WPG P110C04DC User manual

P1-DC: #351111
INTENDED FOR USE BY SKILLED
PROFESSIONALS • READ AND
UNDERSTAND BEFORE OPERATING
OPERATING
INSTRUCTIONS 908 W. Main • P.O. Box 368
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
SINGLE-CHANNEL
LIFTER, DC-VOLTAGE
Model numbers: P110C04DC, P1HV1104DC,
P11104DC (shown)
Record serial number in blank space above (to locate, see serial
label on the product).
KEEP FOR FUTURE REFERENCE

P1-DC: #35111 Rev 29.0/11-192

Rev 29.0/11-19 P1-DC: #351111
SPECIFICATIONS .....................................................................................3
SAFETY...................................................................................................5
OPERATING FEATURES............................................................................6
ASSEMBLY..............................................................................................7
INTENDED USE .......................................................................................9
LOAD CHARACTERISTICS.................................................................................9
OPERATING ENVIRONMENT..........................................................................10
DISPOSAL OF THE LIFTER .............................................................................10
OPERATION..........................................................................................11
BEFORE USING THE LIFTER...........................................................................11
Taking Safety Precautions .................................................................................................11
Performing Inspections and Tests .....................................................................................11
Checking the Battery.........................................................................................................12
TOATTACH THE PADS TO ALOAD ..................................................................13
Positioning the Lifter on the Load.....................................................................................13
Sealing the Pads on the Load............................................................................................14
Reading the Vacuum Gauge..............................................................................................14
TOLIFT AND MOVE THE LOAD......................................................................15
Interpreting the Warning Light and Optional Warning Buzzer .........................................15
Watching Vacuum Indicators ............................................................................................15
Controlling the Lifter and Load .........................................................................................16
In Case of a Power Failure.................................................................................................16
TOROTATE THE LOAD .................................................................................17
TOTILT THE LOAD ......................................................................................18
TORELEASE THE PADS FROM THE LOAD .........................................................19
AFTER USING THE LIFTER.............................................................................19
Storing the Lifter ...............................................................................................................20
INSPECTIONS AND TESTS......................................................................21
INSPECTION SCHEDULE ................................................................................21
TESTING ...................................................................................................22
Lifter/Load Compatibility Test...........................................................................................22
Operational Tests ..............................................................................................................23
TABLE OF CONTENTS

P1-DC: #35111 Rev 29.0/11-192
Vacuum Test......................................................................................................................23
Rated Load Test.................................................................................................................24
MAINTENANCE ....................................................................................25
VACUUM PAD MAINTENANCE.......................................................................25
Pad-to-Load Friction Coefficient .......................................................................................25
Pad Inspection ..................................................................................................................25
Pad Cleaning .....................................................................................................................26
BATTERY RECHARGE....................................................................................27
REPLACEMENT PARTS...........................................................................28
LIMITED WARRANTY ............................................................................29
TOOBTAIN REPAIRS OR WARRANTY SERVICE...................................................29
TABLE OF CONTENTS

Product
Description
Designed for use with hoisting equipment, P1-04DC lifters support loads using vacuum and manipulate
loads using manual 180° rotation and manual 90° tilt motions.
Model
Number P110C04DC P1HV1104DC P11104DC
Vacuum Pads:1
1...... Available with other rubber compounds for special purposes (see www.WPG.com).
(4 each, standard rubber)
10" [25 cm] nom. diameter, con-
cave (Model G0750)
10" [25 cm] nom. diameter,
lipped (Model HV11)
11" [28 cm] nom. diameter,
lipped (Model G3370)
Pad Spread
(to outer edges)
49" x 10"
[125 cm x 25 cm]
50" x 11"
[127 cm x 28 cm]
51" x 12"
[130 cm x 30 cm]
Maximum Load
Capacity2
2...... 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 24).
Per-Pad 150 lbs [68 kg] 150 lbs [68 kg] 175 lbs [80 kg]
Overall 600 lbs [270 kg] 600 lbs [270 kg] 700 lbs [320 kg]
Lifter
Weight 90 lbs [41 kg]
Power
System 12 volts DC, 3.5 amps
Battery
Capacity 7 amp-hours
Rotation
Capability Manual, 180°, with latching at each ¼ turn (when required)
Tilt
Capability Manual, 90°, with automatic latching in vertical position
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 intended3
3...... Vacuum pads, filter elements and other wear-out items are excluded.
!!–CE–!! This symbol appears only when a CE Standard is different from other applicable standards. CE requirements are
mandatory in the European Union, but may be optional elsewhere.
ASME Standard
BTH-1 Design Category "B", Service Class "0" (see www.wpg.com for more information)
Rev 29.0/11-19 P1-DC: #351113
SPECIFICATIONS

P1-DC: #35111 Rev 29.0/11-194
SPECIFICATIONS
Note: A standard P11104DC is shown.

Rev 29.0/11-19 P1-DC: #351115
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.

