Installation Manual:

TM
i-6000 SERIES LIVE FLOOR CONVEYING SYSTEMS
One-Way (i-6100) and Two-Way (i-6200)

West Coast USA Central USA East Coast USA

6605 Ammunition Road 8276 Hwy. 16 North 480 Millrun Rd.
P.O. Box 505 Poteet, TX 78065 Salisbury, NC 28144
Tillamook, OR 97141 Ph. 877-425-5261 Ph. 800-230-0190
Ph. 800-542-5526 Ph. 830-742-8441 Ph. 704-636-4122
Ph. 503-842-8886 Fax: 830-742-8682 Fax: 704-636-1644
Fax: 503-842-4866
Web: www.hallcoind.com Email: info@hallcoind.com Doc # 99-5559
 -FOR YOUR SAFETY-
Read Carefully Before Operating Floor

This floor contains moving components and carries large loads which are capable of causing injury or death, if the
following precautions are not followed carefully:
• Lock out or isolate the power source from floor while performing installation, inspections, cleaning, or
maintenance.
• Keep all body parts clear of the floor mechanisms while the floor is operating.
• DO NOT operate floor while a person is on the floor.
• DO NOT stand at the opening of the container while the floor is unloading or in the way of the unloading doors
which may be pushed by the moving load.
• Use caution when opening container doors even when floor is not operating. The load may have shifted
against the door in transit causing the door to open rapidly when unlatched.
• DO NOT operate the floor in the unloading direction with the unloading door(s) closed. DO NOT shift the load
material against the forward wall with the floor. The installing activity must provide a means for the operator to
visually monitor the load when shifting it forward. This floor is capable of causing serious damage to the box
structure and may pose a safety hazard, if the load is shifted against the rear or forward box structure.
• DO NOT operate floor above the maximum operating pressure specified in this manual.
• Observe Hallco safety sticker instructions.

-INSTALLATION NOTICE-

Installing your Hallco LIVE FLOORTM system will require some alterations to your truck, trailer,
or bin. Any alterations without the approval of the equipment manufacturer may void the
equipment warranty. Check with the equipment manufacturer before performing any alterations.
This installation manual is intended as a guide only and may not cover all the nuances of your
application.
Hallco assumes no liability for damages which may occur as a result of installing any of the LIVE
FLOORTM systems manufactured by Hallco Industries, Incorporated.

-Related Document-

Refer to the i-6000 Series Owner’s Manual, document # 99-5560, for additional information
which may not be included in this manual, such as
• Unload Speeds
• Floor Maintenance: Cleaning, Inspections, Repairs
• Subassembly Exploded Views
• Parts Numbers

Copyright 2010 2 Doc # 99-5559

TABLE OF CONTENTS

SAFETY.............................................................................................................................................................2

INSTALLATION NOTICE ...................................................................................................................................2

RELATED DOCUMENT .....................................................................................................................................2

SPECIFICATIONS .............................................................................................................................................3

HOW THEY WORK............................................................................................................................................4

FLOOR COMPONENTS ................................................................................................................................ 5-6

HYDRAULIC SYSTEM REQUIREMENTS ..................................................................................................... 7-8

FLOOR LAYOUT ..........................................................................................................................................9-10

INSTALLATION STEPS ..............................................................................................................................11-40

1. CONTAINER PREPARATION ...................................................................................................11-13
2. DRIVE UNIT—CENTER FRAME STYLE...................................................................................14-17
3. DRIVE UNIT—PERIMETER FRAME STYLE.............................................................................18-20
4. SUB-DECK ................................................................................................................................21-24
5. SIDE TRIM SUPPORT ...................................................................................................................25
6. BEARINGS ................................................................................................................................26-27
7. DECKING ..................................................................................................................................28-30
8. SIDE TRIM .....................................................................................................................................31
9. SLOPE SHEET & WIPER...............................................................................................................32
10. PLUMBING................................................................................................................................33-35
11. SAFETY & OPERATIONAL DECALS .............................................................................................36
12. CHECKLIST ...................................................................................................................................37
13. SETTING THE SWITCHING ROD STOPS .....................................................................................38
14. OPERATION & TESTING...............................................................................................................39
15. HOLD DOWN BLOCKS ..................................................................................................................40

TROUBLESHOOTING .....................................................................................................................................41

WARRANTY ....................................................................................................................................................42

SPECIFICATIONS
Hydraulic Module: i-6100 (One-Way) or i-6200 (Two-Way)
Maximum Hydraulic Pressure: 3000 psi [207 Bar]
Maximum Hydraulic Flow Rate: 30 gal/min [114 l/min]
Floor Stroke: 9.1/4 inches [235 mm]
Hydraulic Module Shaft Diameter: 1.5 inch [38.1 mm]
Hydraulic Module Cylinder Diameter: 3.5 inches [88.9 mm]
Load Capacity: 45 Ton [40 Tonne]

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HOW THEY WORK

1. All Slats Move Together Moving the Load With Them. →

← 2. One-Third of the Slats Retract.

Two-Thirds Hold the Load.

3. Next One-Third of the Slats Retract. →

Two-Thirds Hold the Load.

← 4. Last One-Third of the Slats Retract.

Two-Thirds Hold the Load.

Cycle Repeats....

-Figure 1-
How They Work

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Copyright 2010
FLOOR COMPONENTS

Slope Sheet

5
Deck Slat

Deck Bolt

Cross Drive Shoe

Cross Drive
Hydraulic Module
Control Valve
Hold Down Block
Drive Unit Frame

Bearing -Figure 2-
Sub-deck Floor Components

Doc # 99-5559
 -Figure 3-
Drive Unit - Center Frame Style

-Figure 4-
Drive Unit - Perimeter Frame Style

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HYDRAULIC SYSTEM REQUIREMENTS

HALLCO RECOMMENDS CONSULTING A HYDRAULIC SPECIALIST

TO CONFIGURE THE HYDRAULIC SUPPLY SYSTEM.

Hydraulic
Pump: This floor is rated to 3000 psi [207 Bar] operating pressure. Installing a pump which provides
lower output pressure may result in poor operation. Maximum flow rate is 30 gallons [114 liters]
per minute.

