Savage Bros LifTILTruk B User manual

Savage Bros. Co.
1825 Greenleaf Avenue
Elk Grove Village, Illinois 60007 –USA
Phone: [phone]
World Fax: [phone]
USA Fax: [phone] (800-2-SAVAGE)
Internet: www.savagebros.com
E-mail: [email protected] [email protected]
SAVAGE BROS. CO.
LifTILTruk
Models B, C & D
Installation, Operation, Maintenance
and Parts Manual
December 2015

Savage Bros. Co. ~ since 1855
[LifTILTruk Installation, Operation, Maintenance and Parts Manal]
LifTILTruk December 2015
2
CONTENTS
LifTILTruk
CONTENTS ........................................................................................................................................................2
GENERAL CONCEPT OF OPERATION.................................................................................................................5
WARNINGS .......................................................................................................................................................6
About Batteries............................................................................................................................................8
Specific Cautions when Servicing the LifTILTruk..........................................................................................9
IMPORTANT SAFETY MEASURES ....................................................................................................................10
General ......................................................................................................................................................10
Safety Rules ...............................................................................................................................................10
Operation Manual and Safety Decals ........................................................................................................11
Operating Qualifications............................................................................................................................11
Clothing and Personal Protective Items ....................................................................................................11
Unauthorized Modification .......................................................................................................................12
Moving Parts..............................................................................................................................................12
Moving the LifTILTruk................................................................................................................................12
INITIAL INSTALLATION....................................................................................................................................14
Step 1. Be certain you have everything you need for the job..........................................................................14
Step 2: Prepare the Base unit for Assembly. .............................................................................................15
Step 3: Remove the LifTILTruk base from the Pallet. ................................................................................16
Step 4: Prepare the Column for Assembly...............................................................................................17
Step 5: Lift the Column over the Base. ......................................................................................................19
Step 6: Bolt the Column to the Base..........................................................................................................20
Step 7: Hydraulic Hose Connection. ..........................................................................................................20
Step 8: Major Electrical Connections. ......................................................................................................22
Step 9: Perform the Initial Hydraulic System Check..................................................................................23
Step 10: Install the Lifting Arms. ..............................................................................................................24
Step 11: Connect the Tilt Motor Cable (if equipped with Power Tilt)............................................................24
Step 12: Test the Completed LifTILTruk. ..................................................................................................25
Installing Adapter Strap.............................................................................................................................25
CONTENTS

[LifTILTruk Installation, Operation, Maintenance and Parts Manal]
Savage Bros. Co. ~ since 1855
LifTILTruk December 2015
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LifTILTruk Safety and Operation Decals ......................................................................................................26
OPERATION.....................................................................................................................................................28
Resetting the Circuit Breaker.....................................................................................................................28
Raising the LifTILTruk Arms........................................................................................................................28
Lowering the Arms.....................................................................................................................................28
Adjusting the Span of the Lift Arms...........................................................................................................29
Adjusting the Latches................................................................................................................................30
Pouring from a Container ..........................................................................................................................31
Removing a Container from the LifTILTruk................................................................................................32
PERIODIC MAINTENANCE...............................................................................................................................33
Periodic Maintenance Chart ......................................................................................................................33
Periodic Maintenance................................................................................................................................34
SERVICING THE LIFTILTRUK.............................................................................................................................37
Main Control Box .......................................................................................................................................37
Battery Charging - Inside the Control Box .................................................................................................38
Battery Charging - Outside the Control Box ..............................................................................................38
Servicing the Battery..................................................................................................................................39
Servicing the Battery Charger....................................................................................................................41
Servicing the Voltmeter .............................................................................................................................44
Servicing the Circuit Breaker......................................................................................................................47
Servicing the Ammeter ..............................................................................................................................50
Servicing the Inline Fuse ............................................................................................................................51
Raising and Lowering the LifTILTruk for Service ........................................................................................51
LiftTILTruk Tilt Motor Troubleshooting......................................................................................................52
Replacing Pendant Switches and Switch Components..............................................................................54
Checking or Adding Hydraulic Fluid ...........................................................................................................55
Removing and Replacing the Column.......................................................................................................55
Replacing the Hydraulic Cylinder Seal ......................................................................................................57
Replacing the Chain and Idler Wheel .......................................................................................................59
Replacement of the Tilt Motor Coil Cord and Connector..............................................................................60
Replacing the Tilt Motor Drive...................................................................................................................61
Lubricating the Column..............................................................................................................................62

