Bayne Revolution HD 1999-0520 Скачать руководство пользователя страница 28

Страница: 28 / 52

Issued June 2017
Revision No: 001

Printed in U.S.A.

Troubleshooting Chart

TROUBLESHOOTING CHART

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
carts.

1. Cart overweight.

1. Reduce loaded weight of cart.

2. Lifter system hydraulic

pressure too low.

2. Check and adjust pressure relief on hand valve and

lifter circuit relief in diverter valve.

3. Truck system hydraulic

pressure too low.

3. Check and adjust pressure on truck system relief and

full system relief in diverter valve.

4. Faulty hand valve.

4. Replace hand valve.

Lifter operates over
recommended cycle time.

1. Engine idle too low.

1. Adjust engine idle.

2. Faulty hand valve.

2. Replace hand valve.

3. Faulty truck hydraulic

pump.

3. Consult truck maintenance manual.

4. Trash in diverter valve.

4. Remove orifice from diverter valve body and clean

thoroughly.

5. Orifice in diverter valve

is too small.

5. Remove orifice from diverter valve body and increase

diameter.

Lifter operates under
recommended cycle time.

1. Engine idle too high.

1. Adjust engine idle.

2. Orifice in diverter valve

is too large.

2. Remove orifice from diverter valve body and replace

with a smaller diameter.

Hydraulic components
down stream of diverter
valve not operating or
operating extremely slow.

1. Truck system hydraulic

pressure too low.

1. Check and adjust pressure on truck system relief and

full system relief in diverter valve.

2. Faulty full system relief

valve cartridge in
diverter valve.

2. Replace full system relief valve cartridge in diverter

valve.

3. Faulty truck system

relief valve.

3. Consult truck maintenance manual.

4. System flow is being

restricted.

4. Ensure there is proper flow throughout the hydraulic

system. Remove any restrictions.

5. Trash in flow regulator

cartridge.

5. Remove flow regulator cartridge from diverter valve

body and clean thoroughly.

Diverter valve leaking oil
around cartridges.

1. Worn or damaged seals

on cartridge valves.

1. Install diverter valve seal kit.

Hand valve lever sticks in
up or down position.

1. Worn or broken spring

center device.

1. Install spring center kit.

2. Trash in or around hand

valve shift spool.

2. Disassemble and clean spool and housing.

3. Pressure ( IN ) and tank

( OUT ) ports are
hooked up backwards.

3. Make sure all hoses are plumbed according to the

hydraulic schematic.

Hand valve leaking oil
around shift spool.

1. Worn or damaged seals.

1. Install hand valve seal kit.

2. Worn spool.

2. Replace hand valve.

Lower hook frequently
breaking or bending.

1. Saddle to hook spacing

not adjusted properly.

1. Adjust saddle to hook spacing per Operation

Instructions.

2. Lift bars on carts are not

standard dimensions.

2. Replace cart or install new bars.

Lifter looses bar lift carts
when dumping.

1. Saddle to hook spacing

not adjusted properly.

1. Adjust saddle to hook spacing per Operation

Instructions.

Содержание Revolution HD 1999-0520

Страница 1: ...ME ____________________ 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...

Страница 2: ...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 met...

Страница 3: ...Assembly Instructions 24 Troubleshooting Chart 26 Appendix A Assembly Drawings and Part Numbers 27 1999 0520 Revolution Lifter Assembly 36 H5700009 Revolution Specification 37 6900 0700 Hydraulic Sch...

Страница 4: ...INTENTIONALLY LEFT BLANK...

Страница 6: ...aintain 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 regu...

Страница 7: ...placed over 13 inside the truck opening in the dump position thus reducing any potential spillage of materials D The lift unit operates at a cycle time of 8 to 10 seconds for safe fast efficient servi...

Страница 8: ...o 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 t...

Страница 9: ...truck color 4 After the paint has dried reassemble the hand valve assembly s on the mounting bracket s Figure 2 C Mounting diverter valve on the truck 1 Choose and mark an acceptable location to moun...

Страница 10: ...y hydraulic connections turn the truck s engine off and release all hydraulic pressure from the system Refer to the hydraulic layouts in the Figure below and hydraulic schematics while performing the...

