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Bayne Thinline BTL 208-12 Operation And Parts Manual

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OPERATION AND PARTS MANUAL
MODEL NUMBER :
PART NUMBER :
SERIAL NUMBER :
BAYNE MACHINE WORKS, INC.
910 FORK SHOALS ROAD
GREENVILLE SC, 29605
WEBSITE: www.baynethinline.com
THE FOLLOWING U.S. AND CANADIAN PATENTS:
5,503,512
1,335,648
LICENSED UNDER ONE OR MORE OF
4,773,812
5,308,211
BTL 208-12
1999-0212
PHONE: 864.288.3877
TOLL FREE: 800.535.2671
FAX: 864.458.7519
E-MAIL: sales@baynethinline.com
1,327,765
5,447,405
5,333,984
5,826,485

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Summary of Contents for Bayne Thinline BTL 208-12

  • Page 1 OPERATION AND PARTS MANUAL BTL 208-12 MODEL NUMBER : 1999-0212 PART NUMBER : SERIAL NUMBER : BAYNE MACHINE WORKS, INC. PHONE: 864.288.3877 910 FORK SHOALS ROAD TOLL FREE: 800.535.2671 GREENVILLE SC, 29605 FAX: 864.458.7519 WEBSITE: www.baynethinline.com E-MAIL: sales@baynethinline.com LICENSED UNDER ONE OR MORE OF THE FOLLOWING U.S.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Page ® THINLINE Specifications ® THINLINE Installation Instructions ® III. THINLINE Operation Instructions ® THINLINE Diverter Valve Information ® THINLINE Maintenance Instructions ® THINLINE Actuator Assembly Instructions VII. Trouble-shooting Chart VIII. Appendix A 1. Unit Assembly Drawings 2.

  • Page 3: Specifications

    G. BTL 208-12 lift units can be a bolt on type installation for easy, quick maintenance and less downtime. H. All parts are manufactured and kept in stock at Bayne Machine Works, Inc. for fast response to customer requests. I. Two ( 2 ) year limited warranty from date of delivery on all units and models when properly maintained and operated within the recommended cycle time.

  • Page 4: Thinline ® Installation Instructions

    INSTALLATION INSTRUCTIONS ( WI-0238-A) ® Bayne THINLINE Premium Lift Systems The following information is intended to be a GENERAL GUIDE to installing the Bayne ® THINLINE lifter on a typical refuse truck. Before starting the installation, read these instructions completely. ALWAYS use the proper tools, lift devices, and personal protective equipment to prevent injury while performing the installation.
  • Page 5 Mounting hand valve(s) on the truck: 1. Choose and mark an acceptable location(s) on the side(s) of the truck to mount the hand valve assembly(s) ( figure I-2 ). 2. Remove the mounting bracket(s) from the hand valve assembly(s) and weld to the truck.
  • Page 6 IV. Making Hydraulic Connections: Before attempting any hydraulic connections, turn the truck’s engine off and release all hydraulic pressure from the system. Refer to the hydraulic layouts (figure I-3) and hydraulic schematics (Appendix A) while performing the following steps. Always clean & lubricate fitting threads before installation. Single Lifter Installation Dual Lifter Installation Figure I-3...
  • Page 7 2500 psi without any adjustment. However, if any adjustment is necessary, follow these instructions. WARNING : Bayne equipment is rated for a maximum pressure of 3000 psi. Operation at pressures above 3000 psi may damage equipment and cause personal injury. In order to avoid injury and maintain manufacturer’s warranty never operate above 3000 psi.
  • Page 8 Figure I-4 1. Determine the truck’s system pressure setting. 2. Remove the cap nut(s) ( 8 ) ( figure I-4 ) from the hand valve relief valve(s) ( 5 ) and turn the adjustment screw(s) clockwise until it bottoms out. 3.
  • Page 9 9. Turn the truck’s engine off and release all hydraulic pressure from the system. 10. Remove the hydraulic pressure gauge from the “G” port of the diverter valve and reinstall the plug. 11. Install the 3000 psi hydraulic pressure gauge with the necessary adapter in the hydraulic line connected to the “IN”...
  • Page 10 14. Setting the hand valve relief valve(s): a) Hold the handle on the hand valve ( 2 ) ( figure I-4 ) ( with pressure gauge installed at the “IN” port ) in the “retract” position to show pressure on the gauge.

  • Page 11: Operation Instructions

    Bayne THINLINE Premium Lift Systems ® The Bayne THINLINE Premium Lift System is a high quality durable cart lifter built to meet your industry’s requirements. To insure the safety of all operators of this equipment, please read this manual carefully before operating the lifter. FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND/OR PROPERTY DAMAGE.
  • Page 12 Bayne THINLINE Premium Lift Systems The Bayne diverter valve establishes priority flow to the lifter circuit “P1” and “P2” ports and bypasses oil to the “OUT” port, which typically supplies flow to the remainder of the truck’s hydraulic circuit. This bypass occurs only after the lifter circuit is satisfied. The priority flow is controlled by the flow regulator cartridge (FR1) (and FR2 in dual applications) in combination with the differential pressure sensing valve (DPS).
  • Page 13 3. On front load residential truck applications, several considerations need to be noted. The Bayne hand valve is an open center valve that allows for the lifter circuit to maintain flow through the hand valve and back to the diverter valve when the lifter is not being operated.

