WPG P110T04DC3 User manual

Rev 4.0/2-21 P1-DC3: #35123AUS1
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).
SINGLE-CHANNEL
LIFTER, DC-VOLTAGE,
WITH INTELLI-GRIP®
TECHNOLOGY
Model numbers: P110T04DC3 (shown),
P110C04DC3, P11104DC3
KEEP FOR FUTURE REFERENCE

P1-DC3: #35123AUS Rev 4.0/2-212

Rev 4.0/2-21 P1-DC3: #35123AUS1
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
Selecting a Screen Language.............................................................................................11
Performing Inspections and Tests .....................................................................................12
Checking the 12-Volt Battery ............................................................................................12
TO ATTACH THE PADS TO A LOAD ..................................................................13
Positioning the Lifter on the Load.....................................................................................13
Powering up the Lifter ......................................................................................................14
Sealing the Pads on the Load............................................................................................14
Reading the Vacuum Gauges ............................................................................................14
TO LIFT AND MOVE THE LOAD .....................................................................16
Interpreting the Lift Light..................................................................................................16
Watching Vacuum Indicators ............................................................................................16
Controlling the Lifter and Load .........................................................................................17
In Case of a Power Failure.................................................................................................17
TO ROTATE THE LOAD .................................................................................18
TO TILT THE LOAD ......................................................................................19
TO RELEASE THE PADS FROM THE LOAD .........................................................20
AFTER USING THE LIFTER.............................................................................21
Transporting the Lifter ......................................................................................................21
Storing the Lifter ...............................................................................................................22
INSPECTIONS AND TESTS......................................................................23
INSPECTION SCHEDULE ................................................................................23
TABLE OF CONTENTS

P1-DC3: #35123AUS Rev 4.0/2-212
TESTING ...................................................................................................24
Lifter/Load Compatibility Test...........................................................................................24
Operational Tests ..............................................................................................................25
Vacuum Test......................................................................................................................25
Rated Load Test.................................................................................................................26
MAINTENANCE ....................................................................................27
VACUUM PAD MAINTENANCE.......................................................................27
Pad-to-Load Friction Coefficient .......................................................................................27
Pad Inspection ..................................................................................................................27
Pad Cleaning .....................................................................................................................28
TO REPLACE SEALING RING IN VPFS10T PADS ...............................................29
12-VOLT BATTERY RECHARGE.......................................................................30
NOTIFICATION BUZZER BATTERY REPLACEMENT ...............................................31
INTELLI-GRIP® DIAGNOSTIC CODES ...............................................................32
REPLACEMENT PARTS...........................................................................36
LIMITED WARRANTY ............................................................................37
TO OBTAIN REPAIRS OR WARRANTY SERVICE...................................................37
TABLE OF CONTENTS

Product
Description
Designed for use with hoisting equipment, P1-04DC3 lifters support loads using vacuum and manipulate
loads using 180° rotation and manual 90° tilt motions.
Model Number P110C04DC3 P110T04DC3 P11104DC3
Vacuum Pads1
1...... Available with other rubber compounds for special purposes (see www.wpg.com).
(4 each, standard rubber)
10" [25 cm] nom. diameter,
concave (Model G0750)
10" [25 cm] nom. diameter,
with replaceable ring2
2...... Standard with replaceable sealing ring for rough or textured surfaces (see “REPLACEMENT PARTS”).
(Model
VPFS10T)
11" [28 cm] nom. diameter,
lipped (Model G3370)
Pad Spread
(to outer edges)
49" x 10"
[125 cm x 25 cm]
50¾" x 11¾"
[129 cm x 30 cm]
51" x 12"
[130 cm x 30 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”).
270 kg 270 kg 320 kg
Lifter
Weight 44 kg
Power System 12 volts DC, 5.5 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
Temperature 32° — 104° F [0° to 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

P1-DC3: #35123AUS Rev 4.0/2-214
SPECIFICATIONS
Note: A standard P11104DC3 is shown.

Rev 4.0/2-21 P1-DC3: #35123AUS5
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-DC3: #35123AUS Rev 4.0/2-216
Features shown here are underlined on their first appearance in each section following.
1 LIFT POINT 2 LIFT BAR 3 INSTRUCTIONS CANISTER
4 TILT RELEASE LEVER 5 ROTATION RELEASE LEVER 6 PAD FRAME
7 Cover for VACUUM PUMP, AIR FILTERS
and VACUUM SENSORS 8 CONTROL HANDLE 9 INTELLI-GRIP® CONTROL UNIT
10 BATTERY 11 BATTERY CHARGER 12 VACUUM RESERVE TANK
13 VACUUM PAD 14 Windows for AIR FILTERS 15 VACUUM GAUGES
16 NOTIFICATION BUZZER 17 POWER BUTTON 18 “RELEASE” BUTTON
19 “ATTACH” BUTTON 20 “FUNCTION” BUTTON 21 LCD SCREEN w/ BATTERY GAUGE
22 WSTROBE LIGHT 23 VACUUM LIFT LIGHT
Note: A standard P110T04DC3 is shown. Although some of the following photos do not show
this specific lifter, they all illustrate how this kind of lifter functions.
For information about specific parts, see “REPLACEMENT PARTS” and/or any separate
instructions for Product Options.
OPERATING FEATURES

