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Bayne Taskmaster Hi-Lift Operation And Parts Manual

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OPERATION AND PARTS MANUAL
Taskmaster ™ ™ ™ ™ Hi-Lift
MODEL NUMBER :
1999-9100
PART NUMBER :
SERIAL NUMBER :

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Summary of Contents for Bayne Taskmaster Hi-Lift

  • Page 1 OPERATION AND PARTS MANUAL Taskmaster ™ ™ ™ ™ Hi-Lift MODEL NUMBER : 1999-9100 PART NUMBER : SERIAL NUMBER :...
  • Page 2 Cart Lifter General Operation Guidelines Always adhere to your company’s safety guidelines when using this lifter. This includes wearing appropriate clothing and personal protective equipment, including reflective gear. Keep in mind that you are operating the lifter on public roads or alleys with moving traffic.
  • Page 3 TABLE OF CONTENTS Page ® THINLINE Safety ® THINLINE Specifications ® III. THINLINE Installation Instructions ® THINLINE Operation Instructions ® THINLINE Diverter Valve Information ® THINLINE Maintenance Instructions VII. Trouble-shooting Chart VIII. Appendix A 1. Unit Assembly Drawings 2. Mounting Height Drawing 3.
  • Page 4 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. Document Number: 1999-9100...
  • Page 5 • 2500 PSI maximum pressure H. Lift unit 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 requests.
  • Page 6 INSTALLATION INSTRUCTIONS ( WI-0235-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 7 Mounting hand valve(s) on the truck : 1. Choose and mark an acceptable location(s) on the truck to mount the hand valve assembly(s), approximately 48” to 54” from the ground as shown in figure I-2. 2. Remove the mounting bracket(s) from the hand valve assembly(s) and weld to the truck.
  • Page 8 VII. 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.
  • Page 9 1. Cut or disconnect truck’s main hydraulic pressure line and install the Bayne 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 full system flow.
  • Page 10 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 11 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. Loosen the lock nut ( 6 ) ( figure I-4 ) on the lifter circuit relief valve ( 3 ) and turn the adjustment screw clockwise until it bottoms out.
  • Page 12 figure I-5 12. Start the truck’s engine and engage the hydraulic system. 13. Setting the diverter valve lifter circuit relief valve: a) Have an assistant hold the handle on the hand valve ( 2 ) ( figure I-4 ) ( with pressure gauge installed at the “IN”...
  • Page 13 14. Setting the hand valve(s) relief valve: 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 14 Bayne THINLINE Premium Lift Systems ® The Bayne THINLINE Premium Lift System is a high quality durable dumper built to meet industry requirements. To insure the safety of all operators of this equipment, please read this manual carefully before operating the dumper. FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND/OR PROPERTY DAMAGE.
  • Page 15 SAFETY ZONES Stand Clear Zone To prevent serious injury or death, operators and bystanders should remain outside the Stand Clear Zone ( figure O-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 16 LOWER HOOK ADJUSTMENT The lower hook is equipped with two settings that must be properly adjusted to accommodate the carts being lifted. Check the distance ( A ) ( figure O-3 ) between the upper bar and the lower bar on the cart. If this dimension is between 15”to 15-1/2”, leave the lower hook attachment in the lower setting.
  • Page 17 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 18 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 NOTE: 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 20 TROUBLE-SHOOTING CHART ( WI-0313-B ) 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 21 TROUBLE-SHOOTING CHART ( WI-0313-B ) 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 22 TROUBLE-SHOOTING CHART ( WI-0313-B ) SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Cylinder leaking oil around 1. Worn cylinder rod seals. 1. Install cylinder seal kit. rod. Lower hook frequently 1. Lower hook not adjusted 1. Adjust lower hook per breaking or bending. properly.
  • Page 23 APPENDIX A Assembly drawings and part numbers Document Number: 1999-9100 Issue Date: 01/23/14 Revision No: 007 Page: 22 of 34...
  • Page 24 Document Number: 1999-9100 Issue Date: 01/23/14 Revision No: 007 Page: 23 of 34...
  • Page 25 Document Number: 1999-9100 Issue Date: 01/23/14 Revision No: 007 Page: 24 of 34...
  • Page 26 Document Number: 1999-9100 Issue Date: 01/23/14 Revision No: 007 Page: 25 of 34...
  • Page 27 Document Number: 1999-9100 Issue Date: 01/23/14 Revision No: 007 Page: 26 of 34...
  • Page 28 Document Number: 1999-9100 Issue Date: 01/23/14 Revision No: 007 Page: 27 of 34...
  • Page 29 Document Number: 1999-9100 Issue Date: 01/23/14 Revision No: 007 Page: 28 of 34...
  • Page 30 Document Number: 1999-9100 Issue Date: 01/23/14 Revision No: 007 Page: 29 of 34...
  • Page 31 Document Number: 1999-9100 Issue Date: 01/23/14 Revision No: 007 Page: 30 of 34...
  • Page 32 Document Number: 1999-9100 Issue Date: 01/23/14 Revision No: 007 Page: 31 of 34...
  • Page 33 Document Number: 1999-9100 Issue Date: 01/23/14 Revision No: 007 Page: 32 of 34...
  • Page 34 Document Number: 1999-9100 Issue Date: 01/23/14 Revision No: 007 Page: 33 of 34...
  • Page 35 Document Number: 1999-9100 Issue Date: 01/23/14 Revision No: 007 Page: 34 of 34...
  • Page 36 www.baynethinline.c om Cus tom er Care: 800.535.2671 Fax: 256.585.6762 The Heil Co. 4301 Gault Avenue North Fort Payne, AL 35967...

This manual is also suitable for:

1999-9100