ul - mac trailer

28
West Coast USA ##MD Ammunition Road PXOX Box DMD Tillamooky OR 97b@b PhX 8MMND@cNDDc# PhX DMfN8@cN888# Fax: DMfN8@cN@8## Central USA 8c7# HwyX b# North Poteety TX 78M#D PhX 877N@cDNDc#b PhX 8fMN7@cN8@@b Fax: 8fMN7@cN8#8c East Coast USA @8M Millrun RdX Salisburyy NC c8b@@ PhX 8MMNcfMNMb9M PhX 7M@N#f#N@bcc Fax: 7M@N#f#Nb#@@ Web: wwwXhallcoindXcom Email: info@hallcoindXcom Doc 8 99N#MbD LIVE FLOOR CONVEYING SYSTEMS TM Owner's Manual: One-Way (i-2300/i-3300) and Two-Way (i-2400/i-3400) i-2000 and i-3000 SERIES FRONT MOUNT

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Page 1: Ul - MAC Trailer

West1Coast1USA##MD1Ammunition1Road

PXOX1Box1DMDTillamooky1OR197b@bPhX18MMND@cNDDc#11PhX1DMfN8@cN888#11Fax:1DMfN8@cN@8##

Central1USA8c7#1HwyX1b#1NorthPoteety1TX178M#DPhX1877N@cDNDc#b11PhX18fMN7@cN8@@b11Fax:18fMN7@cN8#8c

East1Coast1USA@8M1Millrun1RdX

Salisburyy1NC1c8b@@PhX18MMNcfMNMb9M11PhX17M@N#f#N@bcc11Fax:17M@N#f#Nb#@@

Web:11wwwXhallcoindXcom11Email:11info@hallcoindXcom

1Doc18199N#MbD

ULIVEUFLOORUUUCONVEYINGUSYSTEMSTM

Owner'sUManual:

One-Way (i-2300/i-3300) and Two-Way (i-2400/i-3400)

i-2000UandUi-3000USERIESUFRONTUMOUNT

Page 2: Ul - MAC Trailer

OilUFlow2GPMU[LPM]0

CycleUTime2seconds0

ConveyUSpeed2ftWkminWU[mkminW]0

UnloadingUTime2minutes0

HydraulicUModuleUSpecifications

TheoreticalUUnloadUTimes

LoadUCapacity 15NTonN[13NTonne]

i3A888

3000NpsiN[207NBar]MaximumUPressure

25Ngal/minN[95Nl/min]MaximumUFlowURate

1.5NinchN[38.1Nmm]ShaftUDiameter

CylinderUDiameter 3NinchesN[76.2Nmm]

i33888

OneUWay

TwoUWay

i-2300 i-3300

i-2400 i-3400

1.5NinchN[38.1Nmm]

3000NpsiN[207NBar]

30Ngal/minN[114Nl/min]

20NTonN[18NTonne]

3.5NinchesN[88.9Nmm]

Stroke 9-1/4NinchesN[235Nmm] 9-1/4NinchesN[235Nmm]

10N[38]

11N[42]

12N[45]

13N[49]

14N[53]

15N[57]

16N[61]

17N[64]

18N[68]

19N[72]

20N[76]

21N[79]

22N[83]

23N[87]

24N[91]

25N[95] 3.6

3.7

3.9

4.1

4.3

4.4

4.7

5.0

5.3

5.5

5.9

6.4

6.9

7.5

8.0

8.9 5.2N[1.59]

5.8N[1.75]

6.2N[1.88]

6.7N[2.05]

7.3N[2.21]

7.8N[2.38]

8.4N[2.55]

8.8N[2.67]

9.3N[2.84]

9.9N[3.01]

10.4N[3.18]

10.8N[3.30]

11.4N[3.47]

11.9N[3.63]

12.5N[3.80]

13.0N[3.97] 2.1

2.2

2.3

2.5

2.6

2.7

2.8

3.0

3.2

3.3

3.6

3.8

4.2

4.5

4.8

5.5

i3A888 i33888

N/A

N/A

N/A

N/A

N/A

8.4

7.9

7.4

7.0

6.6

6.3

6.0

5.7

5.5

5.2

5.0

N/A

N/A

N/A

N/A

N/A

5.5N[1.68]

5.9N[1.79]

6.2N[1.90]

6.6N[2.01]

7.0N[2.13]

7.3N[2.24]

7.7N[2.35]

8.1N[2.46]

8.4N[2.57]

8.8N[2.69]

9.2N[2.80] 3.1

3.2

3.3

3.5

3.6

3.8

4.0

4.2

4.5

4.8

5.1

N/A

N/A

N/A

N/A

N/A

i3A888 i33888 i3A888 i33888

A8UftWU[8W5Um]UContainerWUUActualUunloadUtimesUvaryW

26N[98]

27N[102]

28N[106]

29N[110]

30N[114] N/A

N/A

N/A

N/A

N/A N/A

N/A

N/A

N/A

N/A N/A

N/A

N/A

N/A

N/AN4.8

4.7

4.5

4.3

4.2

9.5N[2.91]

9.9N[3.02]

10.3N[3.13]

10.6N[3.25]

11.0N[3.36] 2.5

2.6

2.7

2.8

2.9

DocN#N99-6015CopyrightN2014

Page 3: Ul - MAC Trailer

SwitchbRodbAdjustment 13

DocbCb99v6kP5G

CONTENTS

SAFETY

Troubleshooting

CopyrightbGkP4

3

6

Operationb4bMaintenance 9

11

3031

32

33

35

WhatbabLivebFloorbbbConveyorbIsbandbHowbitbWorks

TM

PartsbLists

RepairbGuide

HydraulicbRequirements 8

14

19

27Warranty

Page 4: Ul - MAC Trailer

Safety & Operational Decals

Before-operating-the-LIVE-FLOOR---system-make-sure-the-safety-and-operational-decals-that-come-with-kit-1vvD8804-are-installed-on-the-container-per-the-decal-placement-guide-found-with-the-kitP

TM

The-placement-guide-looks-like-this!

