................13
DISPOSAL OF THE LIFTER .............................................................................13
OPERATION..........................................................................................14
BEFORE USING THE LIFTER...........................................................................14
Taking Safety Precautions .................................................................................................14
Selecting a Screen Language.............................................................................................14
Performing Inspections and Tests .....................................................................................15
Checking the 12-Volt Battery ............................................................................................15
TOATTACH THE PADS TO ALOAD ..................................................................16
Positioning the Lifter on the Load.....................................................................................16
Powering up the Lifter ......................................................................................................17
Sealing the Pads on the Load............................................................................................17
Reading the Vacuum Gauges ............................................................................................18
Interpreting the Lift Light..................................................................................................19
Watching Vacuum Indicators ............................................................................................19
Controlling the Lifter and Load .........................................................................................20
In Case of a Power Failure.................................................................................................20
TOROTATE THE LOAD .................................................................................21
TOTILT THE LOAD ......................................................................................22
TORELEASE THE PADS FROM THE LOAD .........................................................24
AFTER USING THE LIFTER.............................................................................25
Storing the Lifter ...............................................................................................................25
INSPECTIONS AND TESTS......................................................................27
INSPECTION SCHEDULE ................................................................................27
TABLE OF CONTENTS

MRT4-DC3: #35068AUS Rev 4.0/7-202
TESTING ...................................................................................................28
Lifter/Load Compatibility Test...........................................................................................28
Operational Tests ..............................................................................................................29
Vacuum Test......................................................................................................................29
Rated Load Test.................................................................................................................30
MAINTENANCE ....................................................................................31
VACUUM PAD MAINTENANCE.......................................................................31
Pad-to-Load Friction Coefficient .......................................................................................31
Pad Inspection ..................................................................................................................31
Pad Cleaning .....................................................................................................................32
12-VOLT BATTERY RECHARGE.......................................................................33
NOTIFICATION BUZZER BATTERY REPLACEMENT ...............................................34
INTELLI-GRIP® DIAGNOSTIC CODES ...............................................................35
REPLACEMENT PARTS...........................................................................39
LIMITED WARRANTY ............................................................................40
TOOBTAIN REPAIRS OR WARRANTY SERVICE...................................................40
TABLE OF CONTENTS

Product
Description
Designed for use with hoisting equipment, MRT4-DC3 lifters support loads using vacuum and manipulate
loads using manual 360° rotation and manual 90° tilt motions.
Model
Number MRT49DC3 MRT4HV11DC3 MRT411LDC3
Vacuum Pads
(4 each, standard rubber1
1...... Available with other rubber compounds for special purposes (see www.wpg.com).
)
9" [23 cm] nominal diameter
(Model VPFS9)
10" [25 cm] nom. diameter, lipped
(Model HV11)
11" [28 cm] nom. diameter, lipped
(Model G3370)
Pad Spread2
2...... The illustrations under “TOCHANGE THE PAD FRAME CONFIGURATION”on page 9 show the Pad Spread for all approved MRT411LDC(3) pad frame configurations.
---------------------------- (to outer edges) ----------------------------
Length — Maximum 75¼" [192 cm] 77¼" [197 cm] 78¼" [199 cm]
Length — Minimum 29¾" [76 cm] 31¾" [81 cm] 32¾" [83 cm]
Width — Maximum 46½" [119 cm] 48½" [124 cm] 49½" [126 cm]
Width — Minimum 12¾" [33 cm] 14¾" [38 cm] 15¾" [40 cm]
Maximum
Load Capacity3
3...... The Maximum Load Capacity is rated at a vacuum of 16" Hg [-54 kPa] on clean, smooth, nonporous flat surfaces with a friction coefficient of 1. Pad
compound, load rigidity, strength, surface conditions, overhang, angle, center of gravity and temperature can also affect the lifting capacity. A “qualified
person” should evaluate the effective lifting capacity for each use (see definition under “Rated Load Test” on page 30).
Total 225 kg 270 kg 320 kg
Lifter
Weight 57 kg
Power
System 12 volts DC, 5.5 amps
Battery
Capacity 7 amp-hours
Rotation
Capability Manual, 360°, with latching at each ¼ turn (when required)
Tilt
Capability Manual, 90°, with automatic locking in vertical position
Product
Options See separate instructions about options.
Operating
Elevation Up to 6,000' [1,828 m]
Operating
Temperatures 32° — 104° F [0° — 40° C]
Service
Life 20,000 lifting cycles, when used and maintained as intended4
4...... Vacuum pads, filter elements and other wear-out items are excluded.
Software
Version Intelli-Grip®7.6
Design Standard Compliant with AS 4991. Note: Each circuit of the Dual Vacuum System complies with the capacity
requirements of this Standard.
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SPECIFICATIONS

