Dover Environmental Solutions BAYNE TL 1128 Operation And Parts Manual
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Dover Environmental Solutions BAYNE TL 1128 Operation And Parts Manual

Dover Environmental Solutions BAYNE TL 1128 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
TL 1128 (TOP HOLES)
OPERATION AND PARTS MANUAL
CUSTOMER NAME:
SERIAL NUMBER:
1900-0187 Revision No. 006
1,327,765
5,447,405
5,333,984
5,826,485
1900-0187
ISSUED FEBRUARY 2020
____________________
____________________
© 2020 Bayne Premium Lift Systems
.

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Summary of Contents for Dover Environmental Solutions BAYNE TL 1128

  • Page 1 TL 1128 (TOP HOLES) 1900-0187 OPERATION AND PARTS MANUAL ISSUED FEBRUARY 2020 ____________________ CUSTOMER NAME: ____________________ SERIAL NUMBER: 1900-0187 Revision No. 006 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 ©...
  • Page 2 WARNING IF INCORRECTLY USED, THIS EQUIPMENT CAN CAUSE SEVERE INJURY. THOSE WHO USE AND MAINTAIN THE EQUIPMENT SHOULD BE TRAINED IN ITS PROPER USE, WARNED OF ITS DANGERS, AND SHOULD READ AND FULLY UNDERSTAND THIS ENTIRE MANUAL BEFORE ATTEMPTING TO SET UP, OPERATE, ADJUST OR SERVICE THE EQUIPMENT. KEEP THIS MANUAL FOR FUTURE REFERENCE IMPORTANT SAFETY NOTICE ®...

  • Page 3: Table Of Contents

    TL 1128 (TOP HOLES) TABLE OF CONTENTS Safety ......................................2 Specifications ......................................3 Installation Instructions ......................................5 Operation Instructions ......................................11 Diverter Valve Information ......................................14 Maintenance Instructions ......................................16 Actuator Assembly Instructions ......................................17 Troubleshooting Chart ......................................28 Appendix A - Assembly Drawings and Part Numbers ......................................30 1900-0187 - TL 1128 Top Holes Lifter Assembly ......................................31 7603-1501 - Hook Bearing Mount Assembly...
  • Page 4 TL 1128 (TOP HOLES) INTENTIONALLY LEFT BLANK...
  • Page 5 TL 1128 (TOP HOLES) TL 1128 (TOP HOLES) PART NUMBER: 1900-0187 REVISION NO. 006 OPERATION AND PARTS MANUAL Printed in U.S.A. Issued August 2016 Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 6: Safety

    TL 1128 (TOP HOLES) Safety SAFETY WI-0070-A To prevent serious injury, death or equipment damage, read and understand this entire manual before installing, operating, repairing or adjusting your Bayne THINLINE Premium Lift System. Those using and maintaining this equipment must be ®...

  • Page 7: Specifications

    TL 1128 (TOP HOLES) Specifications SPECIFICATIONS WI-0081-A A. Rotary Actuator - rack and pinion style design. Rack, pinion, and shaft bearings are constantly lubricated by the hydraulic oil for extended life. Body and caps are made of high quality ductile iron. Pinion output shaft and racks are made of high tensile alloy steel.
  • Page 8 TL 1128 (TOP HOLES) Specifications H. All lifters can be a bolt on type installation for easy, quick maintenance and less downtime. I. All parts are manufactured and kept in stock at Bayne Machine Works, Inc. for fast response to customer request. J.

  • Page 9: Installation Instructions

    TL 1128 (TOP HOLES) Installation Instructions INSTALLATION INSTRUCTIONS WI-0104-C 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 10 TL 1128 (TOP HOLES) Installation Instructions 2. Remove the mounting bracket(s) from the hand valve assembly(s) and weld to the truck. 3. After the weld has cooled, paint the mounting bracket(s) to match the truck color. 4. After the paint has dried, reassemble the hand valve assembly(s) on the mounting bracket(s). Figure A-2 C.Mounting diverter valve on the truck : 1.
  • Page 11 TL 1128 (TOP HOLES) Installation Instructions D.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 A-3 ) and hydraulic schematics while performing the following steps. See for drawings.
  • Page 12 TL 1128 (TOP HOLES) Installation Instructions 1. Cut or disconnect truck’s main hydraulic pressure line and install the diverter valve in series using the “IN” and “OUT” ports. 2. Connect the “T” port on the diverter valve to the truck’s hydraulic tank line with an appropriate size line to handle the lifter system flow.
  • Page 13 TL 1128 (TOP HOLES) Installation Instructions 1. Determine the truck’s system pressure setting. 2. Loosen lock nut ( 6 ) ( Figure A-4 ) from the hand valve relief valve(s) ( 5 ) and turn the adjustment screw(s) clockwise until it bottoms out. 3.
  • Page 14 TL 1128 (TOP HOLES) Installation Instructions 10.Setting the hand valve relief valve(s) : a. Hold a handle on the hand valve ( 2 ) ( Figure A-4 ) ( with pressure gauge installed at the “IN” port ) in the “retract” position to show pressure on the gauge.

