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LEGACY 3 SERIES
MAINTENANCE & REPAIR MANUAL
GENERAL "BODY" &
HYDRAULICS
LOADMASTER
100 W ELEVENTH AVENUE
PO BOX 186
NORWAY, MICHIGAN 49870
PHONE 906-563-9226
TOLL FREE 800-433-2768
FAX 906-563-9800
EMAIL loadmaster@loadmaster.org
RELEASE APRIL 2006
This is Manual p/n 7700003
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Summary of Contents for LOADMASTER LEGACY 3 Series
- Page 1 LEGACY 3 SERIES MAINTENANCE & REPAIR MANUAL GENERAL “BODY” & HYDRAULICS LOADMASTER 100 W ELEVENTH AVENUE PO BOX 186 NORWAY, MICHIGAN 49870 PHONE 906-563-9226 TOLL FREE 800-433-2768 FAX 906-563-9800 EMAIL loadmaster@loadmaster.org RELEASE APRIL 2006 This is Manual p/n 7700003...
- Page 2 TABLE OF CONTENTS Legacy “3” Maintenance & Repair…general “body” and “Hydraulics” Hydraulics Manual…w/ Hydraulics Repair Schematics…Hydraulics & Electrical Nomenclature “LoadMaster lingo Pgs a & b Section 01 Hydraulics…”how the system works” Sec01-pg01 thru sec01-pg08 Section 02 Hydraulics…Checking & Adjusting the various Hydrau settings...
- Page 3 It includes general body Maintenance & Repair AND is the Hydraulics Manual as well. The information contained in this Manual applies ONLY to the LEGACY3. See other manuals for other LOADMASTER products. For the Legacy Product… There are 3 manuals for a complete set: 1- the OPERATOR’S MANUAL with Preventive...
- Page 4 800-433-2768 LEGACY3 {page date 04-12-06} NOMENCLATURE…the “words” Loadmaster uses…use this lingo to “talk” The “Chassis” Tailgate lift cylinders Upper LightPod Hopper The “body” Undersill Riding step Sweep “light bar The “tailgate” Slider Blade Hopper Blade hopper’s Sill Tellescopic Chute Cylinder Ejector Blade The “Body-Mounted Valve”...
- Page 5 800-433-2768 Gate’s “hinge” LEGACY3 {page date 04-12-06} NOMENCLATURE…the “words” Loadmaster uses…best lingo to communicate with LOADMASTER people “Decals” Tailside-Control “Shafts/Tubes” Gate Ajar Switch Knobbed Lever Gate Ajar Light Rocker Switches “Button Switches” In-cab “Rocker Panel” Gate’s Turnbuckles MudFlaps Access Door “Body-Mount”...
- Page 6 pressure gauge readings will be recorded. The LEGACY’S Section 01 main relief setting is *3150 PSI +/- 50 PSI @ throttle HOW IT WORKS..THE HYDRAULICS auxiliary advanced. The inlet cover also connects the return hose to tank. This auxiliary return provides a path to tank for the body-mtd valve’s functions, since the This section of the manual is an overview of the various power beyond sleeve...
- Page 7 “ratio” built-into the scheme…The is actually relieving, this anticavitation check precludes ratio Loadmaster employs is .85. <1250 setting divided by .85 powerful suction effects that could extrude the sweep equals 1500 psi> When the hopper blade pressure sensing cylinder’s piston seals.
- Page 8 The open loop… When no functions are being performed (all valve spools in their centered, neutral position); the oil flow If the hand lever labeled tailgate is pushed inward , the pump follows a path known as the “open loop”. It originates at the will connect to the gate cylinder’s “lower”...
- Page 9 upstream When the LEGACY3 is “on-the-route” (tailgate fully lowered blocked …this means that the shifted spool and latched , of course), the ejector blade begins parked at closet to the pump (the upstream sweep section) will rear of body and then slowly, automatically drifts forward consume of the available pump flow with any (towards cab) as the garbage is collected and the payload...
- Page 10 LEGACY. Do not shim adjust any of LOADMASTER’s The sweep’s secondary port relief is set to *3700 PSI @ non-adjustable reliefs. “crack”. (Crack being 2 GPM). This particular relief must use VITON seal for performance reasons.