MRT4-DC3: #35068AUS Rev 4.0/7-204
SPECIFICATIONS
Note: A standard MRT411LDC3 is shown.

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SAFETY
Wear personal protective
equipment that is appropriate for
the load material. Follow trade
association guidelines.
Do not remove or obscure safety
labels.
Do not make any modifications to
the lifter (see “LIMITED
WARRANTY”).
Use the lifter only in an approved
“OPERATING ENVIRONMENT”(see
“INTENDED USE”).
Do not use a lifter that is damaged,
malfunctioning, or missing parts.
Do not use a lifter if the sealing
edge of any vacuum pad is cut or
otherwise damaged.
Do not use a lifter to lift cracked or
broken glass.
Do not exceed the Maximum
Load Capacity or lift loads the
lifter is not designed for (see
“INTENDED USE”).
Do not use a lifter if the
Maximum Load Capacity or
any safety label appears to be
missing or obscured.
Make sure the contact surfaces of
the load and vacuum pads are clean
before attaching the lifter (see
“MAINTENANCE”).
Position the vacuum pads correctly
on the load before lifting (see
“OPERATION: Positioning the Lifter
on the Load”).
Do not lift a load if any vacuum
indicator shows inadequate
vacuum.
Keep unauthorized personnel away
from the lifter, to avoid injury in
case of an unintended load release.
Do not touch the vacuum release
controls during a lift.
Do not allow people to ride on the
lifter or the load.
Do not lift a load higher than
necessary or leave suspended loads
unattended.
Do not position a loaded or
unloaded lifter over people.
Before servicing a powered lifter,
place the power control in the
inactive position and, when
possible, disconnect the power source.

MRT4-DC3: #35068AUS Rev 4.0/7-206
Features shown here are underlined on their first appearance in each section following.
1 LIFT POINT 10 INTELLI-GRIP®CONTROL UNIT 17 STROBE LIGHT
2 INSTRUCTIONS CANISTER 11 ROTATION WEAR PLATE 18 CONTROL HANDLE
3 BATTERY CHARGER 12 Enclosure with VACUUM PUMP 19 VACUUM RESERVE TANKS
4 BATTERY CIRCUIT BOARD and 20 VACUUM PAD with MOVABLE PAD MOUNT
5 POWER BUTTON VACUUM SENSORS 21 PAD FRAME
6 “RELEASE” BUTTON 13 NOTIFICATION BUZZER 22 ROTATION RELEASE LEVER
7 “ATTACH” BUTTON 14 VACUUM LIFT LIGHT 23 TILT RELEASE LEVER
8 “FUNCTION” BUTTON 15 AIR FILTER 24 LIFT BAR
9 LCD SCREEN with BATTERY GAUGE 16 VACUUM GAUGES Not shown: EXTENSION ARMS
Note: A standard MRT411LDC3 is shown. Although some of the following photos do not show
this specific lifter, they all illustrate how this kind of lifter functions.
OPERATING FEATURES

