KEEP FOR FUTURE REFERENCE 1 SCFM NOMINAL AIRFLOW SINGLE VACUUM SYSTEM DC-VOLTAGE POWER SYSTEM WITH MANUAL VALVE

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1 KEEP FOR FUTURE REFERENCE SERVICE MANUAL P.O. Box West Main Laurel, MT USA phone phone fax STOCK NUMBER SCFM NOMINAL AIRFLOW SINGLE VACUUM SYSTEM DC-VOLTAGE POWER SYSTEM WITH MANUAL VALVE READ ALL INSTRUCTIONS AND SAFETY RULES BEFORE SERVICING THIS LIFTER DESIGNED FOR THE TECHNICAL SERVICE PROFESSIONAL

3 TABLE OF CONTENTS BEFORE SERVICING LIFTER... 2 SERVICE SCHEDULE... 2 SERVICE FEATURES... 3 FILTER AND PUMP SERVICE... 4 AIR FILTER MAINTENANCE 1 OZ BOWL SIZE... 4 Conditions Requiring Service... 4 Filter Service Procedure... 4 VACUUM PUMP MAINTENANCE DYNAFLO DV Replacing the Diaphragm... 6 Replacing the Head Assembly... 6 VACUUM PUMP MAINTENANCE THOMAS 107CDC Replacing the Diaphragm... 7 Replacing the Intake Valve Flapper... 7 Replacing the Exhaust Valve Flapper and Head Gasket... 7 VACUUM SWITCH ADJUSTMENT... 8 Vacuum Switch Function... 8 Conditions Requiring Readjustment... 8 Adjustment Procedure... 9 REPLACEMENT PARTS LIST LIMITED WARRANTY Rev 1.0/ DC SVS MV: #36110

4 BEFORE SERVICING LIFTER Make sure battery is disconnected before servicing lifter. Service personnel must read and understand the OPERATING INSTRUCTIONS before attempting to service the vacuum lifter. Many of the following discussions assume knowledge of the OPERATING INSTRUCTIONS or access to them. Note: Wiring and/or hose routing diagrams are provided in the final section of this SERVICE MANUAL for reference when servicing the lifter or trouble-shooting a deficiency. If necessary, consult the OPERATING INSTRUCTIONS to determine which diagrams are applicable to your specific lifter model and any associated options. SERVICE SCHEDULE Service must be performed whenever a deficiency is indicated by routine inspections or tests. Follow the Inspection Schedule and Testing Schedule as directed in the MAINTENANCE section of the OPERATING INSTRUCTIONS. Any service warranted must be performed before resuming normal operation of the lifter. Rev 1.0/ DC SVS MV: #36110

(optional) 3 INSTRUCTIONS CANISTER 10 CONTROL HANDLES 15 BATTERY GAUGE 4 TILT RELEASE LEVER 11 AIR FILTER 16 BATTERY 5 ROTATION RELEASE LEVER 12

5 SERVICE FEATURES Note: Components shown here are underlined on their first appearance in each section to follow. P11104DC shown (component locations vary among models) 1 LIFT SPOOL 8 BATTERY TEST BUTTON 14 LOW VACUUM WARNING BUZZER 2 LIFT BAR 9 VACUUM GAUGE (optional) 3 INSTRUCTIONS CANISTER 10 CONTROL HANDLES 15 BATTERY GAUGE 4 TILT RELEASE LEVER 11 AIR FILTER 16 BATTERY 5 ROTATION RELEASE LEVER 12 VALVE HANDLE 17 BATTERY CHARGER 6 PAD CHANNEL 13 Enclosure with VACUUM PUMP 18 VACUUM RESERVE TANK 7 LOW VACUUM WARNING LIGHT and VACUUM SWITCH 19 VACUUM PAD Rev 1.0/ DC SVS MV: #36110

FILTER AND PUMP SERVICE AIR FILTER MAINTENANCE 1 OZ BOWL SIZE Conditions Requiring Service Inspect each air

Immediately remove liquid found in the filter bowl, to prevent contact with the filter element (see Filter

A Replace the element if it has an overall dirty appearance, or if there is a noticeable increase in the

Filter Service Procedure 1) Unscrew the bowl (C) from the body (B) of the air filter.

