KEEP FOR FUTURE REFERENCE INSTRUCTIONS International Version P.O.
SPECIFICATIONS Description: Designed for use with a crane or other hoisting equipment, P21104-DC lifters employ vacuum to hold a load for lifting, and they provide manual 180° rotation and manual 90° tilt movements for load manipulation.
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).
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 P2110445DC shown with Dual Vacuum System option.
ASSEMBLY 1) Remove the vacuum lifter’s components from the shipping containers, using care to avoid damaging any vacuum pads. Save the containers for use whenever the lifter is transported. 2) Suspend the lift frame 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).
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.
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.
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.
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). Center the lifter’s rotation axis to within 2" [5 cm] of the load center, since off-center loading can cause the load to rotate or tilt unexpectedly (see TO ROTATE THE LOAD EDGEWISE or TO TILT THE LOAD to follow), and it may also damage the lifter.
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 all vacuum gauges, except when used at high elevations (see SPECIFICATIONS: Operating Elevation). If not, make sure all vacuum switches are adjusted correctly (see MAINTENANCE: VACUUM SWITCH ADJUSTMENT).
TO LIFT AND MOVE THE LOAD Positioning the Lift Frame WARNING: Lift frame must be oriented vertically to lift load. Never lift the load from a flat position with the lift frame latched parallel to the load. Always disengage the tilt latch (see TO TILT THE LOAD to follow) and raise the lift frame to a vertical orientation before attempting to lift. Load Capacity and the Warning Lights A lifter's Load Capacity is rated at a vacuum level of 16" Hg [-54 kPa] (see SPECIFICATIONS).
Controlling the Lifter and Load When the 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. Once sufficient clearance is established, the load can be rotated or tilted as desired (see TO ROTATE THE LOAD EDGEWISE or TO TILT THE LOAD to follow).
TO TILT THE LOAD WARNING: Never disengage both the rotation latch and the tilt latches at the same time This lifter is not designed for rotation and tilt functions to be used at the same time. Disengaging the rotation and tilt latches simultaneously could cause uncontrolled and unpredictable load movement, potentially resulting in load damage or injury to the operator. CAUTION: Tilt function only works when pad channels are latched in center position of rotation range.
AFTER USING THE LIFTER Leave both valve handles in the “RELEASE” position (power off). CAUTION: Do not set the lifter against any surfaces which could soil or damage the vacuum pads. The control handles at the end of the pad channels can be used to support an unloaded lifter when not suspended from a crane: Make sure the pad channels are oriented vertically with the handles at the bottom. Use the hoisting equipment to gently lower the lifter until the handles support the entire weight of the lifter.
MAINTENANCE WARNING: Always make sure battery is disconnected before servicing lifter. 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 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.
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.
Identify the input voltage marked on the battery charger, and plug it in to an appropriate power source.10 The power source must be equipped with a ground fault circuit interrupter, in order to reduce the risk of electrical shocks. WARNING: Power source must be equipped with ground fault circuit interrupter. Usually a battery takes no more than 16 hours to charge completely, after which the charger shuts off automatically.
• Contaminates on the pad face or sealing edges: Soil build-up can prevent pads from sealing adequately or reduce the friction coefficient (see discussion preceding). Follow the directions to clean pads as necessary (see discussion to follow). • Filter screen missing from pad face: This screen helps prevent debris from plugging the vacuum hose and the air filter. Replace any missing screen immediately (see REPLACEMENT PARTS LIST).
VACUUM TEST Test the vacuum system for leakage routinely, as directed in the preceding INSPECTION and TESTING SCHEDULES. 1) Clean the face of each vacuum pad as previously directed (see VACUUM PAD MAINTENANCE: Cleaning). 2) Apply the lifter to a clean, smooth, nonporous surface. The surface should be flat or possess no more curvature than the lifter is designed for (if any).
AIR FILTER MAINTENANCE (for brass bowl type filters) Filter Function and Conditions Requiring Service An air filter prevents solid particles from contaminating components in the vacuum system. CAUTION: Examine air filter regularly and empty when necessary. Open each filter regularly to determine whether liquid or other contaminants are trapped inside. Remove any liquid or contaminants found in the filter bowl.
VACUUM PUMP MAINTENANCE − DYNAFLO DV1032102 WARNING: Before proceeding with any maintenance, disconnect power source. If the vacuum pump takes too long to attain full vacuum, it may require maintenance. Replace the diaphragm, gasket/flap valves or (when preferable) the entire head assembly13 (see REPLACEMENT PARTS LIST), as necessary to obtain acceptable pump performance. CAUTION: Do not over-tighten the head screws, because this may damage the threads in the pump body.
VACUUM PUMP MAINTENANCE − THOMAS 107CDC20 WARNING: Before proceeding with any maintenance, disconnect power source. If the vacuum pump (14) takes too long to attain full vacuum, it may require maintenance. Replace the diaphragm, valve flappers or head gasket as necessary to obtain acceptable pump performance (see REPLACEMENT PARTS LIST). Replacing the Diaphragm 1) Remove the four head screws (1) and remove the head (2).
VACUUM SWITCH ADJUSTMENT Vacuum Switch Function15 A vacuum switch controls the low vacuum warning light and the vacuum pump (see OPERATING FEATURES for location of vacuum switch): The valve handle activates the warning light and the pump, which evacuates the vacuum pads.16 After the lifter attains a vacuum level sufficient for lifting the maximum load weight (hereafter, “minimum lifting level”), the vacuum switch automatically turns off the pump and the warning light.
Adjustment Procedure WARNING: Lifting capacity decreases whenever vacuum switch is adjusted to maintain lower vacuum level. 1) Using a 1/4" open-end wrench (as provided), turn the adjustment screw about 1/6th turn at a time (approximately one flat of the screw head). To maintain a lower vacuum level, turn the screw clockwise (when viewing vacuum switch from end with electrical connectors).
REPLACEMENT PARTS LIST Stock No. Description Qty. 93220 Vacuum Pump - Diaphragm Type - 1-SCFM [28 liters/minute] - 12 V DC 93217 Vacuum Control Valve w/Handle and Fittings - for Dual Vacuum System 1 66197BM Dynaflo Pump Gasket & Flap Valves 2 66197AM Dynaflo Pump Diaphragm Kit 2 66197 Dynaflo Pump Head Assembly 2 66195 Thomas Pump Repair Kit 2 66130 Vacuum Pump - Diaphragm Type - 1-SCFM [28 liters/minute] - 12 V DC 65440 Vacuum Hose - 1/4" [6.
LIMITED WARRANTY Powr-Grip products are carefully constructed, thoroughly inspected at various stages of production, and individually tested. They are warranted to be free from defects in workmanship and materials for a period of one year from the date of purchase. If a problem develops during the warranty period, follow the instructions hereafter to obtain warranty service. If inspection shows that the problem is due to defective workmanship or materials, Powr-Grip will repair the product without charge.
LOW VACUUM WARNING BUZZER SPECIFICATIONS Maximum Alarm Volume: Function: 103 dBa at 2' [60 cm] While the lifter is powered up, an audible alarm warns the operator whenever vacuum is not sufficient for lifting the maximum load weight. OPERATION Before Using the Lifter WARNING: Make sure alarm is clearly audible over ambient noise at operator position. The volume of the alarm may be adjusted by rotating the shutter of the low vacuum warning buzzer.
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.