Rev 4.0/7-20 MRT4-DC3: #35068AUS7
1)
2A 2B
Remove all lifter restraints and save them with the shipping container for future use.
2) Suspend the lifter from appropriate hoisting equipment:
2.1)
Select a crane and/or hoist rated for the Maximum Load Capacity plus the
Lifter Weight.
Note: Any lifter use must comply with all statutory or regulatory standards for hoisting
equipment in your region.
2.2) Disengage any tilt locks or latches, and raise the lift bar (figs. 2A-C).
2.3) Attach the hoisting hook to the
lift point (figs. 2D-E).
2D 2E
Make sure
hook has
restraining latch
(circled).
2F
Only use rigging rated for Maximum Load
Capacity plus Lifter Weight.
Use
rigging (fig. 2F) as needed to
make sure the hook does not
interfere with the load.
ASSEMBLY
2C

MRT4-DC3: #35068AUS Rev 4.0/7-208
2.4) Use the hoisting equipment to remove the lifter from the shipping container. Avoid
damaging the vacuum pads.
3B3A
3)
3C
3D
Connect the electrical connectors (figs. 3A-B and
figs. 3C-D).
If the lifter has a notification buzzer, install the 9-
volt battery as directed in “NOTIFICATION BUZZER
BATTERY REPLACEMENT”on page 34.
4)
4A
Assemble the pad frame for optimal load support
(see “TOCHANGE THE PAD FRAME CONFIGURATION”on
page 9). Remove the pad covers (fig. 4A) and save them
for future use.
5) Perform tests as required under “TESTING”on page 28.
ASSEMBLY

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TOCHANGE THE PAD FRAME CONFIGURATION
ASSEMBLY

MRT4-DC3: #35068AUS Rev 4.0/7-2010
Various pad frame configurations enable the lifter to match different load dimensions. The
illustrations on the preceding page show all approved configurations. Dimensions show Pad
Spread for a standard MRT411LDC(3) lifter (see “SPECIFICATIONS” on page 3 for other models).
Caution: If the lifter is equipped with a dual vacuum system, position the vacuum pads for the 2
circuits (marked “1” and “2” in the preceding illustrations).
1)
Use only approved pad frame
configurations.
Securely position vacuum hoses to
avoid damage during lifter operation.
Choose an approved configuration to
maximize support across the load
surface and to minimize load overhang
(see “LOAD CHARACTERISTICS” on
page 12).
2) Install or remove the extension arms and reposition the movable pad mounts as needed.
Installing/Removing Extension Arms and Repositioning Vacuum Pads
1)
4A 4B
3B
2A
3A
1A
Remove the cotterless hitch
pin (circled in fig. 1A) that
secures the movable pad
mount to the pad frame.
2) Remove the vacuum pad
from the pad frame (fig. 2A).
3) Insert the extension arm into
the pad frame (fig. 3A). Then
insert a cotterless hitch pin
to secure it (fig. 3B).
4) Position the movable pad
mount on the extension arm
(fig. 4A). Then insert a
cotterless hitch pin to secure
it (fig. 4B).
Notes: Repeat or reverse these
steps to configure the pad frame as
needed. Store removed
components in a clean, dry
location.
ASSEMBLY

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Using Secondary Rotation Stops
Align the secondary rotation stops for correct use of the pad frame in long, narrow
configurations.
ASSEMBLY

