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LOADMASTER
EXCEL SERIES
Maintenance & Repair Manual
General Body & Hydraulics
General Body & Hydraulics
General Body & Hydraulics
General Body & Hydraulics
loadmaster@loadmaster.org
100 west eleventh avenue
Norway, Michigan 49870−0186
Your
....
800−433−2768
tel 906−563−9226 tel
po box 186
fax 906−563−9800 fax
Released June28, 2007
This manual is publication 7700043
Partner
Waste Equipment
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Summary of Contents for LOADMASTER EXCEL Series
- Page 1 LOADMASTER Your Partner …. Waste Equipment EXCEL SERIES Maintenance & Repair Manual General Body & Hydraulics General Body & Hydraulics General Body & Hydraulics General Body & Hydraulics loadmaster@loadmaster.org 800−433−2768 100 west eleventh avenue tel 906−563−9226 tel po box 186 fax 906−563−9800 fax...
- Page 2 TABLE OF CONTENTS Excel 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 EXCEL. See other manuals for other LOADMASTER products. For the Excel Product… There are 3 manuals for a complete set: 1- the OPERATOR’S MANUAL with Preventive...
- Page 4 800-433-2768 EXCEL {page date 06-19-07} Some NOMENCLATURE…the “words” Loadmaster uses…lingo to “talk” Gate lift Upper Light Pod cylinders The “Chassis” The Hopper Hopper Sill The “body” The “Tailgate” or Slider just “Gate” Blade Under sill “light Sweep Slider Shoes Blade...
- Page 5 800-433-2768 EXCEL {page date 06-19-07} Some NOMENCLATURE…the “words” Loadmaster uses Gate’s main “Hinge” “Decals” Tail-side Controls Gate Lift Cylinder Gate Ajar Switch Knobbed Levers “Button” Switches Return Filter Lite (amber) “PTO-Engaged” LIte (red) Gate-Ajar Lite (red) TurnBuckle Mud Flap Pressure Filter (opt)
- Page 6 body-mounted valve is a 2-spool GRESEN V20. The Section 01 rel june 28, 2007 inlet cover. lowermost cover is the The inlet cover is HOW IT WORKS..THE HYDRAULICS closest to the pump and directly connects to the pump pump pressure hose. by the The inlet cover holds the main relief...
- Page 7 is actually relieving, this anticavitation check precludes The EXCEL uses a valve called the synkpak valve to powerful suction effects that could extrude the sweep control the ejector blade/tellescopic cylinder’s automatic cylinder’s piston seals. drift forward (towards the cab) on the route. See the throttle The last working section (the one with the very next topic labeled “EXCEL SYNKPAK”...
- Page 8 The tailgate up/down function… The EXCEL’s tailgate is power-up and gravity-down (known as The auxiliary return hose provides the return path to “single-acting”). The lowermost spool section of the tank during tailgate raising or lowering. body-mounted valve is the “tailgate” section and is The ejector function…...
- Page 9 The compact blades function… tailgate- sweep Two of the shifted. The cylinders begin to move first with all mounted valve’s working sections controls the two of the pump’s flow going to the sweep cylinders. (The compaction blades. The blade that pivots (rotates) is sweep’s valve section is closest to the pump and its sweep blade.
- Page 10 LOADMASTER uses a fixed, non-adjustable secondary port relief that is set to the correct value for the EXCEL. Do not shim adjust any of LOADMASTER’s non- adjustable reliefs. [Sec01-pg05]...
- Page 11 It increases the slider blade speed in the payload/densification performance). downward The orifice size Loadmaster uses in most cases (for options) is 7/64” (non-packing) direction only. The schematic diameter drill size. below is the EXCEL hydraulic circuit with the regen valve installed.
- Page 12 pilot pressure Whenever the at a sequence cartridge is EXCEL SYNKPAK revision 10-03-02 setting greater than that cartridge’s …the cartridge opens. On the route, the EXCEL’s ejector blade must slowly and automatically drift forward (towards vehicle cab) in a As mentioned earlier, the two sequence cartridges are in controlled, pressured fashion to generate good payloads series.
- Page 13 If you become “lost”, acquire fresh cartridges turn your attention to the synkpak valve. from LOADMASTER. Then remember to install in proper positions..the settings are different. Save your old To dial in your two synkpak settings would require cartridges, they could be reset on the bench.
- Page 14 LOADMASTER has installed the male gauge stem for gauge coupling at the inlet cover of the body-mounted valve as standard equipment. SWEEP KNOCK-OUT POSITIONER…...