C B 2) Determine whether the filter element (D) needs to be replaced (see Conditions Requiring Service

6 FILTER AND PUMP SERVICE AIR FILTER MAINTENANCE 1 OZ BOWL SIZE Conditions Requiring Service Inspect each air filter regularly, and service when necessary. Immediately remove liquid found in the filter bowl, to prevent contact with the filter element (see Filter Service Procedure below). Never use bowl drain (A) to remove liquid, because this could cause air leak. A Replace the element if it has an overall dirty appearance, or if there is a noticeable increase in the time required to attain full vacuum (see REPLACEMENT PARTS LIST). Filter Service Procedure 1) Unscrew the bowl (C) from the body (B) of the air filter. Note: Hold the body while turning the bowl, to protect vacuum line fittings from damage. C B 2) Determine whether the filter element (D) needs to be replaced (see Conditions Requiring Service above). If so, proceed to step 3. If not, remove any liquid or contaminates from the bowl; clean the old bowl seal with mild soap and water; and skip to step 6. D 3) Carefully unscrew the element holder (E) and remove all internal parts. E Rev 1.0/ DC SVS MV: #36110

4) Identify the parts in the filter element kit, including the element (D), element holder (E), deflector (F), element gaskets (G), bowl seal (H) and lubricant (I).

Then screw the assembly back into the filter body. Note: Tighten gently finger tight. G F D G E 6) Clean the bowl, using mild soap and water only. Note: Do not use any other cleaning agents.

Note: Do not use synthetic oils, such as esters, and do not use silicones. Then place the bowl seal around the rim of the bowl. 8) Screw the bowl back into the body. Hand-tighten only.

7 4) Identify the parts in the filter element kit, including the element (D), element holder (E), deflector (F), element gaskets (G), bowl seal (H) and lubricant (I). H E I Then dispose of the corresponding old parts. G F D FILTER ELEMENT KIT 5) Place the new element gaskets (G), element (D), and deflector (F) on the element holder (E) as shown. Then screw the assembly back into the filter body. Note: Tighten gently finger tight. G F D G E 6) Clean the bowl, using mild soap and water only. Note: Do not use any other cleaning agents. 7) Lubricate the new or cleaned bowl seal (H), using a mineral-based oil or grease, such as that provided in the filter element kit. Note: Do not use synthetic oils, such as esters, and do not use silicones. Then place the bowl seal around the rim of the bowl. 8) Screw the bowl back into the body. Hand-tighten only. Note: Do not contaminate the filter element with lubricant from the bowl seal. 9) Test the vacuum system to be certain the air filter does not leak (see MAINTENANCE: VACUUM TEST section of lifter's OPERATING INSTRUCTIONS). Note: Repeat this procedure for any other filter of the same type. Rev 1.0/ DC SVS MV: #36110

8 VACUUM PUMP MAINTENANCE DYNAFLO DV 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 or the head assembly (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. Replacing the Diaphragm 1) Remove the four head screws (1) and lock washers (2), and remove the head assembly (3). 2) Remove the diaphragm retaining screw (4), diaphragm (5), rubber O-ring (6) and flat washer (7). Be sure to note the diaphragm orientation for reassembly. 3) Replace the flat washer, rubber O-ring, diaphragm and diaphragm retaining screw. 4) Reverse the steps above for reassembly, as shown. Replacing the Head Assembly 1 1) Remove the hose fittings from the head assembly, and carefully clean the threads. Be sure to note the fitting locations for reassembly. 2) Remove the four head screws (1), lock washers (2) and head assembly (3). 3) Replace the head assembly, and reverse the steps above for reassembly, as shown. 4) Reinstall the hose fittings, using an appropriate thread sealant. 1 HEAD SCREW 5 DIAPHRAGM 2 LOCK WASHER 6 RUBBER O-RING 3 HEAD ASSEMBLY 7 FLAT WASHER 4 DIAPHRAGM RETAINING SCREW 1 Caution: Depending on the product, the head assembly (3) may be rotated to an orientation different from the one shown. When removing the head assembly, always take note of its orientation and install it the same way during reassembly. Rev 1.0/ DC SVS MV: #36110