Savage Bros. Co. ~ since 1855
[LifTILTruk Installation, Operation, Maintenance and Parts Manal]
LifTILTruk December 2015
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How to check the Down Solenoid Valve........................................................................................................62
Up Solenoid Relay......................................................................................................................................63
How to check the Hydraulic Pump Motor....................................................................................................63
Replacing the Slide Assembly Bearings ........................................................................................................64
TROUBLESHOOTING .......................................................................................................................................65
WARRANTY POLICY ........................................................................................................................................69
OBTAINING REPLACEMENT PARTS DURING THE WARRANTY...................................................................69
MECHANICAL DRAWINGS AND MECHANICAL PARTS ....................................................................................70
Electrical/Hydraulic Control Box................................................................................................................71
Control Pendant Assembly ........................................................................................................................72
Basic Mechanical Units .............................................................................................................................73
Base Assembly ...........................................................................................................................................73
Left Arm Assembly.....................................................................................................................................74
Tilt Motor Assembly ..................................................................................................................................74
Tilt Mechanical Subassembly.....................................................................................................................74
Idler Mechanism Assembly........................................................................................................................75
Hand Crank Assembly................................................................................................................................75
Standard Gearbox Assembly......................................................................................................................76
Right Arm Assembly...................................................................................................................................77
Bowl Strap..................................................................................................................................................77
Savage Kettles..........................................................................................................................................77
Hydraulic Cylinder Assembly .....................................................................................................................78
Hydraulic Cylinder Seal Replacement Kit..................................................................................................79
Slide Assembly...........................................................................................................................................79
Slide Bearing Replacement Kit...................................................................................................................79
ELECTRICAL SCHEMATICS AND ELECTRICAL PARTS........................................................................................80
LifTILTruk Electrical Control Circuit Diagram.............................................................................................81
LifTILTruk Electrical Replacement Parts ....................................................................................................82

[LifTILTruk Installation, Operation, Maintenance and Parts Manal]
Savage Bros. Co. ~ since 1855
LifTILTruk December 2015
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GENERAL CONCEPT OF OPERATION
GENERAL CONCEPT OF OPERATION
The Savage Bros. Co. LifTILTruk is designed for the safe lifting, transporting and pouring of a
mixing bowl or kettle. The unit is engineered to be operated by one person. A mixing bowl or
kettle can be lifted off of a mixer or stove, transported to another location, raised and tilted so
that product can be safely poured onto a table or into a hopper or other container.
The Auto-Lift Model “C” lifts and lowers the bowl or kettle by means of a hydraulic system that is
powered by an on-board 12 Volt battery. The LifTILTruk has fixed front casters and rear casters
that swivel for maneuverability. Once in position for pouring, the bowl or kettle can be tilted.
Savage Bros. manufactured candy kettles adapt directly to the LifTILTruk. Mixing bowls
manufactured by Hobart and others require a special adapter or lifting strap with the proper
handles for safe tilting. Straps for various size and makes of mixing bowls are available from
Savage Bros.
LifTILTruk