  • Page 15: Operation Instructions

    TL 1128 (TOP HOLES) Operation Instructions OPERATION INSTRUCTIONS WI-0124-A 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 16 TL 1128 (TOP HOLES) Operation Instructions SAFETY ZONES Stand Clear Zone To prevent serious injury or death, operators and bystanders should remain outside the Stand Clear Zone ( Figure B-2 ) at all times during the operating cycle of the lifter. If at any point during the cycle persons enter this area, the operator most stop all motion of the lifter until the area is cleared.
  • Page 17 TL 1128 (TOP HOLES) Operation Instructions LOWER HOOK ADJUSTMENT Check the distance ( A ) ( Figure B-3 ) between the saddle and lower hooks when the lifter faceplate is in the FULL DUMP position. Maintain this dimension at approximately 14 1/4” for the proper “locking” of the cart to the lifter. To adjust the setting, loosen the jam nuts ( 1 ) on the spherical rod ends ( 2 ).

  • Page 18: Diverter Valve Information

    TL 1128 (TOP HOLES) Diverter Valve Information OPERATION AND INSTALLATION 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 19 TL 1128 (TOP HOLES) Diverter Valve Information Possible Problems 1. The most common cause of valve failure is dirty oil. If debris becomes lodged in the cartridge valves they will malfunction. Recommended filtration level is between 15 and 25 microns. Many systems filter the oil on the return side.

  • Page 20: Maintenance Instructions

    TL 1128 (TOP HOLES) Maintenance Instructions MAINTENANCE INSTRUCTIONS WI-0140-A NOTICE 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 ®...

  • Page 21: Actuator Assembly Instructions

    TL 1128 (TOP HOLES) Actuator Assembly Instructions ACTUATOR ASSEMBLY INSTRUCTIONS 1100 Series Roller Bearing Actuator, Part Number 1122-1026 ( WI-1125-C ) Licensed under on or more of the following U.S. Patents: 4,773,812 1,327,765 5,308,211 5,333,984 NOTICE READ INSTRUCTIONS COMPLETELY BEFORE STARTING ASSEMBLY. Before starting the assembly of the Rotary Actuator, refer to the exploded parts drawing and parts list (Figure A-13 found at the end of these instructions) to familiarize yourself with the individual components.
  • Page 22 TL 1128 (TOP HOLES) Actuator Assembly Instructions 3. Thoroughly clean the pinion shaft (1) ( Figure C-3 ) and inner races (10) with a mild solvent and dry completely. Spray the inner race contact area (shown in Figure C-3 ) at each end of the pinion shaft and the inside diameter of the inner race thoroughly with LOCTITE 7649 N PRIMER.
  • Page 23 TL 1128 (TOP HOLES) Actuator Assembly Instructions 5. Coat the head portion of the racks (2) ( Figure C-13 ) with STP Oil Treatment. Install the racks, head portion up with the teeth facing the flanges of the actuator body, into the dual set of bores in the body. Simultaneously slide the racks into the bores so that the racks mesh with the pinion in the same position.
  • Page 24 TL 1128 (TOP HOLES) Actuator Assembly Instructions 7. Coat one end of the actuator tubes (3) ( Figure C-13 ) around the seal area with STP Oil Treatment as shown in Figure C-7. Using a rubber mallet, drive the coated end of the tube onto the exposed rack until the tube end seats in the actuator body, making sure that the seals remain in place as the tube enters the counter-bore.
  • Page 25 TL 1128 (TOP HOLES) Actuator Assembly Instructions 12.Place the rack cap (5) ( Figure C-13 ) bore side up on the table and coat the edge of each bore with STP Oil Treatment. Install the rack cap seals (14) ( Figure C-9 ) in the rack cap. Figure C-9 13.Reposition the actuator on the table mounting flanges down, and the lower tubes facing away from the assembler.
  • Page 26 TL 1128 (TOP HOLES) Actuator Assembly Instructions 16.Thoroughly clean the bearing caps (8) ( Figure C-11 ) with a mild solvent and lubricate all seal grooves with STP oil treatment. Place the bearing caps (8) on the table (mounting surface down) and install the wiper ring (19) in the outside groove using a rubber mallet or small press.
  • Page 27 TL 1128 (TOP HOLES) Actuator Assembly Instructions 21.Install the 45° bulk-head fitting (31) ( Figure C-13 ) up through the hole in the tube mounting bracket (30) bolted to the tube cap as shown in Figure C-13. The 45° end must be pointing down away from the rack cap (5) and back toward the mounting flanges on the actuator body.
  • Page 28 TL 1128 (TOP HOLES) Actuator Assembly Instructions ACTUATOR ASSEMBLY Figure C-13 Issued August 2016 Printed in U.S.A. Copyright 2016, Bayne Premium Lift Systems Revision No: 006...
  • Page 29 TL 1128 (TOP HOLES) Actuator Assembly Instructions SHORT STROKE SLOWDOWN ASSEMBLY INSTRUCTIONS Part Number 1122-1026 ( WI-2303-A ) Licensed under on or more of the following U.S. Patents: 1,327,765 5,308,211 5,333,984 NOTICE READ INSTRUCTIONS COMPLETELY BEFORE STARTING ASSEMBLY. The Slowdown is a patented device used to cushion the unit as it completes its rotation into the dump position. This cushioning prevents the tearing of carts and helps protect the dumper from abuse.
  • Page 30 TL 1128 (TOP HOLES) Actuator Assembly Instructions 2. Place the plunger ( 2 ) ( Figure D-2 ) into the plunger housing ( 1 ). Place the spring ( 4 ) on top of the plunger ( 2 ). Coat the o-ring on the o-ring plug ( 9 ) with STP Oil Treatment. Screw the o-ring plug ( 9 ) into the plunger housing ( 1 ) on top of the spring ( 4 ) and tighten to 30 in-lb.
  • Page 31 TL 1128 (TOP HOLES) Actuator Assembly Instructions Figure D-4 Printed in U.S.A. Issued August 2016 Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 32: Troubleshooting Chart