FRONT-MOUNT-SAFETY-AND-OPERATIONALDECAL-PLACEMENT-GUIDE

1vvD33GG

Qty-Q40 Qty-0

1vvD3bG6

Qty-0

1vvD3bG7Q

1vvD3Qvv

Qty-48

1vvD3Qvb

Qty-46

1vvD3bGb

Qty-Q3

1vvD33G47

Qty-4

Qty-4

1vvD3bGv

8

4

4

Rear-decals-must-be-visible-with-the-doors-completely-open5

Place-Hallco-logo-decal-on-rear-doorP

Doc-1-vvD8804DACopyright-0G4G

Doc-1-vvD6G48QCopyright-0G43

Page 5: Ul - MAC Trailer

DocuAu99-60154

DANGERlAVOIDTtheTproductThazardsTshownTonTthisTpageDURINGTFLOORTMOVEMENTTorTpersonalTinjuryTorTdeathTWILLToccur.

AVOIDTtheTproductThazardsTlistedTonTthisTpagewhileThydraulicTFLUIDTISTFLOWINGTTOTtheTfloorTsystemTorTpersonalTinjuryTorTdeathTMAYToccur.

Theuspaceubetweenutheufrontuwalluanduanuobjectuorupileuonutheuflooruthatuisunearutheufrontuwall.

ProductTHazards

Damageduorucutuhydraulicuhoses,ufittingsuorutubing.uuAusmalluholeinuauhoseuorufittinguwilluproduceuaustreamuofufluiduthatucanupierceutheuskinuinjectinguoiluintouyourublood.

Theuboltuholeuinutheuholdudownublocks.

Theuenduofutheuslatsuandutheufrontuwall.

TheudischargeuenduofuauLiveuFlooruconveyoruanduinufrontuofutheuvehicleduringuoperationuwhenuauloaduisuatutheudischargeuend.

TM

Theuspaceubetweenucross-driveubeams.

Theuspaceubetweenuslatuendsuandutheufrontuwall.

Theuareaubetweenuclamps.

Theuareaubetweenutheutriggersuandutheuswitchingurodubumpers.

Theuareaubetweenutheutriggersuandutheusurroundinguframework.

Copyrightu2014

Insideuofufrontuwall

Page 6: Ul - MAC Trailer

Doc.u.99,6qk55

Do these things to prevent property damage:NOTICE

Watch.the.space.between.the.front.wall.and.the.load.while.operating.the.Live.Floor.in.the.load.modeO..Stop.the.conveyor.if.it.isin.the.load.mode.and.the.load.is.touchingthe.front.wallO

Install.a.high.pressure.filter.in.the.pressure.line.between.the.pump.and.the.conveyor.system.before.operationO

Monitor.the.oil.temperature.during.operation.to.prevent.it.from.exceeding.k8q.degO.F.(84.degO.C2O

Cover.the.shaft.chrome.before.welding.or.painting.nearbyO..Remove.covering.before.operating.the.systemO

Support.hoses.and.protect.them.against.abrasion.from.contact.between.other.componentsO

For.warranty.purposesR.get.approval.from.the.Original.Equipment.Manufacturer.prior.to.welding.or.drilling.on.their.product.(trailerR.etcO2O

Operate.the.Live.Floor.in.the.unload.mode.only.when.the.discharge.doors.are.openO

Install.a.filter.in.the.return.line.as.close.to.the.tank.as.possible.before.operating.thefloor.systemO

Make.sure.the.system.pressure.never.exceeds.the.maximum.pressure.specified.in.this.manualO

Copyright.4qk4

Deck.bolts.must.be.re,torqued.after.the.first.5,kq.loadsS..Failure.to.do.this.will.result.in.damage.to.the.slats.and.drive.unitSSS

Page 7: Ul - MAC Trailer

Docv;v99A6,156Copyrightv2,14

What a Live Floor Conveyor Is and How it Works

TM

Entirevtrailervloadsvarevunloadedvatvoncevby:vvConveyingvallvofvthevslatsvtogethervinvonevdirectionvforvavstroke;vvKeepingvtwovthirdsvofvthevslatsvstationaryvandvretractingvonevthirdvatvavtimeundervthevloadvtovtheirvoriginalvposition;vThenvconveyingvallvofvthevslatsvtogethervagainL

ThevslatsvarevdividedvintovthreevgroupsvandveachvgroupvisvdrivenvbyvavhydraulicvcylinderLvvTherevarevveryvfewvmovingvpartsLvvv

FirstvGroupvRetract SecondvGroupvRetract

ThirdvGroupvRetract AllvGroupsvConveyvTogether

AvLivevFloorvconveyorvisvmadevofvmultiplevslatsvorvboardsthatvarevasvlongvasvthevconveyorLvvThevslatsvarevarrangedvsidevbyvsidevandvallvatvthevsamevlevelvsovtheyvcovervtheentirevwidthvofvthevfloorLvvTheyvdonTtvmovevupvandvdownvorvsidevtovsideSvonlyvbackvandvforthL

Page 8: Ul - MAC Trailer

Docv)v99I6mTb7CopyrightvFmTf

What a Live Floor Conveyor Is and How it Works

TM

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Page 9: Ul - MAC Trailer

Uoc:m:ddOFb,°]

Hydraulic System Requirements

Eopyright:Hb,%

TankMReservoirG

PumpG

qntiOWear:.qWVl::Viscosity:of:ISO:%F:or:F]Petroleum:OR:Mineral:basel::Moisture:contentS:H:O::L:,WH

L::,]b°"::[]H°E]