Hydraulic
Reservoir: 30 gallons [114 liters] minimum capacity. The hydraulic reservoir must have facilities to mount
the relief valve and a return line filter. Both of these items must dump the oil into the reservoir
below the low level line. Hallco suggests a down draft be installed in the reservoir on the return
line to limit the turbulence. The pump supply oil should be taken from 1” to 2” [25 to 51 mm]
above the bottom of the reservoir. This outlet should be screened or baffled to prevent whirlpool.
The whirlpool could introduce air into the system. A sight gauge or other means of visually check-
ing oil level should be installed.

Hydraulic
Oil: Select a petroleum or mineral base anti-wear (AW) hydraulic fluid in ISO viscosity grade 46 or
68. Most synthetic and vegetable based biodegradable hydraulic fluids are also compatible pro-
vided the moisture content in the fluid is kept below 1%. Hydraulic fluid temperatures must al-
ways be kept below 200° F [93° C].

Relief
Valve: The relief valve must be external, relieved directly to tank, and set at 3000 psi [207 Bar] maxi-
mum. The relief valve must be able to handle the maximum system flow rate.

Filler Cap: Filler cap must have a fill filter and a breather cap (unless already provided separately).

Hydraulic
Plumbing: 1” [25 mm] size hydraulic hoses are recommended for the supply and return lines which connect
to the switching valve ports labeled “P” for pressure and “T” for tank/return. See Figure 39, page
33.

Quick
Connects: Mating quick connects must be of the same type and must be rated above the maximum system
flow.

Filter: A 25 micron (or finer) filter rated above the maximum flow rate of the system must be installed on
the return line. A good filter is essential to assure clean oil for a long system life. For units where
quick connects are frequently connected and disconnected (where contaminants may be intro-
duced) a pressure line filter is recommended between the quick connect and the hydraulic mod-
ule.

Pressure
Gage: 0 to 5000 PSI [0 to 350 Bar] range, glycerin filled.

Copyright 2010 7 Doc # 99-5559

 -Figure 5-
Example Hydraulic Supply System

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FLOOR LAYOUT

Sub-Deck End to
Forward Wall:
0 to 10" [0 to 254 mm]
Deck Front Clearance:

Stroke:
9.1/4" [235 mm]

Sub-Deck Overhang:
7/8" [22 mm]

38 1/2" [978 mm]

Rear Sub-Deck Length

Sub-Deck Overhang:
7/8" [22 mm]

Deck/Hold-Down Overlap:
1.3/4" [44 mm]

End of Sub-Deck to Door:

Deck Rear Clearance:

2" [51 mm]

-Figure 6-
Floor Layout
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 Perimeter Frame Width

Drive Unit Hanger

Side Rail (Various Options--Not
Supplied By Hallco)
Perimeter Frame

-Figure 7-
Perimeter Frame Style Installation -- End View

Cross Member Length

Center Frame Width: 16.3/4" [425 mm]

Cross Member Height

Drive Unit Center Frame Side Rail

Shear Plate (If Requested)
Container Center Frame Longitudinal

-Figure 8-
Center Frame Style Installation -- End View

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INSTALLATION STEPS
Perform this installation with the container placed on a flat, firm and level surface. The Live Floor must be in-
stalled in a container with cross members which are straight and level. The side rails and walls must be straight
and the container free from twisting and bowing (a slight center arch from front to rear is okay if it is gradual).

1. Container Preparation
The following steps are for retrofit installations primarily, but the principles still apply to new installations.
a. Determine where the drive unit will be installed — preferably approximately centered on the container length.
Mark the cross members which will need to be removed to provide clearance for the drive unit (see Figure 10,
page 12). Do not remove these cross members at this time.

TIP: Locate the drive unit such that standard lengths of sub-deck can be used in front of or be-
hind the drive unit. Standard sub-deck lengths are 20 & 24 ft [6096 & 7315 mm].

b. Important Note: In many containers the floor is a structural member providing necessary support and
strength to maintain the straightness of the container. Prior to removing the existing floor, install cross brac-
ing (perimeter frame containers) in front of and behind where the drive unit will be located to hold the
straightness of the trailer (unless of course the container is not straight and will first require correction).
c. Remove the old floor. This includes the floor pan/decking, deck screws, clips, debris, weld slag — everything
above the cross members and between the side walls where the LIVE FLOORTM system will be installed.
The tops of the cross members must be clean and smooth.
d. Check the container to make sure the cross members are straight and level and the side walls are straight
using the following methods:
Cross Member Check:
Use a straight edge, slightly shorter than a cross member. Lay the straight edge across the length of
each cross member and check them for bowing. Each cross member must not be bowed more than
1/8” [3 mm]. Use the straight edge to check that the tops of the cross members do not vary vertically
more than 1/8” [3 mm] between adjacent cross members (see Figure 11, page 12). Low cross members
can be shimmed on top to bring them to the level of the surrounding cross members, provided they are in
good condition and uniformly low.
Frame & Side Wall Check:
From the back of the container sight down the length and visually check for twisting, bowing, and other
frame problems.
Use a string to create a reference centerline running from the front of the container to the rear (to be used
in later steps too). At the front start the string at the midpoint between the side walls. At the rear end it at
the midpoint between the side walls. Pull the string tight and secure it about 1” [25 mm] above the cross
members. Measure every 18” [0.5 m] all along the length of the container from the side walls to the string.
These measurements will show whether there is any bowing of the side rails and lower side walls and
should correspond with bowing which is visible when sighting from the back. Bowing more than 1/4” [6
mm] needs to be corrected.
Straight Edge