    TL 1128 (TOP HOLES) Troubleshooting Chart TROUBLESHOOTING CHART SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION 1. Air trapped in system. 1. Bleed all air from lifter hydraulic system. Lifter operation very 2. Low oil level. 2. Add oil to system. erratic. 1. Cart overweight. 1.
  • Page 33 TL 1128 (TOP HOLES) Troubleshooting Chart TROUBLESHOOTING CHART SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION dimension out of Operation Instructions of this manual. rods frequently breaking adjustment. or bending. 2. Bars on carts are not 2. Re-adjust saddle to hook dimension for these carts. standard spread dimensions.

  • Page 34: Appendix A - Assembly Drawings And Part Numbers

    TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers APPENDIX A ASSEMBLY DRAWINGS AND PART NUMBERS Issued August 2016 Printed in U.S.A. Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 35: 1900-0187 - Tl 1128 Top Holes Lifter Assembly

    TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Printed in U.S.A. Issued August 2016 Copyright 2016, Bayne Premium Lift Systems Revision No: 006...
  • Page 36 TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Issued August 2016 Printed in U.S.A. Copyright 2016, Bayne Premium Lift Systems Revision No: 006...
  • Page 37 TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Printed in U.S.A. Issued August 2016 Copyright 2016, Bayne Premium Lift Systems Revision No: 006...
  • Page 38 TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Issued August 2016 Printed in U.S.A. Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 39: 7603-1501 - Hook Bearing Mount Assembly

    TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Printed in U.S.A. Issued August 2016 Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 40: 2000-1230 - Torque Bearing Assembly

    TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Issued August 2016 Printed in U.S.A. Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 41: 2000-1338 - Lower Idler Bearing Assembly

    TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Printed in U.S.A. Issued August 2016 Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 42: 2000-1335 - Upper Idler Bearing Assembly

    TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Issued August 2016 Printed in U.S.A. Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 43: H3000027 - Tl Series Specifications

    TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Printed in U.S.A. Issued August 2016 Copyright 2016, Bayne Premium Lift Systems Revision No: 006...
  • Page 44 TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Issued August 2016 Printed in U.S.A. Copyright 2016, Bayne Premium Lift Systems Revision No: 006...
  • Page 45 TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Printed in U.S.A. Issued August 2016 Copyright 2016, Bayne Premium Lift Systems Revision No: 006...
  • Page 46 TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Issued August 2016 Printed in U.S.A. Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 47: 6900-0700 - Hydraulic Schematic

    TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Printed in U.S.A. Issued August 2016 Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 48: 6900-0704 - Hydraulic Schematic

    TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Issued August 2016 Printed in U.S.A. Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 49: M3500005 - Diverter Valve Parts

    TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Printed in U.S.A. Issued August 2016 Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 50: 8000-0780 - Diverter Valve Seal Kit

    TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Issued August 2016 Printed in U.S.A. Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 51: 6083-1010 - Single Hand Valve With Bracket

    TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Printed in U.S.A. Issued August 2016 Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 52: 8000-0085 - Hand Valve Seal Repair Kit

    TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Issued August 2016 Printed in U.S.A. Copyright 2016, Bayne Premium Lift Systems Revision No: 006...

  • Page 53: Lub2000P - Tl Lubrication Points

    TL 1128 (TOP HOLES) Appendix A - Assembly Drawings and Part Numbers Printed in U.S.A. Issued August 2016 Copyright 2016, Bayne Premium Lift Systems Revision No: 006...
  • Page 54 TL 1128 (TOP HOLES) INTENTIONALLY LEFT BLANK...

  • Page 55: Index

    TL 1128 (TOP HOLES) INDEX adjusting relief valve settings diverter walve information operation and installation information possible problems final operation and mounting installation instructions instructions actuator assembly slowdown assembly lower hook adjustment maintenance instructions making hydraulic connections mounting operation instructions safety safety zones specifications...
  • Page 56 www.baynethinline.com Customer Care: 800.535.2671 Bayne Premium Lift Systems 4301 Gault Avenue North Fort Payne, AL 35967...

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