9 VACUUM PUMP MAINTENANCE THOMAS 107CDC20 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). 2) Remove the four diaphragm hold-down screws (10) and the diaphragm hold-down plate (12). 3) Replace the diaphragm (13) and reverse the steps above for reassembly. Replacing the Intake Valve Flapper 1) Remove the four head screws (1) and remove the head (2). 2) Remove the intake valve flapper screw (8) and the intake valve keeper (7). 3) Replace the intake valve flapper (11) and reverse the steps above for reassembly. Replacing the Exhaust Valve Flapper and Head Gasket 1) Remove the four head screws (1) and remove the head (2). 2) Invert the head and remove the four valve plate screws (9). 3) Lift out the valve plate (6) to access the exhaust valve flapper and head gasket. 2 4) Remove the exhaust valve flapper screw (3) and the exhaust valve keeper (4), and replace the exhaust valve flapper (5). 5) Replace the head gasket (15) and reverse the steps above for reassembly. 1 HEAD SCREWS 6 VALVE PLATE 11 INTAKE VALVE FLAPPER 2 HEAD 7 INTAKE VALVE KEEPER 12 DIAPHRAGM HOLD-DOWN PLATE 3 EXHAUST VALVE FLAPPER SCREW 8 INTAKE VALVE FLAPPER SCREW 13 DIAPHRAGM 4 EXHAUST VALVE KEEPER 9 VALVE PLATE SCREWS 14 VACUUM PUMP 5 EXHAUST VALVE FLAPPER 10 DIAPHRAGM HOLD-DOWN SCREWS 15 HEAD GASKET 2 CAUTION: Depending on the product, the vacuum system may require the valve plate (6) to be rotated to an orientation different from the one shown. When removing the valve plate, always take note of its orientation in the pump head (2), and install the valve plate the same way during reassembly. Rev 1.0/ DC SVS MV: #36110

10 VACUUM SWITCH ADJUSTMENT Vacuum Switch Function 3 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. 4 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. 5 In order to maintain sufficient vacuum, the vacuum switch automatically turns on the pump and warning light again before vacuum decreases to a level that is lower than the minimum lifting level. Conditions Requiring Readjustment At the factory, the vacuum switch is set to maintain the minimum vacuum level specified for the Load Capacity (see SPECIFICATIONS). However, shipping vibrations or shocks, normal wear, or other conditions may adversely affect this adjustment. Periodically verify the switch adjustment by comparing how the vacuum pump and the low vacuum warning light function in relation to the vacuum level registered on the vacuum gauge, as follows: If the pump and the warning light do not turn off after vacuum increases to a level much higher than the minimum lifting level, the vacuum switch may be adjusted to maintain a lower vacuum level. Otherwise, the pump would continue to run unnecessarily after the lifter has attained sufficient vacuum to lift the maximum load weight. If the pump and the warning light do not turn on before vacuum decreases to a level lower than the minimum lifting level, the vacuum switch must be adjusted to maintain a higher vacuum level. 6 Otherwise, the lifter would not maintain sufficient vacuum to lift the maximum load weight. 3 Lifters equipped with the Dual Vacuum System have 2 vacuum switches. Directions are the same for these lifters except that each vacuum switch must be tested and adjusted individually. When you are evaluating vacuum system functions under Conditions Requiring Readjustment, remember that each vacuum switch corresponds with one vacuum gauge and one vacuum circuit. After you have removed the cover from the enclosure with the vacuum switches, you can trace the vacuum lines to determine which components are connected to one another. 4 If the warning light does not turn on when the valve handle is moved to the apply position, the light bulb may be burned out. Replace the bulb when necessary. 5 When using the lifter at high elevations, reduced atmospheric pressure may prevent the vacuum generating system from attaining the vacuum level set at the factory. In this case, the pump would continue to run and the warning light would stay illuminated continuously. If the ability to lift the maximum load weight is not required, the operator can adjust the vacuum switch to maintain a lower vacuum level, allowing the pump to cycle normally. However, be advised that lifting capacity decreases proportionally with decreasing vacuum, based on the vacuum level specified for the Load Capacity (see SPECIFICATIONS). For example, if a lifter's Load Capacity is rated at 16" Hg [-54 kpa], lifting capacity decreases by 6.25% for each inch of Hg subtracted from (or for each 3.4 kpa added to) the vacuum level. Always maintain a minimum vacuum level of 10" Hg [-34 kpa], regardless of the vacuum level specified for the original Load Capacity. In addition, lifter markings should be adjusted to reflect the revised Load Capacity and the vacuum gauge should be marked to indicate the revised minimum lifting level. 6 In order to observe lifter functions while vacuum is decreasing, it may be necessary to create a controlled leak in the vacuum system (eg, by breaking the seal between one or more vacuum pads and the test surface). Rev 1.0/ DC SVS MV: #36110