MRT4-DC3: #35068AUS Rev 4.0/7-2012
INTENDED USE
LOAD CHARACTERISTICS
Do NOT lift explosives, radioactive
substances or other hazardous materials.
Make sure the vacuum lifter is intended
to handle each load according to these
requirements:
• The load weight must not exceed the Maximum Load Capacity.
• The load must be a single piece of relatively nonporous material with a flat and
relatively smooth contact surface.1, 2To determine whether the load is too porous or
rough, perform the “Lifter/Load Compatibility Test” on page 28.
• The load's contact surface must be able to obtain a friction coefficient of 1 with the lifter's
vacuum pads (see “Pad-to-Load Friction Coefficient” on page 31). Otherwise, the
capacity should be derated appropriately.
• The load's surface temperature must not exceed the Operating Temperatures.3
• The load's minimum length and width are determined by the current Pad Spread
(see “SPECIFICATIONS” on page 3).
• The load's maximum length and width are determined by its allowable overhang.4
• 1" [2.5 cm] is the allowable thickness at Maximum Load Capacity.5
Note: Standard vacuum pads can stain or deform load surfaces with light colors or soft
coatings. Test such surfaces for damaging effects before using the lifter on them.6
1..... Although concave vacuum pads can also attach to some curved loads, curvature can reduce lifting capacity. Contact WPG for more information.
2..... A “single piece” of material includes curtainwall assemblies, unitized glazing systems and similar construction units.
3..... Vacuum pads made from a heat-resistant rubber compound can enable you to lift loads with higher surface temperatures. Contact WPG or an
authorized dealer for more information.
4..... The allowable overhang is the amount of load material that can extend sideways beyond the vacuum pad without breaking or otherwise being
damaged. This depends on the load material, its thickness, and the angle of handling (if any). Since every material has different physical
properties, the allowable overhang must be evaluated separately for each load type. Contact WPG or an authorized dealer for more
information.
5..... However, the allowable thickness increases as load weight decreases. Contact WPG for more information.
6..... Alternative rubber compounds are available for these purposes. Contact WPG or an authorized dealer for more information.

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OPERATING ENVIRONMENT
Make sure the vacuum lifter is intended for use in each work environment, given the following
restrictions:
•
Never use lifter in dangerous
environments.
Metal particles and similar
environmental contaminates
could result in vacuum pump failure.
This lifter is not intended for any environment
that is dangerous to the operator or damaging
to the lifter. Avoid environments containing
explosives, caustic chemicals and other
dangerous substances.
• The work environment is limited by the Operating Elevation and Operating
Temperatures.1, 2
• The lifter is not designed to be watertight.
Moisture can result in
reduced lifting capacity.
Do not
use it in rain or otherunsuitable conditions.
DISPOSAL OF THE LIFTER
After the Service Life of the vacuum lifter has ended (see “SPECIFICATIONS” on page 3), dispose
of it in compliance with all local codes and applicable regulatory standards.
Note: Special disposal regulations may apply to the battery.
1..... Although lifter use may be possible at higher elevation, lifting capacity is reduced whenever the lifter is unable to attain vacuum in the green
range on the vacuum gauge. Contact WPG for more information.
2..... Special provisions may allow the lifter to operate outside the specified temperature range. Contact WPG for more information.
INTENDED USE

MRT4-DC3: #35068AUS Rev 4.0/7-2014
OPERATION
BEFORE USING THE LIFTER
Determine whether the vacuum lifter is capable of each intended task (see “SPECIFICATIONS”
on page 3 and “INTENDED USE” on page 12). Then complete the following preparations:
Taking Safety Precautions
•
Read all directions and safety
rules before using lifter.
Always wear appropriate
personal protective equipment.
Be trained in all industry and regulatory
standards for lifter operation in your region.
• Follow trade association guidelines about
precautions needed for each load material.
Selecting a Screen Language
When the lifter is powered up for the first time, the Intelli-Grip®
control unit prompts the operator to select a language for the LCD
screen. Use the buttons as follows:
• To scroll down, press the “release” button ( ).
• To scroll up, press the “attach” button ( ).
• To select a language, press the “function” button ( ).1
Note: A similar process is used to navigate all menus.
1..... To change the language again, refer to the “INTELLI-GRIP®OPERATOR MENUS” section of the SERVICE MANUAL.