Savage Bros. Co. ~ since 1855
[LifTILTruk Installation, Operation, Maintenance and Parts Manal]
LifTILTruk December 2015
6
WARNINGS
The LifTILTruk is designed and manufactured to be a dependable, predictable and safe tool when used by a
SAFE OPERATOR. Savage Bros. Co. cannot predict every circumstance that might involve a potential hazard
in operation and maintenance. Therefore, the safety measures in this manual and on the LifTILTruk may not
include all possible safety cautions. Clearly, no matter how safe we make the LifTILTruk, there are ways to
use it unsafely. This can lead to expensive accidents which could cause serious injury OR EVEN DEATH,
possibly YOUR death! To lessen the chance of breakage, expense, injury or death, we urge you to read,
understand, and work continually with the following cautions in mind:
•Read and understand this entire manual thoroughly before operating or servicing the LifTILTruk.
•Improper operation and maintenance can be hazardous and could result in serious injury or even
death.
•Never modify the LifTILTruk to lift any other type of load, or for any other reason.
•Be sure the handles of the load are securely locked in the lift arms.
About 80% of all problems or accidents happen because the operator failed to be certain the handles
were securely locked by the lock mechanism. There is only one right way for the handles to be captured,
as shown in Figure 1.
•Go slowly. The faster things happen, the less control you have over the outcome, especially when you
are transporting a load, or adjusting the position of a load which has been lifted to its pouring height. GO
SLOWLY.
•Never transport a load unless it has been lowered to its lowest position. You greatly decrease the
possibility of accidents, injury and DEATH if you lower the load completely before moving it.
WARNINGS
Figure 1
Latch Lockplate
Container Handle
Latch Support

[LifTILTruk Installation, Operation, Maintenance and Parts Manal]
Savage Bros. Co. ~ since 1855
LifTILTruk December 2015
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•Use extra caution when moving LifTILTruk over uneven floors.
•Never use the LifTILTruk for any job for which it was not designed.
The LifTILTruk should be used only to lift Savage Bros. Co. kettles or containers of other manufacture
which USE A SAVAGE BROS. CO. ADAPTER STRAP. Only Savage kettles or Savage adapter straps are
designed to provide support for the loads for which the LifTILTruk was designed.
•Never use the LifTILTruk on the job unless the Operator has:
a. Read the manual sections that pertain to operating the LifTILTruk.
b. Read and understand all of the cautions in this section.
c. Practice WITHOUT A LOAD before using with an actual load.
• Don't stand under raised LifTILTruk arms at anytime!
• Keep visitors out of the work area when raising, lowering or moving loads.
• It is your responsibility to be sure you and others can do the procedures and actions outlined in this
manual safely and without damaging the LifTILTruk. If you are unsure about the safety of some
procedures, contact Savage Bros. Co. at 847–981–3000.
DO NOT WALK UNDER
LIFTED ARMS
DO NOT STAND
ON ARMS
DO NOT MOVE WITH
ARMS UP OR ON
ANGLED SURFACE
ONLY ONE PERSON
OPERATION

Savage Bros. Co. ~ since 1855
[LifTILTruk Installation, Operation, Maintenance and Parts Manal]
LifTILTruk December 2015
8
About Batteries
Each time the battery is discharged then recharged, it goes through
a “cycle.” The chemistry in your LifTILTruk battery works when it
enjoys very “deep cycles.”
You can lengthen the LifTILTruk battery's effective life by
discharging it to the deepest working level, then recharging it
completelybefore returning it to service.
The voltmeter on the front of the control box tells you “how the
battery is doing”. Keeping the voltmeter needle in the green makes
a healthy battery in a good state of charge.
At some point in the working day the needle may dip down into the
yellow zone on the voltmeter when you do a lift or tilt. As long as the
needle goes no further than the bottom of the yellow zone, the battery is still charged enough to
continue working.
When the needle will start to dip into the RED ZONE during lifting, THE BATTERY NEEDS TO BE RECHARGED.
It takes approximately 9 hours to recharge the deep cycle battery used on the LifTILTruk. To most people this
will mean “overnight recharging.”Batteries don't usually get into the red conveniently on the last lift of the
day. They usually require charging before or after this moment. Therefore, most businesses usually have a
spare battery fully charged, ready for use when the on-board battery goes into the red.
Working with a spare battery
The spare battery should be of the same size and type as the one delivered with your LifTILTruk. Handling
a spare battery requires the same level of caution and professionalism outlined in our warnings for
working with the original battery delivered with your LifTILTruk. Attach the positive cable first when
installing a replacement battery, followed by the negative cable. Avoid short-circuiting the battery
terminals through accidental contact with tools or other metal objects across the terminals.
BE SURE YOU ARE DOING THINGS SAFELY.
When replacing the battery specify a deep cycle or marine deep cycle battery with a
minimum reserve capacity of 160 minutes.
Figure 2