Hydraulic:"luidG

"luid:TemperatureG

Pump:must:be:a:GearS:Vane:or:Piston:type:that:will:pump:no:more:than:H°:gpm:[d°:Lpm]:at:a:full:<bbb:psi:[Hb[:>ar]l

Pump:must:be:matched:to:its:power:sourcel::Urive:it:directly:or:through:a:PTOl::Eonsulta:hydraulic:expert:to:determine:the:requiredmotorMengine:powerl SpeedG::Motor:or:PTO:::::::::Pump

"low::L::H°:gpm:[d°:Lpm]

Pressure::7::<bbb:psi::[Hb[:bar]

Power:Source::7::Qnough:for:the:"low:and:Pressure

Use:a:reservoir:that:has:all:of:these:featuresG

Pump

Tank

iOHbbbMiO<bbb:Module

PT

HoseTube

HoseTube

Use:all:of:these:featuresl

Hallco recommends consulting a hydraulic specialist to design the hydraulic supply system.

H°:Gall:[d°:L]

Sight:level:gage

ThermometerG:::O,°:to:<bb°":[OHF:to:,°b°E]

>reather:fill:capwith:filter

7:F:inl::[,°b:mm]

7:,lH°:inl[<H:mm]

7:H:inl[°b:mm]

,:O:H:inl[H°:O:°b:mm]

Low

High

ReturnTo:Pump

>affles

qntiOwhirlpl

Location:and:specification:information:is:shown:in:the:sketch:to:the:rightl

H°:gall:[d°:L]:minimum:capacitylInlet:diameter:greater:than:,lH°:in:[<H:mm]lOutlet:diameter:greater:than:H:in:[°bmm]lTurbulence:reducer:on:Return:inletlPump:supply:outlet:near:the:bottomlWhirlpool:prevention:on:the:outletl"iller:cap:with:breather:and:filterlVisible:fluid:level:gagelVisible:thermometerl

SummaryG

Pressure:Relief:Valve:set:at:<bbb:psi:[Hb[:>ar]:and:rated:to:handle:at:leastthe:maximum:pump:output:flowl::

Quick:Eonnects:that:are:matched:and:rated:for:the:maximum:system:pressure:and:flow:ratel

H°:micron:Return:"ilter:rated:to:handle:more:than:,l°:times:the:maximum:pump:flow:and:at:least:[°b:psi:pressurel::Place:it:as:close:to:the:tank:as:possiblel::Make:the:hydraulic:line:between:the:filter:and:the:tank:at:least:,O,M%u:[<H:mm]:diameter:and:as:short:as:possible:to:prevent:filter:failurel

.OptionalV::[°:micron:Pressure:"ilter:ratedto:handle:the:maximum:system:pressureand:flowl

Visible:Pressure:Gagel::b:to:°bbb:psi:[b:to:<°b:bar]l::Glycerin:filledl

HydraulicSupplyEircuit

,:inl:[H°:mm]:Hydraulic:Pressure:Line

,O,M%:inl:[<H:mm]:Hydraulic:Return:Line

Page 10: Ul - MAC Trailer

Operationu&uMaintenance

DANGERN

DamagedForFcutFhydraulicFhosesCFfittingsForFtubing4FFAFsmallFholeFinFaFhoseForFfittingFwillFproduceFaFstreamFofFfluidFthatFcanFpierceFtheFskinFinjectingFoilFintoFyourFblood4

TheFspaceFbetweenFcross2driveFbeams4

TheFendFofFtheFslatsFandFtheFfrontFwall4

Avoidutheseuhazardsuwhenutheuflooruisumoving:

Unloading

Neutral

Loading

FloorFmayFcreepFwhenFvalveFisFinFNeutralFandFthereFisFnoFload4FFStopFPTOForFturnFoffFshutoffFvalveFtoFcompletelyFturnFoffFfloor4F

Unloading

Loading

OR

OR

PTO

DocFPF99260159CopyrightF2014

Page 11: Ul - MAC Trailer

Docl:lAAxWFBVBFCopyrightlSFB)

Operation]-]Maintenance

Inspect]your]floor]regularlylinlorderltolmonitorlwearlandltolpreventlfurtherldamagelifldamagelhaslalreadyloccurred,llThelfollowinglislallistloflcriticallareasltolinspectN

Deck]Bolts:

Theldecklboltslconnectingltheldecklslatsltolthelcrossldriveslmustlbelkeptltightlatlallltimes.llLooseldecklboltslwillldamagelyourldecklandlcrossxdrivelshoes,llTheltorquelofltheldecklboltslmustlbelcheckedlonlalregularlbasislandlatlleastlafterlthelfirstlVltolBFlloads,llRextorqueltoN

ATCb][A6]mm]]diameter]bolts]torque]to]85]fthlbs][A58]Nhm]W

Decking:

Inspectlforlwearlorldamage,

Bearings:

Inspectlforlwearlorldamage,

Hydraulic]Plumbing:

Inspectlthelhydrauliclsystemlforlleakslandlabrasion,lMaintainlreservoirlminimumHmaximumllevels,

Floor]Structure:

Inspectlthelfloorlstructurelincludinglhydrauliclmodulelmountlandlframework/lhydrauliclshafts/lshaftxtoxcrossldrivelconnections/lcrossldrives/landlsubxdecklforldamagelandlwear,

Hydraulic]Module:

Inspectlthelhydrauliclmodulelforlleaks/llooselmountinglbolts/llooselmanifoldlbolts/lwornlwiperslandlseals/landlpittedHwornHdamagedlshafts,

Sloped]Sheet]-]Wiper:

Makelsurelthelslopedlsheetlislinlgoodlconditionlandlthatlthelwiperlattachedltolthelslopedlsheetlislkeepinglthelgaplbetweenlthelforwardlwalllandlthelendlofltheldeckinglclearloflmateriallwhichlcouldlcauselthelfloorltolbind,

HexlHeadlFlangelDecklBolt

DecklSlat

BearingSeallqiflapplicableR

ViewlLookinglForward

DecklSlat

ForwardlWallSubxdeck

SlopelSheet

SlopelSheetlSupportlBracketqSeverallOverlthelWidthR

FWD

FloorlStructureHydrauliclModule

Plumbing

Checkltheltorquelofltheltielbolts/lanchorlboltslandlclampboltslregularlylandlatlleastlafterlthelfirstlVxBFlloads,l

Tie]Bolts]Torque:]]A55]fthlbs][C56]Nhm]Anchor]Bolts]Torque:]A55]fthlbs][C56]Nhm]Clamp]Bolts]Torque:]]AC5]fthlbs][A66]Nhm]

TielBolts

AnchorlBolts

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NordxLocklllWasherlqSlpieces,lSeelPglBVR

CrossxDrive

SlatlSpacer

Slat

ThreadedlInsert

WiperlBeltlorlBlock

R

Page 12: Ul - MAC Trailer

Troubleshooting

DocWwWPP"7AM3MMCopyrightWVAM/

TheWslatsWreachWtheirWendWofWstrokeWandWnothingWhappensLWWWhenWIWshutWtheWpowerWtoWtheWsystemWoffWandWturnWitWbackWonEWtheWfloorWmayWcycleWorWmoveWonceWbutWitWalwaysWgetsWstuckWatWoneWendWevenWthoughWtheWpumpWsoundsWlikeWitWisWpumpingWfluidWatWtheWmaximumWpressureLWW

Trouble

TheWslatsWwonvtWmoveWandWtheWfloorWisWloadedLWWIWdonvtWwantWtoWuseWaWshovelI

TheWslatsWmoveWmuchWslowerWthanWnormalWwhenWtheWfloorWisWloadedLWWTheWspeedWlooksWfineWwhenWthereWisWnoWloadL

TheWslatsWmoveWseperatelyWwhenWtheyWshouldWtraveltogetherLWWW!

WhenWtheWslatsWshouldWbeWretractingWseparatelyEWtheWfirstWcross"driveWretractsEWthenWthe second cross-drive tries to move and can't orWmovesWveryWslowlyLWWEverythingWworksWfineWwhenWtheWcontrolWvalveWisWswitchedWtoWmoveWtheWloadWinWtheWoppositeWdirectionL

WhenWtheWslatsWshouldWbeWretractingWseparatelyEWtheWfirstWcross"driveWretractsEWtheWsecondWretractsWandWthe third tries to move and can't orWmovesWveryWslowlyLWWEverythingWworksWfineWwhenWtheWcontrolWvalveWisWswitchedWtoWmoveWtheWloadWinWtheWoppositeWdirectionL

TheWhydraulicWfluidWisWoverheatingWwithinWM3WminutesWofWoperationL

ItemWw

TheWslatsWmoveWtogetherWallWtheWtimeLWWItWdoesnvtWmakeWaWdifferenceWifWIWpushWtheWcontrolWvalveWhandleallWtheWwayWinWorWpullWitWallWtheWwayWoutL

InWtheWuTroubleuWcolumnWbelowEWfindWtheWdescriptionWthatWbestWmatchesWtheWtroubleWyouWareWexperiencingWwithWtheWLiveWFloorWWWWWsystemLWWTheWItemWwWcolumnsWreferWtoWtheWpicturesWonWtheWfollowingWpageLWWAWdarkWcellWmeansWthatWtheWitemWisWaWsuspectedWcauseWofWtheWtroubleWdescribedWinWthatWrowLWW

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CheckWtheWperformanceWofWeachWsuspectedWcomponentLWWVerifyWthatWitWmeetsWtheWminimumWrequirementsWlistedWforitWinWthisWmanualLWWCheckWitWforWvisibleWdamageWandForWinterferenceWfromWotherWpartsLWW

IfWtheWsuspectWisWaWhydraulicWpartEWmeasureWitsWtemperatureWusingWanWinfraredWthermometerWorWsimilarWdeviceWwhileWtheWsystemWisWrunningWtoWseeWifWitWisWwarmerWthanWtheWotherWhydraulicWpartsLWWAWhydraulicWcomponentWthatWisWdamagedWandWbypassingWoilWwillWheatWupWaWlotWfasterWthanWtheWotherWhydraulicWpartsWinWtheWsystemL

M V q / 3 7 8 H P MA MM MV Mq M/ M3 M7 M8 MH

!WWWTheWloadWonWtheWfloorWworksWtoWkeepWtheWslatsWallWmovingWtogetherLWWIfWthereWisWnoWloadWonWtheWfloorWitWdoesnvtWtakeWmuchWextraWfrictionWonWoneWcross"driveWtoWkeepWitWfromWmovingWwithWtheWrestLWWMostWofWtheWtimeWthisWtroubleWisWfixedWbyWloadingWtheWfloorL

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Page 13: Ul - MAC Trailer

Troubleshooting Pictures

(

b

)

4

(6

(5(7

6

7

5

8

(b

((

9

(B

()

ViewSFromSUnderneath

HydraulicSPowerSSupply(4

(8

DocS#S99k6B(5(bCopyrightSbB(4

(/SSSSHydraulicSPump/b/SSSSPressureSReliefSValve/)/SSSSTankQReservoir/4/SSSSQuickSConnectSCouplers/5/SSSSSwitchingSRodSBumpers/6/SSSSControlSValve/7/SSSSPistonsQCylinders/8/SSSSCrosskDriveSBeams/9/SSSSFrontSPoppetS#(/

(B/SSFrontSPoppetS#b/((/SSRearSPoppetS#(/(b/SSRearSPoppetS#b/()/SSSlatSendsSatSfrontSwall/(4/SSSlats/(5/SSPressureSFilter/(6/SSReturnSFilter/(7/SSHoseSRoutingSsPlumbingR/(8/SSSwitchingSValve