Side Rail Cross Member

-Figure 9-
Checking for Cross Member Bow

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 Straight Edge

Cross Member

-Figure 11-
Checking Cross Member Level
Cross Bracing

Measure Measure
Every 18" [0.5 m] Every 18" [0.5 m]
FWD

Centerline String

Bowing
Clearance for Drive Unit:
77.1/2" Absolute Minimum
85.1/2" Recommended

Cross Member

Side Rail/Wall

-Figure 12-
Checking for Side Rail Bowing
-Figure 10-
Container Preparation

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e. Provide a back sill plate made from approximately .100” [2.5 mm] thick material which extends from the rear
bumper to a cross member located 14” [356 mm] from the rear door (see Figure 13, below). The top of the
sill plate must be level with the tops of the cross members. This sill plate is for mounting the rear hold-down
blocks and acts as a pan between the hold-down blocks when the deck slats cycle forward.
f. Provide at least two cleanout holes 4” [100 mm] in diameter at the front of the trailer, if there is a pan under-
neath the floor such as a fifth wheel plate (see Figure 13, below).
g. Hallco recommends that the first cross member behind the forward wall be placed 12” [305 mm] minimum
from the inside edge of the wall (see Figure 13, below) so that the forward-most deck bearings installed over
that cross member will be far enough back that the front edge of the deck never cycles past the front edge of
the bearings. Alternately the bearings may be installed behind that cross member, if it is closer than recom-
mended — as long as the front edge of the bearings is always behind the front edge of the deck when it
moves back.
h. Remove the cross members where the drive unit will be installed. Clean the side rails in this area. Remove
broken bolts. Grind smooth any welds or slag. The side rail mounting surface must be clean and smooth for
proper installation.
i. Temporarily remove or reroute the air and electrical lines in the area where the drive unit will be installed.

Cross Member

Cleanout
Holes

Sill Plate
Front Wall,
Inside Edge

Door to Cross Member (Recommended)

Inside Edge of Door

-Figure 13-
Preparing Front & Rear of Container

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2. Drive Unit—Center Frame Style

NOTICE: Protect the chrome cylinder shafts during welding, burning, grinding and painting.
Any scarring of the shafts may damage the hydraulic seals resulting in system leakage.
a. Cut four short steel cross members as shown in Figure 14, page 15, which will provide a 16.3/4” [425 mm]
gap for the drive unit center frame. Make sure the gap will be centered on the centerline string. Note the
positions and the clearances specified in Figure 14, page 15. Do not attach the short cross members to
the container at this point. Also note that a notch may have to be made in the left rear short cross mem-
ber for the switching rod.
b. Position the drive unit in place with the switching valve end of the drive unit toward the rear as shown in
Figure 17, page 16. Maintain the position and clearances specified in Figure 14, page 15. The top of the
center frame must be level with the tops of the cross members. Use a straight edge to make sure the top
of the drive unit frame is flush with the tops of the cross members. Align the “C/L” marks on the rear and
front head manifolds of the hydraulic module with the centerline string. Check the alignment to centerline
using a square as shown in Figure 16, page 15.
c. Tack weld the four short cross members to the side rails and container center frame longitudinals, or
clamp them in place. Also, tack weld them to the drive unit center frame.
d. Recheck the alignment, position, and clearances of the drive unit and the short cross members.
e. Weld the short cross members to the drive unit center frame. Also, finish attaching them to the container
center frame longitudinals and the side rails.
f. Supply shear plates (or use Hallco-made shear plates) which will extend from the drive unit center frame
to the container center frame longitudinals. The undersides of the shear plates must mate with the top
side of the container center frame longitudinals (see Figure 8, page 10). Note that cutouts will be required
to access the deck nuts and switching rod bumpers from underneath.
g. Tack and then finish weld the shear plates to the container center frame longitudinals and to the drive unit
center frame with 1/4” [6 mm] fillet welds, 2” [51 mm] long with 1” [25 mm] gaps between welds all along
the lengths of the shear plates. Alternately, the shear plates may be bolted to the container center frame
longitudinals per the following table.
Table 1—Minimum No. of Bolts* in Each Shear Plate
3/8” Diameter 1/2” Diameter 10 mm Diameter 12 mm Diameter
Qty 24 Qty 14 Qty 22 Qty 15
*SAE Grade 5 or better [ISO class 8.8 or better] coarse or fine threads, or equivalent fastener.
h. Grind welds which are on the top surface of the short cross members flush.
i. Additional bracing is recommended for containers with partial length center frame longitudinals to brace
the side walls against the movement of the load (see Figure 19, page 17).
j. Paint the bare metal (weld joints, etc.).

Copyright 2010 14 Doc # 99-5559

 Center Frame Longitudinal

Centerline String

3.1/4"
83 mm
Ø 1/2" Minimum
[13 mm]
Cross
Member

2"
[51 mm]

-Figure 15-
Hole for Switching Rod
Minimum Front
Short
Clearance:
Cross
Member

Cross Drive Bay:

Hole May Be 8.3/8" 38.1/2" [978 mm]
Needed for 213 mm
Square
Switching Rod
(Figure 15)
C/L String

16.3/4" Minimum Rear

425 mm Clearance:
20.1/4" [514 mm]

C/L Mark
Side Rail

Shaft

-Figure 16-
Checking C/L Alignment

-Figure 14-
Short Cross Members for Center Frame Installation

Copyright 2010 15 Doc # 99-5559

 Center Frame Longitudinal
Side Rail

Cross Member

Switching Valve

Short Cross Member

Top of Center Frame Must

Be Flush With the Tops of
Hole for Switching Rod
the Cross Members

Switching Rod

-Figure 17-
Positioning the Center Frame Drive Unit

Centerline String

Shear Plate

Align These Edges

(Front and Rear)

-Figure 18-
Aligning the Center Frame Drive Unit

Copyright 2010 16 Doc # 99-5559

 Additional Bracing

-Figure 19-
Additional Bracing -- Underside View

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3. Drive Unit—Perimeter Frame Style