[LifTILTruk Installation, Operation, Maintenance and Parts Manal]
Savage Bros. Co. ~ since 1855
LifTILTruk December 2015
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Acid burn
Deadly
Wear eye
potential
fumes
protection
Specific Cautions when Servicing the LifTILTruk
•Unplug the LifTILTruk from the outside power source. When plugged in for charging, SERIOUS INJURY OR
DEATH BY ELECTROCUTION CAN RESULT!!
•Always wear eye protection –a face mask or goggles equal to ANSI Z87.1 specifications when opening
the electrical control box. The battery is an EXPLOSION HAZARD!
•Remove ringsor other jewelry when servicing the inside of the electrical control box. Severe burns result
from metal touching the battery posts or other exposed electric parts.
•Disconnect the battery (–) cable from the battery when performing service inside the control box or
when servicing the battery.
•Avoid sparks or open flame when servicing inside the control box. Remember, the battery is an
EXPLOSION HAZARD.
•Perform all service in a well-ventilated area. Ideally, a fan should be used to provide positive ventilation to
avoid the EXPLOSION HAZARD of hydrogen gas accumulation when opening the control box to service the
battery or any other component inside the electrical control box.
•Do not tip or drop the battery. The battery contains sulfuric acid which can burn holes in skin and
clothing and causeSEVEREINJURYtoanyonecontactingtheacid.
•Battery Acid will burn skin and clothing, and it will cause blindness if splashed into the eyes. If battery
acid is contacted, flush liberally with lots of water and get medical attention immediately. If swallowed,
drink a large quantity of water or milk mixed with beaten egg white or vegetable oil. Call a doctor or
poison control center immediately.
•Take care when near the column slider and the chain to keep fingers out of the chain slot.
•Keep enclosure vents free and clear –in order to avoid the buildup of fumes.

Savage Bros. Co. ~ since 1855
[LifTILTruk Installation, Operation, Maintenance and Parts Manal]
LifTILTruk December 2015
10
IMPORTANT SAFETY MEASURES
General
Rotating and moving machinery of any type presents a risk of injury. The LifTILTruk lifts tilts and rolls which
means the operator (one trained person at a time only) must be alert at all times. Ideally, everyone who will
have any contact with the LifTILTruk should be trained in its function, operation, care and respect –as with all
tools and machines.
Safety Rules
•Do not operate the LifTILTruk or other machinery if you are fatigued, if you have been drinking alcohol or
have taken any medication which can make you sleepy.
•When carrying out operation, inspection or maintenance ofthe LifTILTruk, always follow all work shop rules,
safety regulations and precautions.
•Do not overload. Do not exceed the weight limitation as seen on the top of the pendant hook on the
control pendant. Weight limitation is also included on the serial plates, which are on the outside and
inside the control box and on the side of the tilt motor cover.
•Always pay attention to safety and be careful of other people, equipment and surrounding conditions.
•Do not use the LifTILTruk for anything other than the intendedpurposes.
•Use tools that are suitable for inspection and maintenance. It is extremely dangerous to use broken tools
or tools designed for another purpose.
•SAFETY IS UP TO YOU.
IMPORTANT SAFETY MEASURES