P1-DC: #35111 Rev 29.0/11-196
Features shown here are underlined on their first appearance in each section to follow.
1 LIFT POINT
2 LIFT BAR
3 INSTRUCTIONS CANISTER
4 TILT RELEASE LEVER
5 ROTATION RELEASE LEVER
6 PAD FRAME
8BATTERY TEST BUTTON
9VACUUM GAUGE
10 CONTROLHANDLES
11 AIR FILTER
12 VALVE HANDLE
13 Cover with VACUUM PUMP
7 LOW VACUUM WARNING LIGHT and VACUUM SWITCH
14 LOW VACUUM WARNING BUZZER
(optional)
15 BATTERY GAUGE
16 BATTERY
17 BATTERY CHARGER
18 VACUUM RESERVE TANK (obscured by lift bar)
19 VACUUM PAD
Note: A standard P11104DC is shown here. Although some of the following photos do not
show this specific lifter,they all illustrate how this kind of lifter functions.
OPERATING FEATURES

Rev 29.0/11-19 P1-DC: #351117
1)
2A
Remove all restraints from the vacuum lifter and
save them with the shipping container for future
use.
2) Position the lift point as needed for the lifter's
intended use (fig. 2A): Loosen or remove the bolts
and move the lift point to create the best hang
angle. Then reinstall all hardware and tighten the
bolts securely.
3) Suspend the lifter from appropriate hoisting equipment:
3.1) 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.
3A 3B 3C
3.2)
3D 3E
Make sure
hook has
restraining latch
(circled).
Disengage the tilt
latch and raise the lift
bar (fig. 3A-C).
3.3) Attach the hoisting
hook to the lift point
(fig. 3D). Use rigging
(fig. 3E) as needed to
make sure the hook
does not interfere
with the load.
Only use rigging rated for Maximum Load Capacity
plus Lifter Weight.
ASSEMBLY

P1-DC: #35111 Rev 29.0/11-198
3.4) Use the hoisting equipment to remove the lifter from the shipping container. Avoid
damaging the vacuum pads.
4B4A
4)
4C
4D
Connect the electrical connectors (figs. 4A-B
and figs. 4C-D).
5)
5A
Remove the pad covers (fig. 5A) and save
them for future use.
6) Perform tests as required under “TESTING”on page 22.
ASSEMBLY

Rev 29.0/11-19 P1-DC: #351119
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 a “Lifter/Load Compatibility Test” on page 22.
• 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 25). 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.

P1-DC: #35111 Rev 29.0/11-1910
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

Rev 29.0/11-19 P1-DC: #3511111
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 9). 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.
Performing Inspections and Tests
• Follow the “INSPECTION SCHEDULE”on page 21 and “TESTING”on page 22.
•
Examine air filter regularly
and service when needed.
Service the air filter whenever the bowl contains
liquid or other contaminates, or the element
appears dirty (see “AIR FILTER MAINTENANCE”in
SERVICE MANUAL).
•
1A
If the lifter has a low vacuum warning buzzer (fig. 1A), make sure it is
clearly audible at the maximum distance between the operator and
the lifter, despite any barriers or obstacles.1, 2
Make sure warning buzzer can be heard over noise at operator
position.
1..... Maximum alarm volume is 103 dBA at 2' [60 cm]. If CE Standards apply, consult EN 7731 to make sure the warning buzzer is compliant.
2..... The “Vacuum Test” on page 23 provides a convenient opportunity to check this.

P1-DC: #35111 Rev 29.0/11-1912
Checking the Battery
Always check battery energy before
every lift.
Use the battery gauge to determine whether the battery needs to be charged (see “BAT TERY
RECHARGE”on page 27).1Never use the lifter unless battery energy appears in the green range.
• While the valve handle is in the “attach” position ( / power on), the battery gauge
automatically shows battery energy.2
• While the valve handle is in the
“release” position ( / power off),
use the battery test button (circled)
to check the battery energy.3
1..... If the pump is running or the battery charger is connected to an AC power source, the reading on the battery gauge will not be accurate.
2..... After the vacuum pump stops running, the battery gauge requires a few moments to stabilize before it shows an accurate energy level.
3..... If the lifter has not been used since the battery was charged, the battery gauge may falsely show a high energy level. This “surface charge”
dissipates after the pump runs for about 1 minute, allowing the gauge to show accurate energy.
OPERATION

Rev 29.0/11-19 P1-DC: #3511113
TOATTACH THE PADS TO ALOAD
Make sure the contact surfaces of the load and vacuum pads are clean (see
“Pad Cleaning” on page 26).
Positioning the Lifter on the Load
1) Center the pad frame on the load.1
2) Make sure all vacuum pads will fit on
the load and will be loaded evenly.
Consult the Per-Pad Load
Capacity.
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.
OPERATION