11 Adjustment Procedure 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). To maintain a higher vacuum level, turn the screw counter-clockwise (when viewing vacuum switch from end with electrical connectors). 2) Recheck the vacuum switch setting following each 1/6th turn of the adjustment screw. In order to test the adjustment accurately, release the vacuum pads completely before reapplying them to a test surface. 1 ELECTRICAL CONNECTORS 2 ADJUSTMENT SCREW 3 TO MAINTAIN HIGHER VACUUM 4 TO MAINTAIN LOWER VACUUM When the vacuum switch is adjusted correctly, the vacuum pump turns off only after vacuum increases to a level higher than the minimum lifting level; and the pump turns on again before vacuum decreases to a level lower than the minimum lifting level. Rev 1.0/ DC SVS MV: #36110

12 REPLACEMENT PARTS LIST Stock No. Description Vacuum Pump Diaphragm Type 1-SCFM [28 liters/minute] 12 V DC (Dynaflo) Air Filter/Vacuum Control Valve w/handle and Fittings (for MRT4) Vacuum Control Valve w/handle and Fittings AM Dynaflo Pump Diaphragm Kit Dynaflo Pump Head Assembly Thomas Pump Repair Kit (including diaphragm, head gasket and valve flappers) Vacuum Pump Diaphragm Type 1-SCFM [28 liters/minute] 12 V DC (Thomas) Vacuum Hose 1/4" [6.3 mm] ID x 48" [122 cm] length Coiled (for MRT4) Vacuum Hose 1/4" [6.3 mm] ID Red * Check Valve 1/8 NPT Audio Alarm 5-15 V DC Panel Mount (for low vacuum warning buzzer, if applicable) Battery Charger 0.8 Amp 240 V AC Australian Type Battery Charger 0.8 Amp 240 V AC Battery Charger 0.8 Amp 100 / 120 V AC Battery 12 V DC 7 Amp-Hours Battery Gauge Circuit Breaker 15 A Bulb 13 V Bayonet (for low vacuum warning light) Red Indicator Light 12 V DC (aka, low vacuum warning light) Vacuum Switch 1/4 NPT Roller-Lever Switch Push-Button Switch (for battery test button) NC Battery Connector Twin Lead NC Power Lead Hose Fitting Tee 5/32" [4.0 mm] ID * Pad Fitting Tee 3/64" [1.2 mm] ID * Pad Fitting Elbow 3/64" [1.2 mm] ID * Hose Fitting Coupler 1/4" [6.4 mm] Barb (for MRT4) /4" [6.4 mm] Open-End Wrench (for adjusting vacuum switch) Filter Element Kit (for 1 oz [30 ml] bowl size air filter) Vacuum Gauge 1/8 NPT CBM Type 1 * Quantity varies, depending on lifter model or options selected. SERVICE ONLY WITH IDENTICAL REPLACEMENT PARTS, AVAILABLE AT WPG.COM OR THROUGH AN AUTHORIZED WPG DEALER Qty. Rev 1.0/ DC SVS MV: #36110

13 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. WARRANTY DOES NOT APPLY WHEN: Modifications have been made to the product after leaving the factory. Rubber portions have been cut or scratched during use. Repairs are required due to abnormal wear and tear. The product has been damaged, misused, or neglected. If a problem is not covered under warranty, Powr-Grip will notify the customer of costs prior to repair. If the customer agrees to pay all repair costs and to receive the repaired product on a C.O.D. basis, Powr-Grip then will proceed with repairs. For purchases in North America: TO OBTAIN REPAIRS OR WARRANTY SERVICE Contact the Technical Service Department at Wood s Powr-Grip Co. When factory service is required, ship the complete product prepaid along with your name, address and phone number to the street address hereafter. For purchases in all other localities: Contact your dealer or the Technical Service Department at Wood s Powr-Grip Co. for assistance. Wood's Powr-Grip Co., Inc. 908 West Main St. / P.O. Box 368 Laurel, MT USA phone phone fax Rev 1.0/ DC SVS MV: #36110

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KEEP FOR FUTURE REFERENCE FLAT LIFTER 300 DC-VOLTAGE READ ALL INSTRUCTIONS AND WARNINGS BEFORE OPERATING THIS LIFTER

KEEP FOR FUTURE REFERENCE FLAT LIFTER 300 DC-VOLTAGE READ ALL INSTRUCTIONS AND WARNINGS BEFORE OPERATING THIS LIFTER KEEP FOR FUTURE REFERENCE INSTRUCTIONS International Version P.O. Box 368 908 West Main Laurel, MT USA 59044 phone 800-548-7341 phone 406-628-8231 fax 406-628-8354 MODEL NUMBER: FL1HV11DC SERIAL NUMBER: