WPG VL411LDC User manual

KEEP FOR FUTURE REFERENCE
INSTRUCTIONS
International Version
MODEL NUMBER: VL411LDC
SERIAL NUMBER: ___________
(please see serial label and record number here)
VERTICAL LIFTER 700
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 19.3/9-18 1 VL411LDC: #35162
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 APPLY THE PADS TO A LOAD ........................................................................................ 10
Positioning the Lifter on the Load ...............................................................................................................10
Sealing the Pads against the Load...............................................................................................................10
Reading the Vacuum Gauge .......................................................................................................................11
Vacuum Level on Optimal Surfaces .............................................................................................................11
Vacuum Level on Other Surfaces ................................................................................................................11
TO LIFT AND MOVE THE LOAD........................................................................................... 12
Load Capacity and the Warning Light ..........................................................................................................12
Monitoring Vacuum Indicators ....................................................................................................................12
Monitoring the Low Vacuum Warning Buzzer (if applicable) ..........................................................................12
Controlling the Lifter and Load....................................................................................................................13
In Case of Power Failure ............................................................................................................................13
TO RELEASE THE PADS FROM THE LOAD.............................................................................. 13
AFTER USING THE LIFTER ................................................................................................ 14
Storing the Lifter........................................................................................................................................14
MAINTENANCE.............................................................................................................. 15
INSPECTION SCHEDULE ................................................................................................... 15
Every-Lift Inspection ..................................................................................................................................15
Frequent Inspection ...................................................................................................................................15
Periodic Inspection ....................................................................................................................................15
Infrequent Use ..........................................................................................................................................16
TESTING SCHEDULE ........................................................................................................ 16
Operational Tests.......................................................................................................................................16
Load Test ..................................................................................................................................................16
MAINTENANCE SCHEDULE ................................................................................................ 17
BATTERY TEST ............................................................................................................... 17

Rev 19.3/9-18 2 VL411LDC: #35162
BATTERY RECHARGE ....................................................................................................... 18
VACUUM PAD MAINTENANCE............................................................................................ 18
Friction Coefficient .....................................................................................................................................18
Inspection .................................................................................................................................................19
Cleaning ....................................................................................................................................................19
VACUUM TEST ............................................................................................................... 20
AIR FILTER MAINTENANCE −SMALL ................................................................................. 21
Filter Function and Conditions Requiring Service ..........................................................................................21
Filter Service Procedures ............................................................................................................................21
VACUUM PUMP MAINTENANCE −DYNAFLO DV1032102..................................................... 22
Replacing the Diaphragm ...........................................................................................................................22
Replacing the Head Assembly .....................................................................................................................22
VACUUM PUMP MAINTENANCE −THOMAS 107CDC20 ........................................................ 23
Replacing the Diaphragm ...........................................................................................................................23
Replacing the Intake Valve Flapper .............................................................................................................23
Replacing the Exhaust Valve Flapper and Head Gasket .................................................................................23
VACUUM SWITCH ADJUSTMENT ........................................................................................ 24
Vacuum Switch Function ............................................................................................................................24
Conditions Requiring Readjustment .............................................................................................................24
Adjustment Procedure ................................................................................................................................25
REPLACEMENT PARTS LIST .......................................................................................... 26
LIMITED WARRANTY.................................................................................................... 27

Rev 19.3/9-18 3 VL411LDC: #35162
SPECIFICATIONS
Model Number:
Description:
Power Source:
Battery Capacity:
Vacuum Pads:
Pad Spread:
Load Capacity:
Per-Pad:
Maximum:
Lifter Weight:
Vacuum Pump:
Vacuum Reserve Tank:
Vacuum Gauge:
VL411LDC
Designed for use with a crane or other hoisting equipment, the VL411LDC
lifter employs vacuum to hold a load for lifting in the upright orientation.
12 volts DC, 10 amps (with Thomas pump) or 3.5 amps (with Dynaflo pump)
7 amp-hours
Four 11" [28 cm] nominal diameter, lipped (Model G3370), standard rubber,
spring-mounted (¼" [7 mm] travel), with #60 filter screen
23½" x 58" [597 mm x 1474 mm] to outer edges
(rated at 16" Hg [-54 kPa] on clean, smooth, nonporous flat surfaces1)
175 lbs [80 kg]
700 lbs [320 kg]
65 lbs [30kg]
Diaphragm type, 1 SCFM [28 liters/minute] nominal airflow
Vacuum reservoir helps prevent immediate vacuum loss in case of power
failure and extends battery life by reducing pump cycles required to maintain
vacuum.
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 pump to re-engage.
Low Vacuum Warning Buzzer (if applicable): Maximum Alarm Volume = 103 dBA at 2' [60 cm].
While lifter is powered up, audible alarm warns the operator whenever
vacuum is not sufficient for lifting the maximum load weight.
Options:
See separate instructions about optional features.
Operating Elevation:
Maximum = 6,000' [1,828 m]
Operating Temperatures:
32° to 104° F [0° to 40° C]
Service Life:
This lifter is designed to have a service life of 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.

Rev 19.3/9-18 4 VL411LDC: #35162
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 Maximum 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
attaching the pads (see MAINTENANCE: VACUUM PAD MAINTENANCE).
Never exceed the Maximum Load Capacity or attempt to lift loads that 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
ATTACH 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 could compromise its safety. Wood’s Powr-
Grip cannot be responsible for the safety of a lifter that has been modified by others. For
consultation, contact Wood's Powr-Grip (see LIMITED WARRANTY).

Rev 19.3/9-18 5 VL411LDC: #35162
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 VL411LDC shown.
1 LIFT SLING
6 Enclosure with VACUUM PUMP,
11 CONTROL HANDLES
2 LIFT SPOOL
VACUUM SWITCH and LOW VACUUM
12 VACUUM GAUGE
3 PAD FRAME
WARNING BUZZER (if applicable)
13 VACUUM RESERVE TANK
4 VACUUM PAD
7 VALVE HANDLE
14 BATTERY CHARGER
5 LOW VACUUM WARNING LIGHT
8 BATTERY TEST BUTTON
15 BATTERY
9 BATTERY GAUGE
10 AIR FILTER

Rev 19.3/9-18 6 VL411LDC: #35162
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 (e.g., relevant OSHA
standards in the USA).
Tilt the lifter upwards until the pad frame is in a vertical orientation, resting on the integrated
parking feet. Make sure the lift slings are securely attached to the lifter. Then attach the
free eye of each lift sling onto the hoisting equipment hook.
WARNING: Hoisting equipment hook must be fitted with restraining latch to
prevent lift slings from slipping off under any circumstances.
Note: It may be desirable to use a large clevis to connect the lift slings to the hoisting
equipment hook. This makes suspending the lifter easier, since only the clevis must be
attached to or removed from the hoisting equipment hook.
WARNING: Clevis and clevis pin must be rated to carry maximum load weight
plus lifter weight.
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. The lifter is now operational.
4) Perform Operational and Load Tests for the lifter as directed in MAINTENANCE: TESTING
SCHEDULE.

Rev 19.3/9-18 7 VL411LDC: #35162
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.
2
To determine whether the load is too porous or rough, perform the
test under Vacuum Level on Other Surfaces (see OPERATION: TO ATTACH THE PADS TO A LOAD).
• The load's contact surface must be suitable for obtaining a friction coefficient of 1 with the
lifter's vacuum pads (see MAINTENANCE: VACUUM PAD MAINTENANCE: Friction Coefficient), as
verified by a friction test, or capacity should be derated appropriately. If necessary, contact
Wood's Powr-Grip for help in conducting a friction test.
• 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 that 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.
• 1" [2.5 cm] is the maximum allowable thickness of loads at the maximum weight (see
SPECIFICATIONS: Maximum Load Capacity). However, allowable thickness increases as load
weight decreases. If necessary, contact Wood’s Powr-Grip for help in determining the
maximum thickness permitted when handling any specific load.
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.
2
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 Maximum Load Capacity for a particular curved load.

Rev 19.3/9-18 8 VL411LDC: #35162
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 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:
Moisture on contact surfaces of the load or vacuum pads diminishes the lifter’s slip resistance,
thereby reducing the lifting capacity (see MAINTENANCE: VACUUM PAD MAINTENANCE: Friction
Coefficient).
WARNING: Moisture reduces slip resistance of vacuum pads.
Although the lifter's exterior surfaces can tolerate some exposure to water vapor, they are not
designed to be watertight. 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 19.3/9-18 9 VL411LDC: #35162
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).
If the lifter is equipped with a low vacuum warning buzzer, the volume of the alarm may be
adjusted by rotating the shutter of the warning buzzer. Make sure the alarm is loud enough to
be heard over any other noise that may be present while the lifter is in use. In addition, the
alarm must be clearly audible at the maximum distance the operator may be from the lifter, as
well as through any barriers or obstructions between the operator and the lifter.
WARNING: Make sure alarm is clearly audible over ambient noise at operator
position.

Rev 19.3/9-18 10 VL411LDC: #35162
In order to be considered clearly audible, the alarm volume must exceed ambient noise by
at least 15 dBA at the operator position.
3
Since the Maximum Alarm Volume is 103 dBA,
ambient noise must not exceed 88 dBA under any circumstances. Furthermore, if ambient noise
measures 88 dBA, the alarm volume must be set to maximum and the operator must remain
within 2 ft [60 cm] of the warning buzzer, in order for it to be effective.
TO APPLY THE PADS TO A LOAD
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 prevent the pads from sealing against the load (see MAINTENANCE:
VACUUM PAD MAINTENANCE).
The lifter must be attached only to vertically oriented loads. Center the pad frame from left to
right on the load, and position the uppermost pads near the top edge. This position maximizes
stability while lifting the load. 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 apply the lifter to the load so that
all pads are touching the contact surface.
Sealing the Pads against the Load
Firm pressure at the center of the lifter
helps the vacuum pads begin to seal
against the load. Pull the valve handle
outward until it latches securely in the
“apply”( ) position (power on), as
shown. This energizes the vacuum
pump, causing air to be drawn at the
pads immediately. The red low
vacuum warning light also turns on and remains illuminated until the lifter attains sufficient
vacuum to lift the maximum load weight (see TO LIFT AND MOVE THE LOAD: Load Capacity and the
Warning Light to follow). The valve handle must remain in the “apply”( ) position throughout
the entire lift.
WARNING: Keep valve handle latched securely in “APPLY” position throughout
lift.
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.
3
Consult CE Standard EN 457 for alternative ways to determine whether the alarm is clearly audible to operators.
TO APPLY

Rev 19.3/9-18 11 VL411LDC: #35162
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.
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.
4
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 pump stops running, disconnect the electrical connector uniting the battery
with the vacuum generating system.
Note: After the test is completed, move the valve handle to the “release”( ) position
(power off ) before reconnecting the battery.
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.
5
4
Contaminated loads can also cause the vacuum pump to run frequently or continuously. Since excessive pumping quickly
reduces battery energy, the operator should clean the load when possible, to minimize pumping.
5
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 19.3/9-18 12 VL411LDC: #35162
TO LIFT AND MOVE THE LOAD
WARNING: Never attempt to lift load when lifter is in
horizontal orientation.
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 pump turns 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.
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
pump turns 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
pump is running, to signal the reduction in vacuum to the operator.
If the pump 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 pump runs
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.
Monitoring the Low Vacuum Warning Buzzer (if applicable)
If the lifter is equipped with a low vacuum warning buzzer, an alarm sounds until the lifter attains
sufficient vacuum to lift the maximum load weight (see SPECIFICATIONS: Load Capacity). After
the lifter has attained this vacuum level, the alarm stops sounding, to indicate that the lifter is
ready to lift the load.
WARNING: Never attempt to lift load while alarm is sounding.
Do not attempt to lift the load while the alarm is sounding; such an attempt could result in a load
release and possible injury to the operator.

Rev 19.3/9-18 13 VL411LDC: #35162
If the vacuum system experiences leakage while the lifter is attached to the load, the vacuum
pump turns on automatically, as required to maintain sufficient vacuum. The alarm also sounds
while the pump is running, to signal the reduction in vacuum to the operator. If the alarm
sounds while you are lifting a load, make sure the vacuum gauge shows a vacuum level of 16"
Hg [-54 kPa] or higher. If not, immediately 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 alarm is sounding.
Discontinue lifter use until the cause of the vacuum loss can be determined. Using the lifter on
contaminated, rough or porous surfaces may result in a vacuum loss, due to leakage between
the vacuum pads and the load. Since the alarm may sound in such circumstances, consult the
section TO APPLY THE PADS TO A LOAD: Vacuum Level on Other Surfaces to determine whether the
lifter can be used to lift the load. If the vacuum loss is due to any other cause, 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 handles to keep the lifter and load in the desired
orientation while they are suspended from the crane.
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.
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, pinch the valve release lever
against the valve handle, to unlatch the
handle. Then push the valve handle
inward to the “release”( ) position
(power off), as shown. Do not attempt to
move the lifter until the vacuum pads
disengage completely from the load.
TO RELEASE