Rev 4.0/2-21 P1-DC3: #35123AUS7
1) Remove all shipping materials and save them with the shipping container for future use.
2)
2A
Adjust the lift point to optimize the lifter's
hang angle:
2.1) Remove the retaining bolt and loosen
the pivot bolt (fig. 2A).
2.2) Move the lift point to the appropriate
position.1
2.3) Reinstall the retaining bolt and tighten
both 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) Disengage the tilt latch and raise the lift bar (fig. 3A-C).
1..... Moving the lift point forward (away from operator) helps keep the hang angle vertical while the lifter is loaded; moving the lift point rearward
(towards operator) helps keep the hang angle vertical while the lifter is unloaded.
ASSEMBLY

P1-DC3: #35123AUS Rev 4.0/2-218
3.3)
3D 3E
Make sure
hook has
restraining latch
(circled).
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.
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).
If the lifter has a
notification buzzer, install
the 9-volt battery as directed in “NOTIFICATION BUZZER BATTERY REPLACEMENT”.
5)
5A
Remove the pad covers (fig. 5A) and save them for future use.
6) Perform tests as required under “TESTING”.
ASSEMBLY

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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, 2 To determine whether the load is too porous or
rough, perform the “Lifter/Load Compatibility Test”.
• 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”). 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”).
• 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 pads 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-DC3: #35123AUS Rev 4.0/2-2110
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 other unsuitable conditions.
DISPOSAL OF THE LIFTER
After the Service Life of the vacuum lifter has ended (see “SPECIFICATIONS”), 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

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OPERATION
BEFORE USING THE LIFTER
Determine whether the vacuum lifter is capable of each intended task (see “SPECIFICATIONS”
and “INTENDED USE”). 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.

Always check battery
energy before every lift.
P1-DC3: #35123AUS Rev 4.0/2-2112
Performing Inspections and Tests
• Follow the “INSPECTION SCHEDULE” and “TESTING”.
•
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
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”).
• 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”). 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” 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

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TOATTACH THE PADS TO ALOAD
Make sure the contact surfaces of the load and vacuum pads are clean (see
“Pad Cleaning”).
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.
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-DC3: #35123AUS Rev 4.0/2-2114
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”).
Keep “attach” function
activated throughout lift.
Sealing the Pads on the Load
1B
Press the lifter’s “attach” button ( — fig. 1B).
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”). 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

Rev 4.0/2-21 P1-DC3: #35123AUS15
•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.2 If it does not, perform the
“Vacuum Test”.
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”), it may not be able to maintain sufficient vacuum for lifting.
Contact WPG for more information.
OPERATION
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:

P1-DC3: #35123AUS Rev 4.0/2-2116
TOLIFT AND MOVE THE LOAD
Lift bar must be vertical to lift
load.
Interpreting the Lift Light
Never lift load unless lift
light is illuminated,
because premature lifting could
result in load release and
personal injury.
When the vacuum lifter is ready to lift
the Maximum Load Capacity, the
vacuum lift light turns on automatically and
the vacuum pump turns off temporarily, to
conserve battery energy.
Watching Vacuum Indicators
1A
Watch the vacuum lift light and both vacuum gauges
throughout the entire lift (fig. 1A).
Make sure all vacuum indicators remain
completely visible.
The vacuum pump turns on and off to overcome any
leakage. However, if the leak rate is greater than
normal, the notification buzzer chirps and the LCD
screen displays the message “Vacuum decrease on
circuit #”, along with a diagnostic code (see “INTELLI-
GRIP® DIAGNOSTIC CODES”).1 Such leaks can cause the
battery to be discharged more quickly.
If the vacuum pump is unable to overcome leakage, the notification buzzer sounds
continuously, the lift light turns off, and the LCD screen displays the message “INSUFFICIENT
VACUUM!”, along with a diagnostic code (see “INTELLI-GRIP® DIAGNOSTIC CODES”). If this happens:
1)
Stay clear of any suspended load while
indicators warn of low vacuum.
Keep everyone away from a
suspended load until it can be safely
lowered to a stable support.
1..... Automatic leak detection is not a substitute for performing the “Vacuum Test”, required by the “INSPECTION SCHEDULE” and “TESTING”. Sensitivity
of leak detection can be adjusted (see “INTELLI-GRIP® OPERATOR MENUS” in SERVICE MANUAL).
OPERATION

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2) Stop using the lifter until the cause of the vacuum loss can be identified: Conduct the
“Pad Inspection” and perform the “Vacuum Test”.
3) Correct any faults before resuming normal operation of the lifter.
Controlling the Lifter and Load
1A
When the lifter is ready, use the hoisting
equipment to raise the lifter and load as
needed.
Use a 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
In the event of a battery failure or electrical system failure, the notification buzzer will sound
continuously.
Although the vacuum reserve tanks are designed to support the load for at least 5 minutes
without power, this depends on many factors, including the “LOAD CHARACTERISTICS” and the
condition of vacuum pads (see “VACUUM PAD MAINTENANCE”).
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 lowered safely to a stable
support. Correct any faults before resuming normal
operation of the lifter.
OPERATION

P1-DC3: #35123AUS Rev 4.0/2-2118
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