P1-DC: #35111 Rev 29.0/11-1914
Sealing the Pads on the Load
1A
Pull the valve handle outward until it latches (circled
in fig. 1A) in the “attach” position ( ).
Keep valve handle in “attach” position
throughout lift.
The vacuum pump will turn on, the low vacuum
warning light will remain lit and the low vacuum warning buzzer, if present, will sound until the
vacuum pads seal. This is normal.
Press the lifter firmly against the load to help the pads begin to seal.1
Reading the Vacuum Gauge
A vacuum gauge shows the current vacuum level in positive inches of Hg and negative kPa:
•
1B 1C
Green range (>16" Hg [-54 kPa]):
Vacuum level is sufficient to lift the
maximum load weight (fig. 1B).
• Red range (<16" Hg [-54 kPa]):
Vacuum level is not sufficient to lift
the maximum load weight (fig. 1C).
If it takes more than 5 seconds for the
vacuum level to reach 5" Hg [-17 kPa], 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:
• Make sure the vacuum switch is adjusted correctly (see SERVICE MANUAL).
• When necessary, perform the “Vacuum Test” on page 23.
1..... Although a vacuum pad may become distorted during shipping or storage, this condition should correct itself with continued use.
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

Rev 29.0/11-19 P1-DC: #3511115
TOLIFT AND MOVE THE LOAD
Lift bar must be vertical to lift
load.
Interpreting the Warning Light and Optional Warning Buzzer
Never lift load unless warning devices turn off, because
this could result in load release and personal injury.
When the vacuum
lifter is ready to lift
the Maximum Load
Capacity, the vacuum pump and the low vacuum warning light turn off temporarily, to conserve
battery energy.
When air leaks into the vacuum system, the vacuum pump turns on and off (along with the
warning light) as necessary to maintain sufficient vacuum for lifting.
1A
Note: The low vacuum warning buzzer, if present, turns on and off together with the warning
light.
Watching Vacuum Indicators
Watch the low vacuum warning light and the vacuum
gauge (fig. 1A) throughout the entire lift.
Make sure vacuum indicators remain
completely visible.
If the warning light turns on and the vacuum gauge
shows a level less than 16" Hg [-54 kPa]:
1) Keep everyone away from a suspended load until
it can be safely lowered to a stable support.
Stay clear of any suspended load while
indicators warn of low vacuum.
2) Stop using the lifter until the cause of the vacuum loss can be identified: Conduct the
“Pad Inspection” on page 25 and perform the “Vacuum Test” on page 23.
3) Correct any faults before resuming normal operation of the lifter.
OPERATION

P1-DC: #35111 Rev 29.0/11-1916
Controlling the Lifter and Load
1A
When the lifter is ready, use the hoisting equipment to raise
the lifter and load as needed.
Use the control handle (circled in fig. 1A) to keep the lifter
and load in the required position.
Once there is enough clearance, you may move the load as
required.
In Case of a Power Failure
A vacuum reserve tank helps maintain vacuum temporarily in the event of a battery failure or
electrical system failure. Although the lifter is designed to support the load for at least 5
minutes without power, this depends on many factors, including the “LOAD CHARACTERISTICS”on
page 9 and the condition of the vacuum pads (see “VACUUM PAD MAINTENANCE”on page 25).
Stay clear of any suspended
load during power failure.
If a power failure occurs, keep everyone away from a
suspended load until it can be safely lowered to a stable
support. Correct any faults before resuming normal
operation of the lifter.
OPERATION

Rev 29.0/11-19 P1-DC: #3511117
TOROTATE THE LOAD
Make sure load is positioned correctly
on lifter (as previously directed).
Never disengage rotation and tilt latches at the same time,
because this could result in load damage or personal injury.
1)
2A
3A
Make sure the load has
enough clearance to
rotate without contacting
anyone or anything.
2) Use a control handle
(circled in fig. 2A) to keep
the load under control at
all times.
Unbalanced loads may
rotate unexpectedly
when latch is disengaged.
3) Pull the rotation release
lever (fig. 3A) to
disengage the rotation
latch, and rotate the load
as required.
4) To stop rotation, let go of
the lever and guide the
load to the next stop.
Note: Whenever rotation is not
required, keep the rotation latch
engaged, to prevent load
damage or personal injury.
OPERATION

Make sure load is positioned correctly on lifter (as
previously directed).
Never disengage rotation and tilt latches at the same time,
because this could result in load damage or personal injury.
P1-DC: #35111 Rev 29.0/11-1918
TOTILT THE LOAD
1)
3A
2A
Make sure the load has enough
clearance to tilt without
contacting anyone or anything.
2) Use a control handle (circled in
fig. 2A) to keep the load under
control.
Unbalanced loads may tilt
unexpectedly when latch is
disengaged.
3) If the pad frame is latched, pull
the tilt release lever (fig. 3A) to
disengage the tilt latch. Then tilt
the load as required.
4A
Note: See “LOAD CHARACTERISTICS”on
page 9 for information about
allowable overhang.
A load with overhang may force you to
release the control handle as the load
approaches the flat position. In this
case, use a hand cup (circled in fig. 4A)
or other appropriate means to control
the load.
Note: The pad frame automatically
latches when tilted to the vertical
position.
OPERATION