Page 14: Ul - MAC Trailer

SwitchingrRodrAdjustment

FrontBTrigger

RearBTrigger

SwitchingBValve

#02fBSpacerBCollar

a.rBBReleaseBandBmoveBstopsB“A”BandB“B”BawayBfromBtheBfrontBandBrearBtriggers1

b.BBBMoveBtheBswitchingBrodBrearwardBtowardBtheBswitchingBvalveBuntilBitBstops1

c.BBBApplyBhydraulicBpressureBxloadBorBunloadBmode,BuntilBtheBshaftsBareBfullyBextendedBforwardBawayBfromBtheBswitchingBvalve3BthenBshutBoffBpressure1

d.BBBMoveBtheBswitchingBrodBawayBfromBtheBswitchingBvalveBuntilBitBstops1BBMoveBandBsetBstopB“A”BfirmlyBagainstBtheBrearBtrigger1

e.rrBApplyBhydraulicBpressureBuntilBtheBshaftsBareBfullyBretractedBrearwardBtowardsBtheBswitchingBvalve3BthenBshutoffBpressure1

f.rrBMoveBtheBswitchingBrodBrearwardBtowardBtheBswitchingBvalveBuntilBitBstops1BBMoveBandBsetBstopB“B”BfirmlyBagainstBtheBfrontBtrigger1

g.BBBMarkBtheBpositionsBofBstopsB“A”BandB“B”BonBtheBswitchingBrod1

h.rBBApplyBhydraulicBpressureBtoBtheBcylindersBuntilBtheBtriggersBareBfreeBfromBtheBstopsBbyBatBleastBj02”1BBShutBofftheBpressure1BBMoveBstopB“A”Bj02”B[!]Bmm]BtowardBtheBrearBtriggerBandBtightenBfirmly1BBMoveBstopB“B”Bj02”B[!]Bmm]BtowardBtheBfrontBtriggerBandBtightenBfirmly1

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.

TIP

a.rrStopBfAf

a.rrStopBfBf

b.rrSwitchingBRod

DANGERy

DamagedBorBcutBhydraulicBhoses3BfittingsBorBtubing1BBABsmallBholeBinBaBhoseBorBfittingBwillBproduceBaBstreamBofBfluidBthatBcanBpierceBtheBskinBinjectingBoilBintoByourBblood1

TheBspaceBbetweenBcross[driveBbeams1

TheBspaceBbetweenBshoeBendsBandBtheBsubdeckBends1

TheBendBofBtheBslatsBandBtheBfrontBwall1

Avoidrtheserhazardsrwhenrtherfloorrisrmoving:

DocB.B44[9]!#!jCopyrightBD]!-

Page 15: Ul - MAC Trailer

Docf.fLLMw7RSRj

Parts Lists - Plumbing

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Page 16: Ul - MAC Trailer

Parts Lists - Drive Unit

DocLqLBBWAR7F7FCopyrightLVR7d

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Page 17: Ul - MAC Trailer

Parts Lists - Hydraulic Module

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Page 18: Ul - MAC Trailer

Parts Lists - Switching Valve

PilotcRod

ForwardcEndcCap

").fcNPTcPlughcAW(x.Ab

ValvecSpool

ValvecBody

RearcEndcCap

,IndicatescContentscofcSwitchingcValvecSealcKithcW/(Nm/b

,O(RingcPair1cSizecN(N".hcW/(NA.m

7Qtyc.OCapcScrewcx)AfcNCcxcNQ")Nf

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CompletecAssembly:ccP)NcW6(xb6.

Note:ccThecswitchingcvalvecisconlycsoldcascaccompletecassemblyQccIndividualccomponentscarecnotcsoldcseparatelyQ

Docchcbb(6/"W"mCopyrightcN/".

Page 19: Ul - MAC Trailer

Docn/nbb7w)umuA

Parts Lists - Control Valve

CopyrightnF)ux

ValvenBody

ValvenSpool

RetainingnRing/nAu7M)Mu

ValvenHandle/nmw7MbxM

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ControlnValvenSpacernCollar/nmw7mxNM

sQtynFOnMQxHnPlugznO7RingAm7MNbF

sQtynFOnFittingzMQxHnMalenO7RingnxnMQxHnFemalenPipenSwivel

/nAm7MbmF

HexnHeadnCapnScrewznMQAHNFnxnMQxH/nAu7MFmm

One-Way Control Valve

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Two-Way Control Valve

CompletenAssembly:nnOne7Way:nPQNnmw7mxNFTwo7Way:nPQNnmw7MwMF

Note:nnThencontrolnvalvenisnonlynsoldnasnancompletenassembly(nnIndividualncomponentsnarennotnsoldnseparately(

Page 20: Ul - MAC Trailer

RepairCGuideC-CHydraulicCModule

RecommendedCToolsCforCOverhaulC&CRepairs

PartCNumber Description Comment

#w"[www HeadxManifoldxInstallationxTool Includedxinxtoolxkit/x#w"[wN]

#w"NNmm HydraulicxModulexRebuildxFixture/xi"Series Forxbench"topxoverhauls

N]"wD.A PoppetxSeatingxTool/xi"Series

j]"A#DA PressurexGauge/xm"NmmmxPSI

#w"[w.. RodxSealxInsertionxTool#w"[Dmj wq[hxTiexBoltxInstallationxTool Forxquick"drivingxthextiexbolts

