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Bayne Revolution HD 1999-0520 Operation And Parts Manual

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LICENSED UNDER ONE OR MORE OF
THE FOLLOWING U.S. AND CANADIAN PATENTS:
5,503,512
4,773,812
1,335,648
5,308,211
OPERATION AND PARTS MANUAL
CUSTOMER NAME:
SERIAL NUMBER:
1999-0520 Revision No. 001
1,327,765
5,447,405
5,333,984
5,826,485
1999-0520
ISSUED JUNE 2017
____________________
____________________
© 2017 Bayne Premium Lift Systems
.

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  • Page 1 OPERATION AND PARTS MANUAL ISSUED JUNE 2017 ____________________ CUSTOMER NAME: ____________________ SERIAL NUMBER: 1999-0520 Revision No. 001 LICENSED UNDER ONE OR MORE OF THE FOLLOWING U.S. AND CANADIAN PATENTS: 5,503,512 4,773,812 1,327,765 5,447,405 1,335,648 5,308,211 5,333,984 5,826,485 © 2017 Bayne Premium Lift Systems...
  • Page 2 ATTEMPTING TO SET UP, OPERATE, ADJUST OR SERVICE THE EQUIPMENT. KEEP THIS MANUAL FOR FUTURE REFERENCE IMPORTANT SAFETY NOTICE ® Proper service and repair are important to the safe, reliable operation of the Bayne THINLINE ® products. Service procedures recommended by Bayne THINLINE are described in this Operation and Parts Manual and are effective for performing service operations.

  • Page 3: Table Of Contents

    6083-1010 - Single Hand Valve with Bracket ......................................41 8000-0085 - Hand Valve Seal Repair Kit ......................................42 LUB4205B - Revolution HD Lubrication Points ......................................43 Index ..................................45 Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...
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  • Page 5: Revision No

    PART NUMBER: 1999-0520 REVISION NO. 001 OPERATION AND PARTS MANUAL ISSUED JUNE 2017 Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...

  • Page 6: Safety

    Premium Lift System warn of hazards related to the use of this equipment. Operators must read and follow all safety instructions while using this equipment. If the safety decals are ® not clearly readable, new decals may be obtained from your local dealer or directly from Bayne THINLINE Premium Lift Systems.

  • Page 7: Specifications

    All lift units and parts are inspected by our Quality Control Department before shipment to guarantee the highest performance and satisfaction. For more information, please contact us at 800.535.2671. Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...

  • Page 8: Installation Instructions

    INSTALLATION INSTRUCTIONS WI-0252-A ® 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 9 3. After the weld has cooled, paint the mounting bracket to match the truck color. 4. After the paint has dried, bolt the diverter valve to the mounting bracket using the 1/4” bolts, washers, and elastic lock nuts. Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...
  • Page 10 Refer to the hydraulic layouts in the Figure below and hydraulic schematics while performing the following steps. See Appendix A for drawings. NOTICE Always clean & lubricate fitting threads before installation. Single Lifter Installation Dual Lifter Installation Figure 3. Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...
  • Page 11 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 12 Figure 5. If installing dual lifters, install the hydraulic gauge at either one of the hand valves. Figure 5. Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...
  • Page 13 Make any adjustments to the mounting position of the lifter(s) to ensure correct operation. 3. After locating an acceptable mounting position, complete the welding of the lifter(s) to the truck. Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...

  • Page 14: Operation Instructions

    ( Figure 6 ). Moving the handle in the opposite direction will cause the lifter to perform the actuator reverse stage. Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...
  • Page 15 To provide a clear, unobstructed view of both the Stand Clear Zone and Dump Zone, operators should remain within the Operator Area ( Figure 7 ) at all times during the operating cycle of the lifter. Figure 7. Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...
  • Page 16 It is the responsibility of the owner / operator of this equipment to adjust these dimensions to be compatible with his specific application. If the bar spacing is not within the specified range, please contact us on available options for non- standard carts. Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...

  • Page 17: Diverter Valve Information

    WI-0026 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.
  • Page 18 “bleed line” circuit needs be installed on the truck to allow passage of the lubricating oil back to tank. 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 19: Maintenance Instructions

    In order to maintain warranty and for preventive maintenance, grease all points every 40 hours or 2500 cycles (once weekly) with a good multi-purpose grease at points shown in the lubrication drawing. See Appendix A for Revolution HD Lubrication Guide. Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...