Страница 11: ...ary actuator s 7 Disassemble each hose clamp assembly and position weld plates where needed and weld in place 8 After the weld has cooled paint the weld plates to match the truck color 9 After the pai...

Страница 12: ...t relief valve 3 and turn the adjustment screw clockwise until it bottoms out 4 Start the truck s engine and engage the hydraulic system 5 Operate the handle on the hand valve 2 Figure 4 back and fort...

Страница 13: ...on the gauge is either 200 psi less than truck system pressure or 1800 psi which ever is the lowest c Release the handle on the hand valve d Turn the truck s engine off and release all hydraulic press...

Страница 14: ...latch mechanism then place the cart at the lifter 2 DUMP The rotary actuator cycles to dump the contents of the cart into the box During this cycle the lower hook automatically extends to lock the ca...

Страница 15: ...ersons enter this area the operator most stop all motion of the lifter until the area is cleared Dump Zone To prevent serious injury or death operators and bystanders should remain outside the Dump Zo...

Страница 16: ...he distance A Figure 8 between the upper bar and the lower bar on the cart If this dimension is between 14 3 4 to 15 1 2 adjust the lift saddle spacing B as required to match the cart Figure 8 CAUTION...

Страница 17: ...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 tank line i...

Страница 18: ...rs because of the differential 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 doe...

Страница 19: ...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 bolts fittings oil leaks etc Tighten...

Страница 20: ...values given apply to clean dry threads only Follow these directions closely when repairing the Rotary Actuator 1 Install the piston seal load ring 13 Figure 9 in the small groove on the head of the...

Страница 21: ...e inner races Slide the inner races 10 on the pinion shaft radius end first as shown in Figure 11 until the races seat against the gear teeth After the races seat against the gear teeth twist the race...

Страница 22: ...o 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 Rotate the pinion shaft to engage the racks into the pinio...

Страница 23: ...Figure 21 by screwing the short threaded end into the actuator body Hand tighten only at this time the torque needed will be applied later in the procedure 9 Place the tube cap 4 Figure 21 on the tabl...

Страница 24: ...he tube cap as shown in Figure 21 Attach the rack cap to the actuator body using the socket head bolts 22 Figure 21 and lock washers 26 Torque the bolts to 90 ft lb in the sequence shown in Figure 18...

Страница 25: ...e installation Install the bearing cap seal 15 and thrust washer 32 into their respective grooves on the bearing cap mounting surface as shown in Figure 19 17 Coat the bearing cap seal area and pinion...

Страница 26: ...toward the mounting flanges on the actuator body Hand tighten only at this time 22 Install the rack cap extension tube assembly 29 Figure 21 between the fitting in the rack cap and the bulk head in t...

Страница 28: ...perating or operating extremely slow 1 Truck system hydraulic pressure too low 1 Check and adjust pressure on truck system relief and full system relief in diverter valve 2 Faulty full system relief v...

Страница 29: ...ard dimension 2 Replace cart or install new bars 3 Broken spring on lower hook 3 Replace spring on lower hook 4 Lower hook not operating freely 4 Clean and grease hook area Lift bars on cart are being...

Страница 30: ...Issued June 2017 Revision No 001 Printed in U S A Copyright 2017 Bayne Premium Lift Systems Appendix A Assembly Drawings and Part Numbers 26 APPENDIX A ASSEMBLY DRAWINGS AND PART NUMBERS...

Страница 48: ...INTENTIONALLY LEFT BLANK 44...

Страница 49: ...ion and installation information 13 possible problems 13 F final operation and mounting 4 I installation instructions 4 instructions actuator assembly 16 slowdown assembly 16 L lower hook adjustment 1...

Страница 50: ...INTENTIONALLY LEFT BLANK 46...

Страница 51: ...hers and supplied by Bayne the same being subject to warranties if any provided by their respective manufacturers BAYNE MACHINE WORKS INC will not warranty wear items used for anti friction purposes B...

Страница 52: ...www baynethinline com Customer Care 800 535 2671 Fax 256 585 6762 Bayne Premium Lift Systems 402 North 44th Avenue Phoenix AZ 85043...

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