Dover Environmental solutions bayne tl 1128 Guide

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

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

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. Some of these

service operations may require the use of tools or blocking devices specially designed for the

purpose. Special tools should be used when and as recommended. It is important to note that

some warnings against the use of specific methods that can damage the product or render it

unsafe are stated in the service manual. It is also important to understand these warnings are

not exhaustive. Bayne THINLINE®could not possibly know, evaluate and advise the service trade

of all conceivable ways in which service might be done or of the possible hazardous

consequences of each method. Consequently, Bayne THINLINE®has not undertaken any such

broad evaluations. Accordingly, anyone who uses service procedures or tools which are not

recommended by Bayne THINLINE®must first satisfy himself thoroughly that neither his safety

nor the product safety will be jeopardized by the method he selects.

TABLE OF CONTENTS

TL 1128 (TOP HOLES)

Printed in U.S.A.

Issued August 2016

Revision No: 006

........................................................................................................................................................................................2Safety

........................................................................................................................................................................................3Specifications

........................................................................................................................................................................................5Installation Instructions

........................................................................................................................................................................................11Operation Instructions

........................................................................................................................................................................................14Diverter Valve Information

........................................................................................................................................................................................16Maintenance Instructions

........................................................................................................................................................................................17Actuator Assembly Instructions

........................................................................................................................................................................................28Troubleshooting Chart

........................................................................................................................................................................................30Appendix A - Assembly Drawings and Part Numbers

........................................................................................................................................................................................311900-0187 - TL 1128 Top Holes Lifter Assembly

........................................................................................................................................................................................357603-1501 - Hook Bearing Mount Assembly

........................................................................................................................................................................................362000-1230 - Torque Bearing Assembly

........................................................................................................................................................................................372000-1338 - Lower Idler Bearing Assembly

........................................................................................................................................................................................382000-1335 - Upper Idler Bearing Assembly

........................................................................................................................................................................................39H3000027 - TL Series Specifications

........................................................................................................................................................................................436900-0700 - Hydraulic Schematic

........................................................................................................................................................................................446900-0704 - Hydraulic Schematic

........................................................................................................................................................................................45M3500005 - Diverter Valve Parts

........................................................................................................................................................................................468000-0780 - Diverter Valve Seal Kit

........................................................................................................................................................................................476083-1010 - Single Hand Valve with Bracket

........................................................................................................................................................................................488000-0085 - Hand Valve Seal Repair Kit

........................................................................................................................................................................................49LUB2000P - TL Lubrication Points

...................................................................................................................................................................... 51

Index

INTENTIONALLY LEFT BLANK

TL 1128 (TOP HOLES)

Issued August 2016

Revision No: 006

Printed in U.S.A.

1

TL 1128 (TOP HOLES)

PART NUMBER: 1900-0187 REVISION NO. 006

OPERATION AND PARTS MANUAL

TL 1128 (TOP HOLES)

Issued August 2016

Revision No: 006

Printed in U.S.A.

Safety

2

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

thoroughly trained and familiar with the product.

A. Manual:

This manual must be kept in a location that is readily available for those who operate or maintain this equipment.

Additional copies may be obtained from your local dealer or directly from Bayne THINLINE® Premium Lift Systems.

B. Lockout/Tagout Procedures:

All applicable OSHA lockout/tagout regulations must be followed when working on this equipment. Failure to comply with

these procedures can result in serious injury or death.

C.Safety Decals:

Safety decals attached to your Bayne THINLINE® 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.

TL 1128 (TOP HOLES)

Issued August 2016

Revision No: 006

Printed in U.S.A.

Specifications

3

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.

The rotary actuator provides smooth motion throughout the lift cycle, which results in longer cart life with virtually no

cart damage or abuse.

B. Arm bearings are made of a composite material which provides superior compression strength along with self-

lubrication, thus eliminating the need to grease the arm bearings.

C. The THINLINE® lift unit can measure as little as 5” thick from the front of the mainframe to the front of the faceplate

depending on the types of arms used. This allows for easy dumping of large commercial containers without interference.

D. The faceplate is normally at 45 degrees in the dump position and extends 13” to 15” from the back of the mainframe into

the hopper or container opening. This places the cart or barrel 16” to 18” into the truck or container opening thus

reducing any potential spillage of materials.

E. Cycle times for safe, fast, efficient service.

6 - 8 seconds for rear-load and side-load units

8 - 10 seconds for units with 9” and 15” vertical lifts

10 - 12 seconds for stationary, recycling, and double wide, and 24” vertical units

15 - 30 seconds for 3300 series and 3300 series stationary units

NOTICE

Cycle time is controlled by flowrate, as flowrate increases, cycle times decrease.

WARNING

Never exceed the cycle times listed above. In order to avoid injury and maintain manufacturer’s warranty never operate

outside of these recommendations.

F. Recommended flowrates are as follows:

2 to 2 1/2 GPM for 1100 series units

2 to 4 GPM for 2200 series units

2 1/2 to 6 GPM for 3300 series units

G.Hydraulic pressure requirements are as follows:

2000 to 2500 PSI normal working pressure

3000 PSI maximum pressure

TL 1128 (TOP HOLES)

Issued August 2016

Revision No: 006

Printed in U.S.A.

Specifications

4

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. Two ( 2 ) year limited warranty from date of delivery on all units and models when properly maintained and operated

within the recommended cycle time.

NOTICE

All lift units and parts are inspected by our Quality Control Department before shipment to insure that you always receive

the highest quality available in the lift business.

For more information, please contact us at 800.535.2671 or by fax at 864.458.7519.

TL 1128 (TOP HOLES)

Issued August 2016

Revision No: 006

Printed in U.S.A.

Installation Instructions

5

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.

NOTICE

If a Bayne THINLINE® Tap-In Kit was also acquired for this installation, refer to the installation instructions included in the

Tap-In Kit manual for more detailed information.

A. Mounting lifter(s) on the truck :

1. The truck should be emptied and cleaned before any installation. The truck should be parked on a level solid surface,

a concrete floor if possible.

2. All lights, tags, steps, etc. that will interfere with the installation should be removed and/or relocated.

3. Position the lifter(s) on the sill of the truck per Figure A-1 and mounting height drawing and tack weld in place. See

Appendix A for drawings. If using an “S” unit for bolt on applications, tack weld the mounting plate in place and

attach the lifter to the mounting plate using the 1/2” studs.

NOTICE

Tack weld only at this time so that adjustments can be made if necessary.

Figure A-1

B. 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). See

Figure A-2.

30

TL 1128 (TOP HOLES)

Issued August 2016

Revision No: 006

Printed in U.S.A.

Installation Instructions

6

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. Choose and mark an acceptable location to mount the diverter valve assembly. This location should be near the

truck’s main hydraulic pressure and tank lines on the same area of the truck where the lifter is mounted.

2. Weld diverter valve mounting bracket to the truck.

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.

Dover Environmental Solutions BAYNE TL 1128 Guide

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