NOTICE: Protect the chrome cylinder shafts during welding, burning, grinding, and painting.
Any scarring of the shafts may damage the hydraulic seals resulting in leakage.
a. Position the drive unit in place (see Figures 20 & 21, pages 18 & 19). Use at least two leveling tubes to
make sure that the tops of the drive unit frame cross members are flush with the tops of the container
cross members. Support the weight of the drive unit with something other than the leveling tubes so that
the leveling tubes remain accurate. Maintain the clearances shown in Figure 21, page 19. Align the “C/L”
marks on the rear and front head manifolds of the drive unit with the centerline string. Check the align-
ment with the centerline string using a square as shown in Figure 16, page 15.
b. Clamp or tack weld the drive unit frame in place and recheck the alignment, clearances, and position of
the drive unit.
c. Measure the difference in width between the drive unit P/F and the side rails on both sides front and rear
for designing drive unit hangers (see Figure 22, page 20). As shown in Figure 22, page 20, hangers may
not be required to joint the perimeter frame to the side rails.
d. Fabricate the drive unit hangers, if required.
NOTICE: Hangers must not extend above the tops of the cross
members, otherwise they may interfere with the deck slats.

e. Attach the drive unit hangers or the P/F directly to the side rails and to the drive unit frame. If welding,
refer to Figure 22, page 20, for the weld criteria. If bolting, use a locking device such as lock washers or
lock nuts, and install the number of fasteners required as follows:
Table 2—Minimum No. of Bolts* (Each Side) Attaching Perimeter Frame to Side Rails
3/8” Diameter 1/2” Diameter 10 mm Diameter 12 mm Diameter
Qty 16 Qty 12 Qty 16 Qty 12
*SAE Grade 5 or better [ISO class 8.8 or better] coarse or fine threads, or equivalent fastener.

f. Grind welds which extend above the top surface of the cross members flush.
g. Paint the bare metal (weld joints, etc.).

Cross Member

Clamp

Leveling Tube

NOTICE: When handling the drive

unit, lift only by the perimeter frame
cross members. Never lift by the Side Rail
perimeter frame bridge.
Perimeter Frame Cross Member Perimeter Frame Bridge
-Figure 20-
Positioning the Perimeter Frame Drive Unit
Copyright 2010 18 Doc # 99-5559
 Centerline String

Minimum Front
Clearance:

Minimum Total
Clearance:
77.1/2" [1969 mm]

Recommended
Total Clearance:
85.1/2" [2172 mm]

Minimum Rear
Clearance:
20.1/4" [514 mm]
Clamp

Leveling Tube

-Figure 21-
Perimeter Frame Drive Unit Position & Clearances

Copyright 2010 19 Doc # 99-5559

 Example 1 -- Hanger Welded to Side Rail

Side Rail
Note: Weld the hanger assembly
to the drive unit perimeter frame
the same way.

3" [76 mm] Gaps Between Welds,

Topside & Underside
Example 2 -- Hanger Bolted to Side Rail Rectangular Tubing

Note: Weld the hanger assembly

to the drive unit perimeter frame
the same way.

Side Rail Bolt, Lock Washer, Nut

3" [76 mm] Gaps Between Welds,

Topside & Underside

Rectangular Tube Example 3 --

Perimeter Frame Attached Directly to Side Rail

Side Rail

Drive Unit Perimeter Frame

Example 4 --
Shim Between Perimeter Frame & Side Rail
Using a patter similar to Examples

perimeter frame directly to side rails.

Side Rail

TIP: Use existing holes from fasteners

removed with cross members or
Drive Unit Frame
temporarily removed from side posts
as drill guides.
Fasten the perimeter frame through the shim to
the side rail or weld the shim to the side rail, and
then weld the perimeter frame to the shim. Use
Shim [76 mm] gaps between welds, topside & underside.

-Figure 22-
Example Perimeter Frame Anchoring Methods

Copyright 2010 20 Doc # 99-5559

4. Sub-deck
a. Measure and cut the front and rear sub-deck to the correct lengths. Refer to Figure 6, page 9.
NOTICE: The sub-deck is installed relative to the centerline string. This is done by installing
the middle (or one of the middle) sub-deck rows relative to the string, and then the rest of the
sub-deck is installed with a guide that engages with that first sub-deck row. Take extra care to
install the first row of sub-deck accurately.

b. Maintain the clearances and the overlaps specified in Figure 6, page 9. If there are an odd number of
sub-deck rows, position the first sub-deck row centered on the centerline string (see Figure 24, page 22).
If there are an even number of sub-deck rows, position one of the middle two sub-deck rows the specified
distance from the centerline string (see Figure 23, page 21). Clamp the sub-deck to the cross members
every 4 ft [1.2 m] of length and recheck the alignment of the row to the centerline string over its full length.
Verify that this row of sub-deck is aligned with a cross drive shoe.
c. When the alignment and position of the first sub-deck row is correct, after being clamped, attach it to the
cross members. Aluminum sub-deck may be welded to aluminum cross members or fastened to steel or
aluminum cross members. Steel sub-deck may be welded to steel cross members. Refer to Figures 25,
page 22.
d. Remove the centerline string.
e. By this point you must decide where the hydraulic lines will be routed. Most of the time hydraulic lines are
routed though holes cut in the middle of the cross members. If it is undesirable to route the hydraulic lines
through the cross members (such as over the fifth wheel plate when retrofitting), they may be routed on
top of the cross members over the obstructions and then bent down and run under the cross members
from there on. Refer to Figure 27, page 23, for this method. This is also a good point to prepare the
cross members, if the hydraulic tubes are to be installed through them.
f. Position the remaining sub-deck and use the provided sub-deck guides to space them laterally relative to
the first sub-deck row. Note the correct and incorrect ways to use the sub-deck jigs shown in Figure 26,
page 23. Place guides at the front and rear of each sub-deck piece, and clamp them in place when they
are in the correct position. Start anchoring the sub-deck to the cross members from one end using a sub-
deck guide where the sub-deck is being fastened. Fasten every sub-deck to a cross member, then move
the guide to the next cross member, fasten all the sub-deck to that cross member, and so on. Note: In the
middle regions of the container away from the doors, walls and drive unit the sub-deck may be anchored
to every other cross member. Alternate which sub-deck rows are skipped at each cross member.