- Page 11 ORIFICES (speed control) and/or workport mounted will have been typically programmed for 1400RPM. This PORT RELIEF(S) (pressure control) with or without programming is same regeneration (which is unlike Loadmaster’s EXCEL models…thrtl adv This chart applies to LEGACY3 (may2004/apr 2005): programming value will change EXCEL “regeneration”…see EXCEL’s manuals).
- Page 12 Later in the day …when hopper blades pressure has LOADMASTER has installed the male gauge stem for risen above 1400 psi….the sensed hopper blades gauge coupling at the inlet cover of the body-mounted pressure will “open” the resistance cartridge. This 1400 valve as standard equipment.
- Page 13 “harness”. The TELESCOPIC CYLINDER…The ejector blade is actuated by a overall electrical harnessing is made up of several HYCO telescopic cylinder. It is built to a LOADMASTER subharnesses dimensional specification for to suit the LEGACY3. When the...
- Page 14 LEGACY3 capabilities. The person manning the controls must be in a state LOADMASTER does not require this speed. A slower of ready to “push in” (and release) the hand control blade speed (longer cycle time) can be acceptable. levers at the very instant that both levers are seen to kick-out to neutral.
- Page 15 Turning the adjuster outward (ccw) will decrease Legacy3 (only). the setting. Tighten jamb nut when done “adjusting”. Never exceed the LOADMASTER specification. Expensive component failures and/or structural damage can occur. Also, if the main relief is set too low, loss of compaction Guage, hose, coupler and/or functional performance can occur.
- Page 16 The best way to check “where the resistance cartridge is “set” is to remove it from the cavity and check it’s setting on a Loadmaster “bench-test stand”. There is no available way to check the Resistance-Cartridge’s This is the .062 diameter ORIFICE…orifice “setting”...
- Page 17 CHECK and SETUP…EJECTOR’S 6- Shift the hand lever labeled “ejector” to the position labeled “extend” and hold it there (‘”soaking” the “PUSH-OUT” PRESSURE ejector extended since it is already fully extended). throttle advanced Read the gauge while holding the This is the ejector’s “push-out pressure”. “PUSH-OUT PRESSURE”...
- Page 18 CHECKING AND ADJUSTING THE KNOCK-OUT POSITIONERS FOR LEGACY3 The LEGACY3’s correct knock-out specifications are… SLIDER 2950 PSI @ THROTTLE ADVANCED (will “advance” automatically during procedure) SWEEP 2250 PSI @ THROTTLE ADVANCED (A second person will have to hold depressed a t- adv button switch for sweep).
- Page 19 CHECKING AND ADJUSTING THE KNOCK-OUT POSITIONERS…(CON’TD) LEGACY “3” 3-The “rule of thumb” is…1/4 turn of the k-o’s allen-head adjuster is roughly equivalent to 100 PSI of setting change. Based upon where the k-o positoner is presently “checked” to be set at…turn the k-o’s allen head adjuster inward (cw…raising the pressure setting) or outward (ccw…lowering the pressure setting) to get closer to the LEGACY3 specification.
- Page 20 Troubleshooting to order from LOADMASTER a brand new bench set cartridge Section of this manual for other possible causes and remedies.
- Page 21 [Sec02-pg08]...
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Page 22: Troubleshooting
DETAILED LOCKOUT/TAGOUT PROCEDURES. Another possible cause is a “bad” ground somewhere. A lot to SERVICE/MAINTENANCE PEOPLE MUST UNDERSTAND LOADMASTER’s circuitry is designed as “make a ground and something OPERATION THE SAFE OF THE LEGACY3 AND RESPECT is supposed to happen.” (This is actually true of many DC circuits). - Page 23 LOADMASTER spec (usually about 1:1.3 for LEGACY; varies; you are spinning too fast and probably should adjust downward to contact Loadmaster) if it has been replaced in last few months. If PTO reduce noise emissions and not be “overspeeding” the componentry, ratio is wrong, the pump itself will spin at wrong speed and you will which really will shorten their life.