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Ifxthexhydraulicxmodulexisxaccessible/xxitxmayxbexoverhauledxin"placeBxxAnxadvantagexofxdoingxthisxisxthatxthexshaftsxarexkeptxfromxrotatingxbyxthexcrossxdrivexclampsBxxxThisxisxusefulxsincexthexpistonxnutsxmustxbextightenedxwithxwmmxft"lbsx[[mDxN"m]xofxtorqueBxxSomexotherxadvantagesxarexthatxnoxheavyxliftingxisxrequiredxandxthexshaftsxarexalwaysxkeptxinxproperxalignmentxwithxthexcross"drivesBxxx

ThexfollowingxpagesxillustratexthexassemblyxofxaxhydraulicmoduleB

Dependingxonxshopxequipmentxavailablexandxthexextentxofxthexoverhaul/xitxmayxbexmorexconvenientxtoxremovexthexentirexhydraulicxmoduleBxxAnxadvantagexofxthisxisxthatxthexmajorityxofxthexworkxwouldxbexdonexinxaxcomfortablexplaceB

HydraulicxmodulesxmayxbexshippedxtoxHallcoxforxoverhaulBxxHallcoxrecommendsxkeepingxthexswitchingxvalvexassembledxinxorderxtoxallowxHallcoxtoxfullyxtestxthexoverhauledxmoduleB

HydraulicCModuleCOverhaul

Docxpx##"]m.N.#CopyrightxAm.[

Page 21: Ul - MAC Trailer

DocbAb99:6HM52H

Repair Guide - Hydraulic Module Overhaul

Copyrightb2HM4

SlipbthebtwobpartbpistonbsealsbintobthebgroovebonbeachbpistonObbThebblackbbasebgoesbonbfirstO

ApplyboilbtobthebpistonbsealbbeforebinsertingbintobthebbarrelObbbPutbthebbevelbsidebofbthebpistonbintobthebbarrelbfirstbsobthatbitbisbtowardbthebheadbmanifoldbwhenbthebbarrelbisbplacedboverbthebshaftbandbontobthebheadO

UsebabhydraulicbpressborbotherbtoolbtobpushbthebpistonbintobthebbarrelBcylinderObbThebflatbsurfacebofbthebpistonbshouldbbebaroundbMB2binchb[M3mm]binsidebthebbarrelbtobmakebspacebforbthebo:ringbbossbonbthebbasebmanifoldO

i:2k:bOrientbPistonbBevelbTowardbHeadbManifoldO

Page 22: Ul - MAC Trailer

Repair Guide - Hydraulic Module Overhaul

Stretchxaxparabolicxbackupxringxintoxeachxo4ringxbossxgroovexonxthexheadxandxbasexmanifolds.xxThexcuppedxsurfacexshouldxfacextowardxthexinsidexofxthexbarrel.x

Wipexoilxontoxthexo4rings.xxIfxtheyxarexnotxoiledxthexo4ringscouldxbexdamagedxwhenxthexbarrelxisxslidxoverxthexo4ringxboss.

Wipexoilxontoxthextransferxtubexo4ringsxandxthenxinsertxthemxintoxthextransferxtubexgroovesxinxthexheadxandxbasemanifolds.

Usexthexpoppetxseatxtoolxandxaxhammerxtoxformxthexseatxforxthexpoppetxtoxsealxagainst.xx

Foldxthexwearxringsxandxinsertxthemxintoxthexwidexgrooveinxthexshaftxholes.

Usexthexrodxsealxinsertionxtoolxtoxfoldxthexshaftxsealxasxshown.xxInsertxthexsealxintoxthexnextxgroovexupxfromxthexwearxringxinxthexshaftxholes.xxOrientxthexsealxsoxthatxthexwiperxlipxisxtowardxthexbarrels.

Thenxstretchxanxo4ringxintoxthexgroovesxsoxthatxthexo4ringxwillxbexfurthestxtowardxthexinsidexofxthexbarrel.xxBexsurexthatxthexo4ringxisxsittingxdownxinxthexgroovexallxthexwayandxnotxrestingxonxthexbackupxring.

Before installing any seal be sure to inspect the sealand sealing surface/groove and remove any debris or rough surface.

O4Ring

Backup

DocxRx994601521Copyrightx2014

Page 23: Ul - MAC Trailer

Doc.".9976j!OII

Repair Guide - Hydraulic Module Overhaul

Copyright.Ij!A

Use.the.head.installation.tool.to.draw.the.shafts.throughthe.shaft.sealsN..Slide.the.heads.onto.the.shafts.so.that.the.inside.face.of.the.heads.is.!!7!qA/.[I8O.mm].from.the.end.of.the.shaftsN

Take.a.barrel.with.a.piston.installed.in.one.of.its.ends.andslide.the.open.end.without.the.piston.over.a.shaft.and.push.it.over.an.o7ring.bossN..The.threaded.end.of.the.shaftwill.slide.into.the.piston.holeN..The.end.of.the.barrel.should.seat.against.the.bottom.of.the.o7ring.boss.slotN..Do.this.on.all.of.the.shaftsN

Thread.the.piston.nuts.on.the.shafts.and.tighten.to.,jjft7lbs.[Aj7.N7m].torque.against.the.pistonsN..Theassembly.jig.is.very.helpful.in.keeping.the.shafts.from.turning.when.torquing.the.piston.nutsS

Insert.the.poppet3.spring.and.cap.into.the.poppet.ports.in.the.head.manifolds.as.shownN..Apply.oil.to.the.poppet.capo7rings.before.inserting.the.capsN

Apply.oil.to.the.shaft.seals.and.slide.the.heads.onto.the.shaftsN..Orient.the.heads.so.that.the.centerline.marks.bothface.in.the.same.directionN

Use.the.rod.seal.insertion.tool.again.to.fold.and.installthe.shaft.wiper.sealsN..Orient.the.seal.so.that.the.wiper.lipis.directed.away.from.the.barrelsN

Clean.the.portion.of.the.shafts.that.will.be.inside.the.cylinder.barrelsN..Inspect.the.chrome.surface.for.dents3missing.chrome.or.any.other.defect.that.would.damagethe.sealsN