  • Page 14: Maintenance Instructions

    THE MOST COMMON CAUSE OF HYDRAULIC COMPONENT FAILURE IS CONTAMINATION OF THE HYDRAULIC FLUID ( WATER, CHIPS, ® DIRT, ETC. ) THE Bayne THINLINE LIFT SYSTEM COMES CLEAN FROM THE FACTORY. IF REMOVED, BE SURE THE HOSES, CYLINDER AND FITTINGS ARE CLEAN BEFORE RE-INSTALLING THEM ON THE UNIT.
  • Page 15 BAYNE PREMIUM LIFT SYSTEMS ASSEMBLY INSTRUCTIONS 1100 SERIES ROLLER BEARING ACTUATOR PART NUMBER 1120-1044 ( WI-1133 ) LICENSED UNDER ONE OR MORE OF THE FOLLOWING U.S. PATENTS: 4,773,812 1,327,765 5,308,211 5,333,984 READ INSTRUCTIONS COMPLETELY BEFORE STARTING ASSEMBLY. Before starting the assembly of the Rotary Actuator, refer to the exploded parts drawing and parts list (fig.
  • Page 16 2. Install the tube seal (12) (fig. A-2) and “square” tube seal backup (16) on each end of the actuator tubes (3) (fig. A-13). Be sure that the “square” tube seal backup ring is toward the inside of the tubes at both ends as shown. Press all rings firmly into the grooves. Repeat this procedure for the other tube.
  • Page 17 4. Place the actuator body (7) (fig. A-4) on the edge of the table, mounting flanges closest to the assembler with the counter-bores facing up. Insert the pinion shaft (1) through the bore on either side of the actuator body with the key ways facing back toward the mounting flanges and up away from the table with the center line of the key ways pointing in the position as shown in figure A-4.
  • Page 18 6. Check the position of the racks in the pinion by making sure both racks seat against the actuator body at the same time and also when the racks are seated against the body, the key ways on the pinion shaft should be facing down toward the table and mounting flanges on the actuator body as shown in figure A-6.
  • Page 19 8. Install the six tie rod studs (6) (fig. A-13) by screwing the short threaded end into the actuator body. Hand tighten only at this time (the torque needed will be applied later in the procedure). 9. Place the tube cap (4) (fig. A-13) on the table. Coat the sides of the two bores in the tube cap with STP Oil Treatment.
  • Page 20 figure A-9 13. Reposition the actuator on the table mounting flanges down, and the lower tubes facing away from the assembler. Rotate the pinion shaft to allow 1” of the rack to protrude from the top of the actuator body. Install the rack cap with the oil port positioned to the left hand side of the actuator opposite the bottom oil port located in the tube cap as shown in figure A-13.
  • Page 21 15. Re-center the actuator pinion in the actuator body by tapping on one end of the shaft with a rubber mallet. Install the roller bearing (9) (fig. A-13), over the pinion shaft and inner race, and into the actuator body. Repeat this procedure for the other bearing. 16.
  • Page 22 19. After both bearing caps have been installed, torque all bearing cap bolts to 30 ft-lb. in the sequence shown in figure A-12. figure A-12 20. Install the 90° fitting (27) (fig. A-13) into the oil port on the side of the rack cap (5). Hand tighten only at this time.

  • Page 23: Actuator Assembly Instructions

    ACTUATOR ASSEMBLY figure A-13 Document Number: 1999-0212 Issue Date: 06/06/07 Revision No: 005 Page: 23 of 38...

  • Page 24: Trouble-Shooting Chart

    TROUBLE-SHOOTING CHART ( WI-0310-A ) SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Lifter operation very erratic. 1. Air trapped in system. 1. Bleed all air from lifter hydraulic system. 2. Low oil level. 2. Add oil to system. Cart lifter will not pick up 1.
  • Page 25 TROUBLE-SHOOTING CHART ( WI-0310-A ) SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Hydraulic components down 1. Truck system hydraulic 1. Check and adjust stream of diverter valve not pressure too low. pressure on truck system operating or operating relief and full system extremely slow.
  • Page 26 TROUBLE-SHOOTING CHART ( WI-0310-A ) SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Slider latch connectors 1. Lift bars on cart bent or 1. Replace cart or install frequently breaking or spread apart. new bars. bending. 2. Broken spring on slider 2. Replace spring on slider latch hook.
  • Page 27 APPENDIX A Assembly drawings and part numbers Document Number: 1999-0212 Issue Date: 06/06/07 Revision No: 005 Page: 27 of 38...
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