- Page 24 “mid-range” packer, not a so-called “high compaction” unit. (High compaction units, like the LOADMASTER EXCEL, are said to be capable allowable levels. The “secondary port relief” is a of doing 1000 pounds per cubic yard.) Keep in mind that the LEGACY cartridge type port relief installed in the sweep is not supposed to be generating 1000 pounds per yard…although it...
- Page 25 PM practices. When ordering that particular valve section from LOADMASTER, be certain you order exactly “that” section… they may appear all the same but they are not. This type of failure sometimes has the spool nearly or completely “frozen”...
- Page 26 Install the new pump to the PTO. Make sure you have the same pump as the original (available from LOADMASTER). Clean up the system. Start by installing a new return line filter. Pull the tank’s magnetic drain plug (in tank’s floor) and clean it up.
- Page 27 Removal procedure; to the cartridge. Use a magnet wand to fish out the mushroom shaped check and spring. Use a penlight to 1- Before removing any port mounted anticavitation by gravity look inside cavity for any debris such as pieces of old O- check, position the blades so it will not move must be rings or the backup ring.
- Page 28 The obvious service advantage is that an individual section can be repaired or replaced while re-using all the other sections. It is important to order from LOADMASTER the particular section you will be replacing. Sections right next to each other...
- Page 29 Reconnect Procedure: LOADMASTER can fax to you at your request the service procedures for the repair the tailgate lift cylinders’ seals. Reconnect the red, positive battery cable FIRST! These procedures written LOADMASTER’s...
- Page 30 Your shop must supplement the above two with additional mechanical support to eliminate any possibility that the gate could suddenly fall. LOADMASTER will offer some suggestions in this section, but your shop must ultimately satisfy this requirement. Very slowly begin raising-up the tailgate (“feather it”) until...
- Page 31 Your shop may have some other way to provide this additional the gate and the body) while a second person (at the support that LOADMASTER can not anticipate here. Be certain tailgate raise/lower hand lever) will very slowly lower the the first two means of support remain effective when rigging tailgate.
- Page 32 If your Legacy “3” has standard turnbuckle style gate latches…then the tailgate service prop rod will be different from the last two pages description (which was written as for a Legacy 3 with the optional AutoLoks). If your Legacy 3 has standard turnbuckles, be sure the end of both tailgate prop rods is inserted into the VEES that are welded to the end of the body ejector trackings.
- Page 33 “anchoring”. The 2-10 uses ½” diameter cable. KEEP THE “CLIP” CLOSEST TO THE LOOP’S THIMBLE AS CLOSE TO THIMBLE AS IS PRACTICAL. INSPECT THE CABLE’S CONDITION AND CABLE’S ROOF-TOP CABLE “ANCHOR” AT LEAST WEEKLY [sec07-pg08] Loadmaster uses ½” dia.
- Page 34 Hydraulics Schematic…FRONT PUMP WITH WET VALVE...
- Page 35 Hydraulics Schematic…FRONT PUMP WITH WET VALVE -and- OPTIONAL REGENERATION VALVE...
- Page 36 Hydraulic Schematic…LOADMASTER’S “own” CartTipper Divertor & HandValve circuit “patch-in”..SINGLE Note: see separate LoadMaster Manual “dedicated” to the CT-HV/D circuit…for more details This schematic is a “SINGLE” CT...
- Page 37 Hydraulic Schematic…LoadMaster’s “own”…CT-HV/D Cart Tippers patch-in…DUAL TIPPERS Note: THESE CT circuits “only” are accurate for the LOADMASTER Divertor/ LOADMASTER’s Hand Valve(s) If your LOADMASTER has a Tipper Company supplied Hydraulic circuit…the schematic for “it” will be in TipperCompany’s manual.
- Page 38 Electrical Schematic… Chassis Interfacing Generic Diagram LoadMaster will “record” each Chassis Interface on “this” Schematic…this CHASSIS-TO-L/M BODY hard wiring “Varies” per “chassis; diesel; transm; pump; etc….
- Page 39 Electrical Schematic… BLANK...
- Page 40 Electrical Schematic…OVERALL “GENERIC” (left “Halve”) ‘16> <SEPT...
- Page 41 Electrical Schematic…OVERALL “GENERIC” (right “Halve”) ‘16> <SEPT...