Page 24: Ul - MAC Trailer

Repair Guide - Hydraulic Module Overhaul

DocfOf99j6q1523Copyrightf2q14

InsertfthefojringsfintofthefswitchingfvalvefportsfonfthefbasefthenfinsertftheffourfswitchingfvalvefboltsfthroughfthefbaseTffOrientfthefswitchingfvalvefsofthatfthefpressurefgagefportfcomesfoutftowardfthefoppositefsideffromfthefcenterlinefmarksfonfthefheadfmanifoldsTffSlidefthefswitchingfvalvefontofthefboltsfandftightenfthefboltsftof3qfftjlbsf[41fNjm]T

ApplyfoilftofthefojringsfoffeachffittingfbeforefinstallingfitTUsefthefplumbingfillustrationsfonfpagef14forf15fasfafguidefforfthefplacementfandforientationfoffeachffittingT

ApplyfteflonftapeftofanyfnonjswivelfpipefthreadfjointT

ThreadfthefswitchingfvalvefstopfassemblyfintofthefspoolfoffthefswitchingfvalveTffDonStfworryfaboutftorquingfitfyetT

InsertftheftransferftubesfintofthefheadfmanifoldsT

InsertfthefbasefmanifoldfojringfbossesfintofthefbarrelsfandftheftransferftubesfintofthefbaseTffOrientfthefbasessofthatftheftransferftubesffromfthefheadsflinefupfwithfthetransferftubefportsfinfthefbasesT

InsertftheftiefboltsfthroughftheffourfholesfinfthefcenterfoffthefbasesfandfthreadfthemfintofthefheadsTffTheftiefboltfinsertionftoolfmakesfitfeasierftofturnftheftiefboltsTffSinktheftiefboltsfintofthefheadsfasffarfasftheyfwillfgoT

TightenftheftiefboltfnutsfbutfdofnotftorquefthemfuntilfinstallingfthefmodulefintofthefframeT

Make sure that the transfer tube is inserted

into both the head and the base before tightening the tie

bolt nuts!

NOTICE

Page 25: Ul - MAC Trailer

Docwbw**O/kIP(H

Repair Guide - Hydraulic Module Overhaul

Copyrightw(kIH

,ttachwthewhydraulicwhoseswusingwthewillustrationswonwpageIHwaswawguideLw

ThreadwthewswitchingwrodwthroughwthewtriggerwnearestwtheswitchingwvalveLwwSlidewthewswitchingwrodwbumperwassemblieswinwplacewaswshownwhereLwwContinuewthreadingthewswitchingwrodwthroughwthewnextwtriggerLww

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Page 26: Ul - MAC Trailer

Repair Guide - Switching Valve Overhaul

Uocs.sNNR/BP3(3]opyrights(BP)

Thesswitching valvescansbesoverhauledstoscorrectsexternalssealsleakagesonlys—snotsbypassEssIfsanysofsthesmajorscomponentssrequiresreplacementHsthesentiresvalveswillsneedstosbesreplacedE

IfsthesswitchingsvalvesissaslotshottersthansthesothershydraulicscomponentssduringsoperationsthensaslargesamountsofsoilsissbeingsbypassedEssSendsthesswitchingsvalvestosHallcosforstestingsorsreplacesthesvalvesentirelyE

RemovesthescapsscrewsswhichsattachsthesendscapsstosthesvalvesbodyE

Disassembling the Switching Valve

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SlidesthesendscapssawaysfromsthesvalvesbodyE

RemovesthespilotsrodsandsthesspoolE

RemovesthesoRringssandsshaftswipersE

Inspecting the Switching Valve Components

InspectsthesspoolHspilotsrodHsspoolsboreHsandspilotsrodsboressforsscoringsandsburrsE

InspectsallsthesremainingssealsareasEssThessealsareassmustsbessmoothsandsfreesofsscoringsandsburrsE

InspectsthesfastenerssandsthreadedsholessforsgoodsthreadsengagementE

Reassembly of the Switching Valve

HallcosrecommendssreplacingsallsthesswitchingsvalvessealsswhensoverhaulingsthesswitchingsvalveE

LubricatesthesshaftswiperssandsoRringsswithshydraulicsfluidsandsinstallsthemsinsthesendscapsE

LubricatesthesvalvesspoolsandspilotsrodswithshydraulicsfluidsandsinsertsthesspoolsintosthesvalvesbodysandsthespilotsrodsintosthesspoolEss]entersthemsonsthesvalvesbodyE

PlacesthesoRringsswhichsgosbetweensonesofsthesendscapssandsthesbodysinstheirsrespectivessealsgroovessandsslidesonsthesendscapEssNotestheslocationsofsthesalignmentspinEssRepeatsforsthesothersendscapE

InstallsthescapsscrewsswhichsholdsthesforwardsendscapsonHssnugsthemsupHsthenstorquesthemstosQBsftRlbss[)PsNRm]EssUsestwosofsthessamessizescapsscrewsstosholdsthesrearsendscapssnugsuntilsitsissreadystosbesinstalledsonstheshydraulicsmoduleE

]ompletesSwitchingsValvesLssemblys.3/RQN/)

Page 27: Ul - MAC Trailer

Dock:k99(601526

Repair Guide - Control Valve Overhaul

Copyrightk2014

Removekthekcapkscrewkandklockkwasherkwhichkattachkthekvalvekhandlektokthekspool)kkNote:kkIfkthekspoolkturnsksokthatkthekscrewkcannotkbekremovedPkholdkthekendkofkthekspoolkatkthekoppositekendkbeyondkthekretainingkringkwithklockingkplierskorksimilar)kkDoknotkgripkthekareakwhichkslideskinkthekvalvekbody)kk