- Page 15 SERIES (april2004) configured LOADMASTER’s chassis used. LOADMASTER uses IDEC brand quality specification. This valve has usually has 3-4 work relays. These relays are the yellowish, transparent “ice sections. Closet to the pump will be any “option” cube” relays that are typically located in a protected worksection(s), followed by the sweep worksection, and “inside-the-cab”...
- Page 16 both back to home position (both hand levers will Section 02 Checks and Setups have “kicked-out” to neutral). CHECK and SETUP… BLADES Record this number of seconds and repeat the time measuring process a total of three times for best CYCLE TIME”...
- Page 17 The EXCEL specification is 2,950 PSI +/- 50 PSI Tighten jamb nut and install acorn nut cap. @ Throttle Advanced RPM (usually about 1400 Never exceed the LOADMASTER specification. Expensive rpm). component failures and/or structural damage can occur. Also, if the main relief is set too low, loss of compaction and/or functional performance can occur.
- Page 18 2-Do the “checking” procedure (above) to find out “where” the K-O CHECKING AND ADJUSTING THE KNOCK-OUT positioner is presently set at. (CONT’D NEXT PAGE) POSITIONERS The EXCEL’s correct knock-out specifications are… SLIDER 2700-2750 PSI @ THROTTLE ADVANCED (will “advance” automatically during procedure) SWEEP 2200-2250 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 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 positioner 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 EXCEL specification.
- Page 20 LOADMASTER a brand new bench set cartridge. Fortunately, changing out this cartridge type valve is a relatively fast operation and the cartridge itself is not...
- Page 21 upper cartridge out of it’s body cavity. This will preclude having oil gurgling out into body (a mess and a fire CHECK AND ADJUST THE EXCEL’S hazard). “SYNKPAK” VALVE See “synkpak” information, also. free Assure the synkpak’s body’s cavities are clean and of debris before re-installing the cartridges (use penlight A proven “rule of thumb”...
- Page 22 DETAILED LOCKOUT/TAGOUT PROCEDURES. cylinder’s linkage. Another possible cause is a “bad” ground somewhere. A lot to LOADMASTER’s circuitry is designed as “make a ground and something SERVICE/MAINTENANCE PEOPLE MUST UNDERSTAND is supposed to happen.” (This is actually true of many DC circuits).
- Page 23 Assure yourself the PTO drive ratio is per spinning too fast and probably should adjust downward to reduce LOADMASTER spec (usually about 1:1.3 for EXCEL) if it has been noise emissions and not be “over-speeding” the componentry, which replaced in last few months.
- Page 24 If you suspect the EXCEL is not packing-out properly…First check LOADMASTER stocks this “secondary port relief” (with new seals) as the hydraulic pressure settings that are most important in terms of P/N 8800605 (3800psi @ crack flow) for the EXCEL. Never substitute...
- 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 Re-installing procedure: Use a open end wrench to unscrew the anticav plug from the valve housing. Use the wrenching flats closest to the Preassemble the cartridge, the load check and spring. Use valve housing. plenty of common grease to hold it all together. Smear The cartridge will come out of cavity “as a unit”.
- 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 Reconnect the red, positive battery cable FIRST! procedures for the repair the tailgate lift cylinders’ seals. Reconnect any harness connectors in battery box.
- Page 30 THE STOP possibility that the gate could suddenly fall. SHAPED TAB VEE LOADMASTER will offer some suggestions in this STOP TAB section, but your shop must ultimately satisfy this requirement. It is critical that it be understood that all three of the just two above support methods be provided.
- Page 31 Your shop may have some other way to provide this additional the EXCEL’s prop rods to their storage pockets. When support that LOADMASTER can not anticipate here. Be certain returning the prop rods to their storage pockets, do not the first two means of support...
- Page 32 “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! Sec04-pg07 Loadmaster uses ½” dia.
- Page 33 Sec07-pg18 (blank for “notes”)
- Page 34 Hydraulics Schematic…XL TYPICAL> LEFT “HALVE” june ’09 REV...
- Page 35 Hydraulics Schematic…XL TYPICAL > RIGHT HALVE june ’09 REV...
- Page 36 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 37 Electrical Schematic… BLANK...
- Page 38 Electrical Schematic…OVERALL “GENERIC” (left “Halve”)
- Page 39 Electrical Schematic…OVERALL “GENERIC” (right “Halve”)