Type 35 Deck: 13/16" [20.6 mm]

Type 37 Deck: 15/16" [23.8 mm]
Type 40 Deck: 1" [25.4 mm]

Aluminum Sub-deck Steel Sub-deck

Centerline
Cross Member

-Figure 23-
First Sub-Deck Row Placement -- Even Number of Sub-Deck Rows

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 Middle Sub-Deck

Centerline

Cross Member

-Figure 24-
First Sub-Deck Row Placement -- Odd Number of Sub-Deck Rows

Aluminum Sub-deck Steel Sub-deck

Weld or Fasten

680 lb [3025 N] Minimum Ultimate Shear Strength Cross Member

-Figure 25-
Sub-Deck Anchoring Options

Copyright 2010 22 Doc # 99-5559

 Subdeck Spacer Guide

Cross Member Sub-deck

Proper Spacing With Tight Guides -- CORRECT

Proper Spacing With Loose Guides -- CORRECT

Improper Spacing With Loose Guides -- INCORRECT

-Figure 26-
Correct & Incorrect Use of Sub-Deck Spacer Guides

NOTICE: When bending hydraulic tubing, use a tube bender. DO

NOT USE HEAT and DO NOT ALLOW TUBING TO BE CRIMPED.
2" [50.8 mm] Flat Bar
3/8" [9.5 mm]

Flat Bar

Hydraulic Tubing

Cross Member
Cross Member

Side View
End View Bend Tubing Down and Route Under
the Cross Members After the Obstruction

-Figure 27-
Alternate Sub-Deck For Routing Hydraulic Lines
Copyright 2010 23 Doc # 99-5559
 Sub-deck

Cross Drive
Shoe

Sub-deck
Spacer
Guides

-Figure 28-
Sub-Deck Spacer Guides -- Top View

Copyright 2010 24 Doc # 99-5559

5. Side Trim Support
a. Refer to the Hallco decking literature for information about the layout of the selected deck type and the
associated side trim. Typical side trim supports are shown in Figure 29, below. Other styles of side trim
support may be acceptable as long as they support the side trim in the correct position.
b. Secure the side trim support to the container structure (side walls and/or cross members).

Angle Side Trim Support

Tube Side Trim Support

Sub-deck

Side Wall

Cross Member

-Figure 29-
Side Trim Support

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6. Bearings
a. Install bearings onto the sub-deck at the intersections with all the cross members.
NOTE: The bearings that mount over the drive unit frame cross members are 2” bearings.
These bearings are packed separately from the rest of the bearings and are the only bearings
which should be used over the drive unit frame.
b. Fill in between the bearings already installed with the remaining supplied bearings. Some areas require
tighter bearing packing than others. See Figure 32, page 27, for the recommended bearing densities over
the container. Continuous bearings are available to fill in between cross members. They can also be
notched so that they run continuously over the cross members. These are especially useful over wheels
where grime is thrown up from the road.

Sub-deck
Bearing

Bearing

Sub-deck

Cross Member

Cross Member

-Figure 30-
Bearing Installation

Continuous Bearing

Std Bearing

Cross Member
Sub-deck

-Figure 31-
Continuous Bearings

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 No Bearings in Stroke Area

Bearings at Every
Cross Member Only

One Additional Bearing

Between Cross Members
On Every Sub-deck Row

Tightly Packed Bearings

Over Wheels

Seven Side
Sub-deck Rows

Middle Area

Drive Unit Up to One Cross

Member Forward Of Drive Unit

Drive Unit

Drive Unit Back to One Cross

Member Behind Drive Unit

Middle Area

Over Wheels

Approximately 12 ft [4 m]
of the Back End

-Figure 32-
Bearing Densities -- Trailer Application

Copyright 2010 27 Doc # 99-5559

7. Decking
a. Position the cross drives:
Front Cross Drive — Push All the Way Forward
Rear Cross Drive — Push all the Way Back
Center Cross Drive — Center Between Front & Rear

b. At this point there should be a gap of (4.3/4” [121 mm]) between adjacent cross drives. Install blocking
between the cross drives close to the cylinder shafts to hold their position (Figure 33, below).
NOTE: Drive units preassembled by Hallco may be delivered with the cross
drives spread out and with blocking to hold them in place.
Center Cross Drive Front Cross Drive
Rear Cross Drive Blocking

-Figure 33-
Preparing the Cross Drives
c. Close the rear door. Mark with a full width line on the rear sill where the inside edge of the rear door
comes (Figure 34, page 29).
d. Measure into the trailer 2” [51 mm] from that line and make a second full width line. Identify this line as
line “A” (Figure 34, page 29).
e. From line “A” measure in half a stroke (4.5/8" [117 mm]) and draw another full width line. Identify it as line
“B” (Figure 34, page 29).
f. From Line “A” measure in a full stroke ( 9.1/4" [235 mm] ) and draw another full width line. Identify it as line
“C” (Figure 34, page 29). Lines “A”, “B”, and “C” mark where the ends of the deck slats should be during
installation.
g. Cut the deck slats (if needed) to the correct length. Refer to Figure 6, page 9 for the layout.
h. Starting on the left side, place a deck slat over the bearings and sub-deck (Figure 35, page 29) with the
back edge approximately 1/2” [13 mm] behind line “C” with the seal or overlap on the left side. Stand on
the slat and use a short length of 4” x 4” [100 mm x 100 mm] lumber to bump the top of the deck slat
down to snap it over the bearings. Work your way down the length of the slat snapping it over the bear-
ings. When the slat is fully snapped onto the bearings bump it forward to align the back edge with line “C”.
Copyright 2010 28 Doc # 99-5559
 Deck Slats

Rear Door

Reference Lines

4.5/8" [117 mm]

4.5/8" [117 mm] FWD
2" [51 mm]