Replacekthektwoko(ringskinkthekvalvekbodykwithknewko(rings)kkLubricatektheko(ringskwithkhydraulickfluidkbeforekinstallingkthem)

Thekcontrolkvalvekcankbekoverhauledktokcorrectkexternalkleakagekonly)kkIfkthekvalvekhaskexcessivekinternalkbypassPkitkwillkneedktokbekreplacedkentirely)

Priorktokreassemblykinspectkallkcomponentskforkwearkandkdamage)kkDoknotkreinstallkdefectivekcomponents)

Disassembling the Control Valve

Reassembling the Control Valve

Removekthekspacerkcollark,one(waykonlyL)

Removekthekspoolkbykslidingkitktowardkthekretainingkringkside)kkNotekthatkthekretainingkringkdoesknotkhavektokbekremoved)

Removekthektwoko(ringskfromkthekvalvekbody)

InstallkthekretainingkringkonkthekspoolPkifkitkwaskremoved)

Lubricatekthekspoolkwithkhydraulickfluidkandkinsertkitkintokthekvalvekbody)

Attachkthekvalvekhandlekwithkthekcapkscrewkandklockkwasher)

Page 28: Ul - MAC Trailer

Boc,“,33O’®bxzvGopyright,z®bT

&allco,;ndustriesF,;ncR,f“&allco”,or,“Gompany”L,warrants,to,the,original,product,purchaser,f“Gustomer”L,each,of,the,&allco,L;Vq,KLOORS®,or,its,other,floor,systems,manufactured,and,sold,by,it,or,any,of,its,authorized,distributorsF,when,properly,assembled,and,installedF,to,be,free,from,defects,in,material,and,workmanshipR,This,warranty,expressly,excludes,deck,sealF,when,usedR,,Gompany’s,obligation,to,Gustomer,under,this,warranty,is,limited,to,repairing,or,replacingF,as,herein,providedF,and,at,its,sole,optionF,any,part,or,parts,of,the,system,which,within,twelve,fbzL,months,after,delivery,to,Gustomer,shall,be,foundF,upon,examination,by,GompanyF,to,be,defectiveF,provided,that,such,part,or,parts,shall,be,returnedF,with,insurance,and,shipping,costs,at,Gustomer’s,expenseF,to,Gompany’s,factory,at,’’®x,Mmmunition,RoadF,TillamookF,Oregon,3vbTbR,Gompany,must,be,notified,in,writing,of,any,claim,under,this,warranty,within,k®,days,of,any,claimed,lack,of,conformity,of,the,productR

WMRRMNTY,qXGLUS;ONSR,,Representatives,of,Gompany,are,not,authorized,to,modify,this,warranty,in,any,wayR,,;t,is,the,Gustomerws,responsibility,to,regularly,examine,the,product,to,determine,the,need,for,normal,service,or,replacementR,,This,warranty,does,not,cover,the,followingW

WMRRMNTY,L;M;TMT;ONSR,T&;S,WMRRMNTY,;S,MMBq,qXPRqSSLY,;N,L;qU,OK,MNY,OT&qR,WMRRMNT;qSF,qXPRqSSqB,OR,;MPL;qBF,;NGLUB;N8,MNY,;MPL;qB,WMRRMNTY,OK,MqRG&MNTMP;L;TY,OR,K;TNqSS,KOR,MNY,PMRT;GULMR,PURPOSqF,MNB,OK,MNY,OT&qR,OPL;8MT;ON,OR,L;MP;L;TY,ON,T&q,PMRT,OK,T&qMMNUKMGTURqRR

;n,no,event,shall,Gompany,be,liable,for,any,lossF,inconvenience,or,damageF,whether,directF,incidentalF,consequential,or,otherwiseF,except,for,the,repair,or,replacement,obligation,as,set,forth,hereinR,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,damagesF,so,the,above,limitations,or,exclusions,may,not,apply,to,youR,This,warranty,will,be,interpreted,pursuant,to,the,laws,of,the,United,States,and,the,State,of,OregonR

&MLLGO,;NBUSTR;qSF,;NGR,O,PROR,POX,x®x,O,T;LLMMOOKF,ORq8ON,3vbTbP&ONq,fA®®L,xTzOxxz’,O,KMX,fx®kL,ATzOTA’’

WARRANTY

wwwwwwwwwwwwwwwwwwwwwwwwDeckwboltswmustwbewre-torquedwafterwthewfirstw5-10wloadsnwwFailurewtowdowthiswwillwresultwinwdamagewtowthewslatswandwdrivewunitnnn

NOTICE

WMRRMNTY,SqRV;Gq,OPT;ONSR,Kor,service,under,this,warrantyF,Gustomer,must,notify,Gompany,in,writing,to,obtain,a,Returned,Material,Muthorization,Number,fRMMNLR,When,requesting,your,written,RMMNF,specify,in,writing,the,part,in,question,by,part,number,),applicable,purchase,order,numberR,,Gustomers,in,countries,other,than,the,United,States,should,contact,Gompany’s,authorized,representative,in,such,countryF,when,applicableR

O,Bamage,occurring,during,shipment,of,the,productR,fSuch,claims,must,be,presented,directly,to,the,freight,companyLRO,Bamage,to,the,product,resulting,from,improper,maintenance,or,repairF,the,use,or,installation,of,parts,and,or,accessories,not,manufactured,by,GompanyF,or,which,are,not,compatible,with,the,systemF,or,failure,to,follow,product,warnings,and,usage,instructionsRO,Normal,wear,and,tearRO,Mny,product,for,which,Gustomer,does,not,follow,the,warranty,procedures,stated,aboveR

O,Products,that,have,been,modifiedF,alteredF,neglected,or,poorly,maintainedF,misusedF,abused,or,involved,in,accidents,or,natural,disastersF,or,repaired,other,than,by,Gompany,in,accordance,with,these,warranty,proceduresN