Rev 19.3/9-18 14 VL411LDC: #35162
AFTER USING THE LIFTER
Leave the valve handle in the “release” ( ) position (power off).
CAUTION: Do not set the lifter against any surfaces which could soil or damage the
vacuum pads.
Parking feet are built into the bottom of the pad frame to support an unloaded lifter when not
suspended from a crane: Use the hoisting equipment to gently lower the lifter until the parking
feet support its entire weight. Make sure the lifter leans securely against an appropriate
support; then detach the hoisting equipment hook from the lift slings.
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. Since the lifter’s intended use does not
include tilting, be careful to protect the vacuum pads and support the lifter while tilting it to the
horizontal position.
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.

Rev 19.3/9-18 16 VL411LDC: #35162
• 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 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.
6
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.
7
2) Apply the vacuum pads to the load as previously directed.
3) After the vacuum pump stops running, disconnect the electrical connector uniting the battery
with the vacuum generating system.
Note: After the test is completed, move the valve handle to the “release” ( ) position
(power off ) before reconnecting the battery.
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. Since the low vacuum warning buzzer is controlled by a vacuum
switch, consult the VACUUM SWITCH ADJUSTMENT discussion for inspection, testing and adjustment
procedures.
6
ASME Standard B30.20 requires the lifter to be tested to 125% of its Load Capacity.
7
Flat Lifters are exempt from this requirement.

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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.
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).
8
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.
While the valve handle is in the “apply”( ) position (power on), the battery gauge
automatically monitors battery energy. 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.
While the valve handle is in the “release”( ) position (power off), 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.
8
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.

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BATTERY RECHARGE
Charge the battery whenever the battery gauge indicates diminished energy (see BATTERY TEST
preceding). CAUTION: Make sure valve handle is in “release” position (power OFF).
Identify the input voltage marked on the battery charger, and plug it in to an appropriate power
source.
9
A ground fault circuit interrupter is necessary to reduce the risk of electrical shocks.
WARNING: Make sure power source is equipped with ground fault circuit
interrupter.
The power lamp (Ф) turns on, to indicate
that the charger is functioning. To
determine charging status, consult the six-
stage display on the charger. The battery is
ready for use at stage 3 and fully charged at
stage 5.
Normally, the battery should take no more
than 8 hours to charge completely.
10
If not,
check for the following conditions and
correct any deficiencies as directed:
• Power lamp (Ф) flashes: Charger is not connected to battery; reconnect charger (see
ASSEMBLY).
• Error lamp (!) turns on: Battery leads connected to the wrong poles; reverse battery leads.
• Error lamp (!) turns on and charging stops at stage 1 or stage 4: Battery is no longer
functioning; replace battery (see REPLACEMENT PARTS LIST).
Be sure to unplug the charger and test the battery energy again before operating the lifter (see
BATTERY TEST preceding).
VACUUM PAD MAINTENANCE
Friction Coefficient
The friction coefficient represents the lifter's ability to resist load slippage when the load is
oriented in any position except horizontal. If the contact surfaces of either the load or the
vacuum pads are not clean, dry and in good condition, slippage is more likely to occur.
The Load Capacity of most Powr-Grip lifters is based on a friction coefficient of 1 (only Flat Lifters
are exempt from this requirement). However, a vacuum pad's ability to maintain this friction
coefficient is reduced by factors such as contamination, wear, age and exposure to sunlight, as
well as the condition of the load's contact surface (see INTENDED USE: LOAD CHARACTERISTICS).
Pads that have surface contamination must be thoroughly cleaned (see Cleaning discussion to
follow). Over time, the rubber in a pad may experience hardening or leaching of chemicals,
9
Any external power supply must conform to all applicable local codes. CAUTION: Do not operate the lifter while the
charger is connected to an AC power source , since this could result in permanent damage to the charger.
10
The charger is designed to automatically sense the energy level of the battery and reduce the charging rate when the battery
is fully charged. Accordingly, the charger does not need to be unplugged until the lifter is going to be used again.