-Figure 34-
Back End Reference Lines

Deck Slat

Bearing
Seal (if applicable)
Sub-deck

Cross Member

-Figure 35-
Snapping Down the Deck Slats

Copyright 2010 29 Doc # 99-5559

i. Place the second slat over the bearings and sub-deck with the seal or overlap on the left side and with its
back edge approximately 1/2” [13 mm] behind line “B”. Snap it over the bearings, then bump it forward
and align the back edge with line “B”.
j. Place the third slat over the bearings and sub-deck with the seal or overlap on the left side and with its
back edge approximately 1/2” [13 mm] behind line “A”. Snap it over the bearings, then bump it forward
and align the back edge with line “A”.
k. Continue snapping the remaining decking onto the bearings. Every third slat must align with the same
reference line, “A”, “B”, or “C”.
l. When all the deck slats have been snapped onto the plastic bearings, check that all the back edges are
correctly aligned with the reference lines, and check that all the deck slats have been fully snapped on the
bearings. Look from underneath to check that the deck slats are fully snapped onto the bearings. If a
plastic seal is used, inspect it to make sure it has not rolled out of shape. There should be no seal pro-
truding above the deck.
m. When all the deck slats and cross drives are in position, drill one hole through each of the outer left three
deck slats and each of the outer right three deck slats using the corresponding cross drive shoe holes as
guides. Drill using a 1/2” [13 mm] bit. Countersink the holes from the top. Countersink just enough for
the screw heads to be flush with the top of the deck. DO NOT COUNTERSINK TOO DEEPLY.
n. Clean out the debris between the deck slats and the shoes and install deck bolts with nuts underneath.
Torque the 1/2” [approx. 13 mm] bolts to 55 ft-lb [75 N-m].
o. Drill and countersink the remaining holes for a total of four bolts per shoe (deck slat). Hole locations
which are inaccessible from underneath may be measured, marked, and drilled from the top. Install the
remaining bolts and nuts and torque to the specified amount above.
p. Remove the blocking from between the cross drives.

Cross Drive Shoe

Deck Slat

Countersink Tool
P/N 93-3640 For 1/2" [13 mm] Holes

-Figure 36-
Deck Drilling & Countersinking

Copyright 2010 30 Doc # 99-5559

8. Side Trim
a. Position the side trim in place on the correct side as shown in the decking literature. Make sure the
lengths are correct for each side. Depending on the deck type, one side may require a seal but the other
may not. Refer to the decking literature.

NOTE: Side trim comes in standard lengths, 20 & 24 ft [6.1 &

7.3 m]. Place them end-to-end to achieve the correct length.

b. Secure the side trim to the side trim support using blind rivets or self tapping screws every 12” to 16” [305
to 406 mm].

Seal Side Trim

Side Trim Joint

Deck Slat

Sub-deck
Note: Example side trim & seal
shown. Side trims vary by deck
type. Refer to decking literature.

-Figure 37-
Side Trim Installation

Copyright 2010 31 Doc # 99-5559

9. Slope Sheet & Wiper
a. Construct a slope sheet to cover the gap at the front of the container left when the floor cycles. An exam-
ple slope sheet is shown in figure 38, below. The slope sheet assembly must also hold the wiper strip or
wiper block (ridged deck types).
b. Install the slope sheet with enough clearance from the deck that it does not risk binding the support
bracket against the deck, but it must keep the wiper close enough to the deck to be effective.

Note: The slope sheet and supporting brackets must

be strong enough to support the load over them.

Slope Sheet Support Bracket

(Several Over the Width)

Slope Sheet

Wiper
Deck Slat

Sub-deck
Forward Wall

-Figure 38-
Example Slope Sheet & Wiper

Copyright 2010 32 Doc # 99-5559

10. Plumbing
a. In many cases drive units are supplied already plumbed. If not, refer to figure 40, page 34, for standard
one-way plumbing or figure 41, page 35, for standard two-way plumbing.
b. Attach the hydraulic system pressure/supply line to the port on the switching valve labeled “P”. Attach the
tank/return line to the port labeled “T”. Refer to figure 39, below. These ports on the switching valve are
SAE-12 o-ring. Do not use pipe threads.

Tank / Return
Pressure Test Port SAE-12 O-Ring Port
(For Pressure Gage)

Pressure / Supply
SAE-12 O-Ring Port

-Figure 39-
Pressure & Tank Ports On Switching Valve

Copyright 2010 33 Doc # 99-5559

 Note: These hose ends may be swapped.

Fitting, 3/4" Male O-Ring x 3/4" Female Pipe Swivel

Fitting, 3/4" Adj. Male O-Ring x 3/4" Female Pipe Swivel 45_
# 85-3952
# 85-3774

Copyright 2010
3/4" Hex Head O-Ring Plug
3/4" Hex Head O-Ring Plug # 85-3792
# 85-3792
One-Way Control (Unload/Neutral) Valve
# 56-5472

Fitting, 3/4" Male O-Ring x 3/4" Female Pipe Swivel

# 85-3952

Hose, 3/4" x 90" Long, 3/4" Male Pipe Ends

# 86-4292

Hose, 3/4" x ___ Long, 3/4" Male Pipe Ends

# Variable

34
Hose, 3/4" x ___ Long, 3/4" Male Pipe Ends
# Variable

Fitting, 3/4" Adj. Male O-Ring x 3/4" Female Pipe Swivel 90_
# 85-3953

Hose, 3/4" x 72" Long, 3/4" Male Pipe Ends Fitting, 3/4" Adj. Male O-Ring x 3/4" Female Pipe Swivel 45_
# 86-2698 # 85-3774
3/4" Hex Head O-Ring Plug
# 85-3792

-Figure 40-
Standard i-6100 (One-Way) Plumbing

Doc # 99-5559
 Fitting, 3/4" Adj. Male O-Ring x 3/4" Female Pipe Swivel 45_
# 85-3774 Note: These hose ends may be swapped.

