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Bayne Thinline BTL 208-12, Operation And Parts Manual

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Bayne Thinline BTL 208-12 Operation And Parts Manual Download Page 2

Document Number:

  1999-0212 

Issue Date:

  06/06/07 

Revision No:

  005 

Page:

  2  of  38 

 

 

TABLE OF CONTENTS

 

 

Page 

 

I.

 

THINLINE

 

®  

Specifications  

 3 

 
 
II.

 

THINLINE

 

®  

Installation Instructions  

 4 

 
 
III.

 

THINLINE

 

®  

Operation Instructions  

 11 

 
 
IV.

 

THINLINE

 

®  

Diverter Valve Information  

 12 

 
 
V.

 

THINLINE

 

®  

Maintenance Instructions  

 14 

 
 
VI.

 

THINLINE

 

®  

Actuator Assembly Instructions  

 15 

 
 
VII.

 

Trouble-shooting Chart  

 24 

 
 
VIII.

 

Appendix A 

 

1.

 

Unit Assembly Drawings  

 28 

2.

 

Mounting Height Drawing  

 31 

3.

 

Hydraulic Schematic Drawings  

 32 

4.

 

Diverter Valve Drawings  

 34 

5.

 

Hand Valve Drawings  

 36 

6.

 

Lubrication Drawing  

 38

 

Summary of Contents for Thinline BTL 208-12

Page 1: ...10 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 AND CANADIA...

Page 2: ...LINE Operation Instructions 11 IV THINLINE Diverter Valve Information 12 V THINLINE Maintenance Instructions 14 VI THINLINE Actuator Assembly Instructions 15 VII Trouble shooting Chart 24 VIII Appendi...

Page 3: ...ll materials into the hopper D The BTL 208 12 lift unit operates at a cycle time of 8 to 10 seconds for safe fast efficient service Note Cycle time is controlled by flowrate as flowrate increases cycl...

Page 4: ...to the installation instructions included in the Tap In Kit manual for more detailed information I Mounting lifter s on the truck 1 The truck should be emptied and cleaned before any installation The...

Page 5: ...e paint has dried reassemble the hand valve assembly s on the mounting bracket s Figure I 2 III Mounting diverter valve on the truck 1 Choose and mark an acceptable location to mount the diverter valv...

Page 6: ...aulic 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 foll...

Page 7: ...e weld plates to match the truck color 9 After the paint has dried reassemble the hose clamp assemblies around the hoses V Adjusting relief valve settings The diverter valve 1 figure I 4 supplies the...

Page 8: ...e necessary adapter in the G port of the diverter valve 6 Start the truck s engine and engage the hydraulic system 7 Operate the handle on the hand valve 2 figure I 4 back and forth a few times to ble...

Page 9: ...ual lifters install the hydraulic gauge at either one of the hand valves Figure I 5 12 Start the truck s engine and engage the hydraulic system 13 Setting the diverter valve lifter circuit relief valv...

Page 10: ...auge in the IN port of the other hand valve as shown in figure I 5 start the truck s engine engage the hydraulic system and repeat step 14 15 Reinstall the cap nut s 8 figure I 4 on the hand valve rel...

Page 11: ...ed at the lifter 2 ACTUATOR DUMP The rotary actuator cycles to dump the contents of the cart into the box During this cycle the slider latch automatically extends to lock the cart to the lifter 3 ACTU...

Page 12: ...bypassed to the OUT port The operation of the diverter valve does not require the use of a tank line to be run to the T port However the efficiency of the block will be significantly increased if a t...

Page 13: ...rential pressure sensing valve needing 80 psi to initially open and allow the flow regulators function The path of the lubrication oil is therefore stopped because the valve does not open When the oil...

Page 14: ...NE 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 Inspect your cart lifter on a weekly basis for loose bolt...

Page 15: ...which to assemble the Rotary Actuator Be sure that all parts are thoroughly clean and dry before starting assembly NOTE All torque values given apply to clean dry threads only Follow these directions...

Page 16: ...er races 10 with a mild solvent and dry completely Spray the inner race contact area shown in figure A 3 at each end of the pinion shaft and the inside diameter of the inner race thoroughly with LOCTI...

Page 17: ...anges and up away from the table with the center line of the key ways pointing in the position as shown in figure A 4 Center the pinion in the actuator body figure A 4 5 Coat the head portion of the r...

Page 18: ...should be facing down toward the table and mounting flanges on the actuator body as shown in figure A 6 figure A 6 7 Coat one end of the actuator tubes 3 fig A 13 around the seal area with STP Oil Tre...

Page 19: ...l port positioned to the left as shown in figure A 13 Using a rubber mallet tap the tube cap over the tubes until the tubes seat in the cap making sure that the seals remain in place 10 Place the tube...

Page 20: ...in the tube cap as shown in figure A 13 Attach the rack cap to the actuator body using the socket head bolts 22 fig A 13 and lock washers 26 Torque the bolts to 90 ft lb in the sequence shown in figur...

Page 21: ...the groove Use fingers to carefully press the seal completely into the groove as shown in figure A 11 Be careful not to score or scratch the sealing surface during the installation Install the bearing...

Page 22: ...p 5 and back toward the mounting flanges on the actuator body Hand tighten only at this time 22 Install the rack cap extension tube assembly 29 fig A 13 between the 90 fitting in the rack cap and the...

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

Page 24: ...cuit relief in diverter valve 3 Check and adjust pressure on truck system relief and full system relief in diverter valve 4 Replace hand valve Lifter operates over recommended cycle time 1 Engine idle...

Page 25: ...iverter valve 3 Consult truck maintenance manual 4 Ensure there is proper flow throughout the hydraulic system Remove any restrictions 5 Remove flow regulator cartridge from diverter valve body and cl...

Page 26: ...t 2 Broken spring on slider latch hook 3 Lower hinged hook not operating freely 1 Replace cart or install new bars 2 Replace spring on slider latch hook 3 Clean and grease hook area Lifter looses bar...

Page 27: ...Document Number 1999 0212 Issue Date 06 06 07 Revision No 005 Page 27 of 38 APPENDIX A Assembly drawings and part numbers...

Page 28: ...Document Number 1999 0212 Issue Date 06 06 07 Revision No 005 Page 28 of 38...

Page 29: ...Document Number 1999 0212 Issue Date 06 06 07 Revision No 005 Page 29 of 38...

Page 30: ...Document Number 1999 0212 Issue Date 06 06 07 Revision No 005 Page 30 of 38...

Page 31: ...Document Number 1999 0212 Issue Date 06 06 07 Revision No 005 Page 31 of 38...

Page 32: ...Document Number 1999 0212 Issue Date 06 06 07 Revision No 005 Page 32 of 38...

Page 33: ...Document Number 1999 0212 Issue Date 06 06 07 Revision No 005 Page 33 of 38...

Page 34: ...Document Number 1999 0212 Issue Date 06 06 07 Revision No 005 Page 34 of 38...

Page 35: ...Document Number 1999 0212 Issue Date 06 06 07 Revision No 005 Page 35 of 38...

Page 36: ...Document Number 1999 0212 Issue Date 06 06 07 Revision No 005 Page 36 of 38...

Page 37: ...Document Number 1999 0212 Issue Date 06 06 07 Revision No 005 Page 37 of 38...

Page 38: ...Document Number 1999 0212 Issue Date 06 06 07 Revision No 005 Page 38 of 38...

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