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Performing Inspections and Tests
• Follow the “INSPECTION SCHEDULE” on page 27 and “TESTING”on page 28.
•
Examine air filters regularly
and service when needed.
Service the 2 air filters whenever a bowl contains
liquid or other contaminates, or an element
appears dirty (see “AIR FILTER MAINTENANCE” in
SERVICE MANUAL).
•
Make sure
notification
buzzer can be
heard over noise
at operator
position.
Make sure the notification buzzer is clearly
audible at the maximum distance between the
operator and the lifter, despite any barriers or
obstacles.1, 2
Checking the 12-Volt Battery
Always check battery
energy before every lift.
While the lifter is powered up, a battery gauge on the LCD
screen displays the current energy level.3, 4
• If battery energy is in the red range, discontinue lifter
use and charge the battery (see “12-VOLT BATTERY
RECHARGE”on page 33).
• If battery energy continues to decrease and you try to
attach the lifter to a load, the notification buzzer will
sound continuously and the LCD screen will display “Lockout (low 12V battery)”, along
with a diagnostic code (see “INTELLI-GRIP® DIAGNOSTIC CODES”on page 35). In this case, you
must charge the battery in order to continue using the lifter.
1..... Maximum buzzer volume is 95 dBA at 2' [60 cm].
2..... The “Vacuum Test” on page 29 provides a convenient opportunity to check this.
3..... If the lifter remains in “Power Save” mode for a long time, the pump will run periodically to test the battery.
4..... If the battery charger is connected to an AC power source, the reading on the battery gauge will not be accurate and “Replace 12V battery” may
appear on the LCD screen, because the system cannot accurately evaluate the battery.
OPERATION

MRT4-DC3: #35068AUS Rev 4.0/7-2016
TOATTACH THE PADS TO ALOAD
Make sure the contact surfaces of the load and vacuum pads are clean (see
“Pad Cleaning” on page 32).
Positioning the Lifter on the Load
1)
1A
Center the pad frame on
the load (fig. 1A).1
2)
2A
Make sure all vacuum pads
will fit on the load and will
be loaded evenly (fig. 2A).
3) Place the vacuum pads in
contact with the load
surface.
1..... The lifter is designed to handle the maximum load weight when the load’s center of gravity is positioned within 2" [5 cm] of the lifter’s rotation
axis. Uncentered loads may rotate or tilt unexpectedly (as applicable).
OPERATION

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Powering up the Lifter
1A
Press the lifter's power button ( — fig. 1A).
The vacuum pump will run for a few seconds,
as a normal function of the Intelli-Grip®self-
diagnostics.
The lifter automatically tests the 9-volt battery
for the notification buzzer each time the lifter
is powered up. When this battery runs down,
the LCD screen displays “Replace 9V battery?”
and the buzzer chirps once per minute.
Replace the battery as needed (see
“NOTIFICATION BUZZER BATTERY REPLACEMENT”on
page 34).
1C
Sealing the Pads on the Load
Press the lifter’s “attach” button ( — fig. 1C).
Keep “attach” function
activated throughout lift.
The vacuum pump will run until the vacuum
pads seal completely. If the lifter takes too
long to attach, the notification buzzer chirps
and the LCD screen displays “Vacuum not
increasing normally”, along with a diagnostic code (see “INTELLI-GRIP® DIAGNOSTIC CODES”on
page 35). In this case, press the lifter firmly against the load to help the pads begin to seal.1
1..... Although a vacuum pad may become distorted during shipping or storage, this condition should correct itself with continued use.
OPERATION

MRT4-DC3: #35068AUS Rev 4.0/7-2018
Reading the Vacuum Gauges
The 2 vacuum gauges of the dual vacuum system show the current vacuum level in positive
inches of Hg and negative kPa:
•
1A 1B
Green range (>16" Hg [-54
kPa]): Vacuum level is sufficient
to lift the maximum load weight
(fig. 1A).
• Red range (< 16" Hg [-54 kPa]):
Vacuum level is not sufficient to
lift the maximum load weight
(fig. 1B).1
If it takes more than 5 seconds for the
vacuum level to reach 5" Hg [-17 kPa]
on either vacuum gauge, press on any
vacuum pad that has not yet sealed.
Once the pads have sealed, the lifter should be able to maintain sufficient vacuum for lifting,
except when used above the maximum Operating Elevation.2If it does not, perform the
“Vacuum Test” on page 29.
1..... The gauge face colors do not correspond with the circuit colors.
2..... If the lifter is used above the maximum Operating Elevation (see “SPECIFICATIONS” on page 3), it may not be able to maintain sufficient vacuum
for lifting. Contact WPG for more information.
OPERATION