Fitting, 3/4" Male O-Ring x 3/4" Female Pipe Swivel

# 85-3952
Hose, 3/4" x 90" Long, 3/4" Male Pipe Ends
# 86-4292 Hose, 3/4" x ___ Long, 3/4" Male Pipe Ends
# Variable

Copyright 2010
Fitting, 3/4" Male O-Ring x 3/4" Female Pipe Swivel
# 85-3952

Two-Way Control (Unload/Neutral/Load) Valve

# 56-3632

Hose, 3/4" x ___ Long, 3/4" Male Pipe Ends

# Variable

35
Hose, 3/4" x ___ Long, 3/4" Male Pipe Ends
# Variable

Hose, 3/4" x ___ Long, 3/4" Male Pipe Ends

# Variable

Fitting, 3/4" Adj. Male O-Ring x 3/4" Female Pipe Swivel 90_
# 85-3953
Fitting, 3/4" Adj. Male O-Ring x 3/4" Female Pipe Swivel 45_
Hose, 3/4" x 72 Long, 3/4" Male Pipe Ends
# 86-2698 # 85-3774

Fitting, 3/4" Adj. Male O-Ring x 3/4" Female Pipe 90_

# 85-3948
Fitting, 3/4" Male Pipe x 3/4" Female Pipe Swivel 90_
#85-2662

-Figure 41-
Standard i-6200 (Two-Way) Plumbing

Doc # 99-5559
11. Safety & Operational Decals
Before operating the LIVE FLOOR system make sure the safety and operational decals are installed on the
container per the figure below.

# 99-4808

-Figure 42-
Safety & Operational Decal Placement Guide
Copyright 2010 36 Doc # 99-5559
12. Checklist
The steps that follow may require operating the LIVE FLOORTM system. Complete the checklist below before
operating the floor.

___ 1. Check the entire floor to make sure all the decking is properly snapped over the bearings.

___ 2. Check the front and rear clearances (Figure 6, page 9).

___ 3. Recheck the torque of the deck bolts.

___ 4. Make sure all the hydraulic fittings are tight.

___ 5. Make sure the switching rod is straight and that the stops are tight (Figure 44, page 38). Skip this
check if the stops have not been set yet.

___ 6. Make sure the cross drive blocking has been removed.

___ 7. Check that the pressure and return lines are correctly plumbed to the hydraulic power source.

___ 8. Check the cylinder shafts for overspray, weld spatter, and other roughness which could damage
the seals.

-Figure 43-
Checklist

Copyright 2010 37 Doc # 99-5559

13. Setting the Switching Rod Stops

NOTE: The switching rod stops are typically pre-set at the factory. If the drive unit
has been pre-assembled and the switching rod stop collars are tight, you may skip
this section, unless it is part of troubleshooting.
a. Release and move stops “A” and “B” away from the front and rear triggers.
b. Move the switching rod rearward toward the switching valve until it stops.
c. Apply hydraulic pressure (load or unload mode) until the shafts are fully extended forward away from the
switching valve, then shut off pressure.
d. Move the switching rod away from the switching valve until it stops. Move and set stop “A” firmly against
the rear trigger.
e. Apply hydraulic pressure until the shafts are fully retracted rearward towards the switching valve, then shut
off pressure.
f. Move the switching rod rearward toward the switching valve until it stops. Move and set stop “B” firmly
against the front trigger.
g. Mark the positions of stops “A” and “B” on the switching rod.
h. Apply hydraulic pressure to the cylinders until the triggers are free from the stops by at least 3/8”. Shut off
the pressure. Move stop “A” 3/8” [10 mm] toward the rear trigger and tighten firmly. Move stop “B” 3/8” [10
mm] toward the front trigger and tighten firmly.

Switching Valve

5/8" Spacer Collar

Rear Trigger

Front Trigger

Switching Rod

Stop "A"

Stop "B"

-Figure 44-
Switching Rod Stops

Copyright 2010 38 Doc # 99-5559

14. Operation & Testing
PERFORM THE INSTALLATION CHECKLIST PRIOR TO OPERATING THE FLOOR.
Activate the hydraulic system, and pull the handle of the control valve to UNLOAD MODE (refer to Figure 45,
below). The floor will begin to move erratically at first while it is clearing out air pockets, but after a few min-
utes should begin to sequence properly. Observe the floor movement for the following:
NORMAL OPERATION IN UNLOAD MODE:
1. Left side shaft and forward cross drive travel forward.
2. Center shaft and middle cross drive travel forward.
3. Right shaft and rear cross drive travel forward.
4. All shafts and cross drives travel rearward in unison.
Cycle repeats...
Move the control valve handle to the NEUTRAL position. The floor should not move.
Turn and push the control valve handle to LOAD MODE (two-way models only), and observe for the following
correct movement:
NORMAL OPERATION IN LOAD MODE:
1. Right side shaft and rear cross drive travel rearward.
2. Center shaft and middle cross drive travel rearward.
3. Left side shaft and forward cross drive travel rearward.
4. All shafts and cross drives travel forward in unison.
Cycle repeats...
FOR NEW INSTALLATIONS, OR IF THE BEARINGS OR DECKING HAVE BEEN REPLACED, CONTINUE
OPERATING THE FLOOR UNLADEN FOR ABOUT 30 MINUTES. OBSERVE THE FLOOR DURING THIS
TIME FOR CORRECT OPERATION AND TO MAKE SURE THE DECK SLATS DO NOT RAISE UP IN CASE
THEY WERE NOT FULLY SNAPPED ONTO THE BEARINGS.

UNLOAD MODE: Pull the handle all the way out.

NEUTRAL: Push the handle in until it hits the valve body

LOAD MODE (Two-Way): Turn the handle forward and push it all the way in.

-Figure 45-
Control Valve Positions

Copyright 2010 39 Doc # 99-5559

15. Hold Down Blocks
The hold down blocks may be installed during decking installation, if the deck slats are slid forward prior to
attaching them so that the hold down block holes are accessible.
a. Cycle the deck slats forward so that the forward hold down block hole will be accessible when the hold
down block is in position.
b. Install the hold down blocks inline with and butted up to the back end of the sub-deck. The deck slats
should overlap the hold down blocks by 1” [25 mm]. Fasten the hold down blocks to the rear sill plate.
Keep screw or bolt heads well below the top surface of the hold down blocks so that the deck slats will not
interfere with them even as the hold down blocks wear.
c. Fill the recessed area in hold down blocks where the fastener head is with epoxy or equivalent filler to
eliminate the pinch point where the deck slats slide over the recess.

Bearing
Deck Slat

Sub-deck

Hold Down Block

IMPORTANT SAFEY NOTE:

After fastening fill recessed area
with epoxy or equivalent filler to
remove pinch point.