  • Page 20: Actuator Assembly Instructions

    ( Figure 21 ). 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. Figure 10. Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...
  • Page 21 Figure 12. Center the pinion in the actuator body. Figure 12. Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...
  • Page 22 Figure 14. Figure 14. Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...
  • Page 23 11.Install the hex nuts (23) ( Figure 21 ) and lock washers (24) on the tie rod studs. Torque the nuts to 50 ft-lb. in the sequence shown in Figure 16. Figure 16. Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...
  • Page 24 (9) ( Figure 21 ), over the pinion shaft and inner race, and into the actuator body. Repeat this procedure for the other bearing. Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...
  • Page 25 (21) ( Figure C-13 ) and lock washers (25). Hand tighten only at this time. Repeat this procedure for other bearing cap. 19.After both bearing caps have been installed, torque all bearing cap bolts to 30 ft-lb. in the sequence shown in Figure Figure 20. Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...
  • Page 26 (36) as shown and tighten. 24.Install the cap nuts (28) ( Figure 21 ) onto the open fittings to prevent contamination of the unit until the hoses are installed. Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...
  • Page 27 Actuator Assembly Instructions ACTUATOR ASSEMBLY Figure 21. Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...

  • Page 28: Troubleshooting Chart

    Lifter looses bar lift carts 1. Saddle to hook spacing 1. Adjust saddle to hook spacing per Operation not adjusted properly. Instructions. when dumping. Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...
  • Page 29 1. Adjust saddle to hook spacing per Operation not adjusted properly. Instructions. spread apart or damaged. 2. Lift bars on carts are not 2. Replace cart or install new bars. standard dimensions. Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...

  • Page 30: Appendix A - Assembly Drawings And Part Numbers

    Appendix A - Assembly Drawings and Part Numbers APPENDIX A ASSEMBLY DRAWINGS AND PART NUMBERS Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...

  • Page 31: 1999-0520 - Revolution Lifter Assembly

    Appendix A - Assembly Drawings and Part Numbers Revolution HD Assembly Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...
  • Page 32 Appendix A - Assembly Drawings and Part Numbers Revolution HD Assembly Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...
  • Page 33 Appendix A - Assembly Drawings and Part Numbers Revolution HD Assembly Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...
  • Page 34 Appendix A - Assembly Drawings and Part Numbers Revolution HD Assembly Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...
  • Page 35 Appendix A - Assembly Drawings and Part Numbers Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...
  • Page 36 Appendix A - Assembly Drawings and Part Numbers Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...
  • Page 37 Appendix A - Assembly Drawings and Part Numbers Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...
  • Page 38 Appendix A - Assembly Drawings and Part Numbers Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...
  • Page 39 Appendix A - Assembly Drawings and Part Numbers Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...

  • Page 40: H5700009 - Revolution Specification

    Appendix A - Assembly Drawings and Part Numbers Revolution HD Specifications Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...

  • Page 41: 6900-0700 - Hydraulic Schematic

    Appendix A - Assembly Drawings and Part Numbers Single Lift Hydraulic Schematic Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...

  • Page 42: 6900-0704 - Hydraulic Schematic

    Appendix A - Assembly Drawings and Part Numbers Double Lift Hydraulic Schematic Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...

  • Page 43: M3500005 - Single/Dual Diverter Valve Parts

    Appendix A - Assembly Drawings and Part Numbers Single/Dual Diverter Valve Parts Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...

  • Page 44: 8000-0780 - Diverter Valve Seal Kit

    Appendix A - Assembly Drawings and Part Numbers Diverter Valve Seal Kit Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...

  • Page 45: 6083-1010 - Single Hand Valve With Bracket

    Appendix A - Assembly Drawings and Part Numbers Single Hand Valve with Bracket Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...

  • Page 46: 8000-0085 - Hand Valve Seal Repair Kit

    Appendix A - Assembly Drawings and Part Numbers Hand Valve Seal Repair Kit Issued June 2017 Printed in U.S.A. Revision No: 001 Copyright 2017, Bayne Premium Lift Systems...

  • Page 47: Lub4205B - Revolution Hd Lubrication Points

    Appendix A - Assembly Drawings and Part Numbers Lubrication Guide Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...
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  • Page 49: Index

    Printed in U.S.A. Issued June 2017 Copyright 2017, Bayne Premium Lift Systems Revision No: 001...
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  • Page 51 OTHER DIRECT, INDIRECT OR CONSEQUENTIAL LOSSES, DAMAGES OR DELAYS. Any improper use, operation at an actuator cycle time of less than six (6) seconds, substitution of parts not approved by Bayne, modifications other than those done at the factory or as authorized by the factory in writing, or any alteration or repair by others in such manner that, in Bayne's judgment, affects the product materially and adversely shall void this warranty.
  • Page 52 Customer Care: 800.535.2671 Fax: 256.585.6762 Bayne Premium Lift Systems 402 North 44th Avenue Phoenix, AZ 85043...

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