-Figure 46-
Hold-Down Blocks

Copyright 2010 40 Doc # 99-5559

TROUBLESHOOTING

Experience has shown that most problems originate with the hydraulic supply system. If your floor is not
functioning properly, first check for visible interference/damage of the floor structure or mechanisms, then
check the hydraulic supply system.

Problem: Floor does not operate or operates slowly

First Check: (A) PTO. Is it fully engaged?

(B) OIL. Is the oil reservoir full?
(C) QUICK CONNECTS. Are they fully connected? Are they a matched set?
(D) PUMP. Is the pump operating? Does it deliver the specified flow rate and pressure?
(E) RELIEF VALVE. Is it set high enough (within specified limit)?
(F) PLUMBING. Is the entire system plumbed correctly?

If the problem persists…

Disconnect the pressure line from the hydraulic module. Attach a hydraulic pressure gage to the pressure
line. Start up the hydraulic system (typically by engaging the PTO) and activate pressure to the pressure line.
If the pressure gage shows sufficient pressure being supplied to the hydraulic module, then the hydraulic sup-
ply system is OK. If there is insufficient pressure being supplied to the hydraulic module, then the hydraulic
supply system may need servicing.

Common hydraulic supply system problems are defective pump and defective relief valve. If the pump ONLY
becomes hot, that is a clue to a bad pump. Another clue to a bad pump is having to rev up the engine to get
enough pressure to operate the floor. If the relief valve ONLY becomes hot, that is a clue that the relief valve
is defective or has debris holding it partially open.

If the hydraulic supply system checks out OK, but the floor still does not operate…

Check the setting of the switching rod stops. See page 38, “Setting the Switching Rod Stops”.

Problem: Floor operates correctly except that the slats do not sequence properly. Adjacent slats (cross
drives) move together when they should move one set at a time.

Likely Cause:A poppet may have debris in the poppet seat, have a damaged poppet seat, or the poppet may
not be seated correctly. To resolve this issue remove the poppet in question. Inspect the poppet seat for
damage and debris. Remove any debris. Small amounts of debris can be flushed out by re-installing the
poppet cap only (without the poppet valve and spring) and running the system, then re-install the poppet,
spring, and cap. A leaky poppet seat can often be corrected with the poppet seating tool, # 56-3712. Place
the coned end of the tool into the poppet seat and tap the other end of the tool firmly with a hammer.

If the problem is in unload mode: A poppet in the rear head manifold may be malfunctioning. Check
the poppet between the shafts of the cross drives which move together. I.e. if cross drives 2 and 3
move forward together, remove the poppet between shafts 2 and 3 in the rear head manifold.

If the problem is in load mode: A poppet in the forward head manifold may be malfunctioning.
Check the poppet between the shafts of the cross drives which move together. I.e. if cross drives 2
and 3 move rearward together, remove the poppet between shafts 2 and 3 in the forward head mani-
fold.

If the above solutions do not bring the floor to correct operation…

Contact Hallco to talk with a technical representative and/or to make service arrangements.

Copyright 2010 41 Doc # 99-5559

 WARRANTY
Hallco Industries, Inc. (“Hallco” or “Company”) warrants to the original product purchaser
(“Customer”) each of the Hallco LIVE FLOORS® or its other floor systems manufactured and sold
by it or any of its authorized distributors, when properly assembled and installed, to be free from
defects in material and workmanship. This warranty expressly excludes deck seal, when used.
Company’s obligation to Customer under this warranty is limited to repairing or replacing, as herein
provided, and at its sole option, any part or parts of the system which within twelve (12) months
after delivery to Customer shall be found, upon examination by Company, to be defective, provided
that such part or parts shall be returned, with insurance and shipping costs at Customer’s expense,
to Company’s factory at 6605 Ammunition Road, Tillamook, Oregon 97141. Company must be
notified in writing of any claim under this warranty within 30 days of any claimed lack of conformity
of the product.

WARRANTY SERVICE OPTIONS. For service under this warranty, Customer must notify Company
in writing to obtain a Returned Material Authorization Number (RMAN). When requesting your
written RMAN, specify in writing the part in question by part number & applicable purchase order
number. Customers in countries other than the United States should contact Company’s authorized
representative in such country, when applicable.

W ARRANTY EXCLUSIONS. Representatives of Company are not authorized to modify this warranty in
any way. It is the Customer's responsibility to regularly examine the product to determine the need
for normal service or replacement. This warranty does not cover the following:

- Products that have been modified, altered, neglected or poorly maintained, misused,
abused or involved in accidents or natural disasters, or repaired other than by Company in
accordance with these warranty procedures;
- Damage occurring during shipment of the product. (Such claims must be presented
directly to the freight company).
- Damage to the product resulting from improper maintenance or repair, the use or
installation of parts and or accessories not manufactured by Company, or which are not
compatible with the system, or failure to follow product warnings and usage instructions.
- Normal wear and tear.
- Any product for which Customer does not follow the warranty procedures stated above.

WARRANTY LIMITATIONS. THIS WARRANTY IS MADE EXPRESSLY IN LIEU OF

ANY OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED
WARRANTY OF MERCHANT ABILITY OR FITNESS FOR ANY P ARTICULAR
PURPOSE, AND OF ANY OTHER OBLIGATION OR LIABILITY ON THE PART OF THE
MANUFACTURER.

In no event shall Company be liable for any loss, inconvenience or damage, whether direct,
incidental, consequential or otherwise, except for the repair or replacement obligation as set forth
herein. Some states or countries do not allow limitation on how long an implied warranty lasts and
some do not allow exclusions or limitations of incidental or consequential damages, so the above
limitations or exclusions may not apply to you. This warranty will be interpreted pursuant to the
laws of the United States and the State of Oregon.

HALLCO INDUSTRIES, INC. - P.O. BOX 505 - TILLAMOOK, OREGON 97141

PHONE (800) 542-5526 - FAX (503) 842-4866

Copyright 2010 42 Doc # 99-5559