Keith KICD Series User manual
©2017 KEITH Manufacturing Co. All Rights Reserved. KEITH, KEITH logo and WALKING FLOOR are registered trademarks of KEITH
Manufacturing Co. Equipment manufactured by KEITH Manufacturing Co. is protected by numerous patents both domestic and foreign.
KEITH®KICD Series Drive
Installation Manual
Original Instructions
www.keithwalkingoor.com
Revised: 8/30/17
KEITH Manufacturing Co.
World Headquarters
800-547-6161
541-475-3802
541-475-2169 fax
CONTENTS:
1 INTRODUCTION............................................................................................................
2 CONTAINER PREPARATIONS
2.1 Container alignment................................................................................................
2.2 Bracing...............................................................................................................
2.3 Hydraulic tubing locations....................................................................................
2.4 Cross-members....................................................................................................
2.5 Shimming.............................................................................................................
2.6Baeplate.............................................................................................................
3 SUB-DECK
3.1 Square tubing.......................................................................................................
4 DRIVE UNIT
4.1 Side seal support .................................................................................................
4.2 Painting.................................................................................................................
4.3 T-block ......................................................................................................
4.4 Hydraulic tubing .................................................................................................
5 FLOORING
5.1 Slide bearings........................................................................................................
5.2 Floor slats..............................................................................................................
5.3 Side seal................................................................................................................
5.4 Front shield...........................................................................................................
6 MISCELLANEOUS
6.1 Caution decals......................................................................................................
6.2 Front guard...........................................................................................................
Appendix 1 Tools..........................................................................................................................
Appendix 2 Materials....................................................................................................................
Appendix 3 ..................................................................................................................................
Check list......................................................................................................................................
Appendix 4 Torque chart...............................................................................................................
1
2
2
3
3
4
6
7
11
12
12
13
14
16
20
22
23
23
23
24
24
24
25
1
Chapter 1 INTRODUCTION
This manual explains procedures for installing the KEITH®KICD Series unloading
system.Manyvariablesaecttheinstallation,butthegeneralprocessremainsconstant.
Details of the installation vary according to container features, slat selections, and
installer preferences. Optional sets of instructions are given for some operations to allow
forexibility.
Thismanualfocusesontheinstallationofa150mmstrokesystemwithSAEooring.
Installation time varies and is between 35 hours and 100 hours, depending upon the
experience of the installer and the adaptability of the container. One person with welding
skills can complete the entire installation.
Anecientinstallationrequiresappropriatetoolsandaccessiblematerials.Alistoftools
is found in Appendix 1. Appendix 2 lists materials. The KEITH®KICD Series owner’s
manual contains more detailed information about the system and operation procedures.
DirectanyquestionstoKEITHManufacturingCo.oroneofourinternationaloceslisted
on the cover of this manual.
WARNING: Installing the WALKING FLOOR®system will require some alterations to
your container.
2
Chapter 2 CONTAINER PREPARATIONS
The container requires preparation before the system is installed. Planning ahead for the
WALKING FLOOR®installationrequirementssavessignicantpreparationtime,
2.1 Container alignment
Check the compatibility of the drive unit with the container before making any alterations
to the container.
1. Adjust the container to meet these conditions:
A) The container must be straight to allow for proper parallel movement of the slats.
Determinestraightnessbysightingdownaoorslatpositionedinthecontainer.
B) The cross-members on which the sub-deck mounts must be level, because the friction
based principle of the WALKING FLOOR®systemrequiresaatoor.
If there are deviations exceeding 3mm, make corrections.
2.2 Bracing
Container bracing prevents warping.
1. Install bracing as shown in Figure 1.
Itisbesttoaddbracingbeforeremovingtheoldoorbecausetheoorkeepsthe
containerstraight.Ifatbarisused,makeacross-bracingbecauseitwillbuckle
easily under compression. The bracing reaches to the drive opening. Weld or bolt
the braces to each intersecting cross-member.
2. Weld temporary bracing onto the outside of the side rails to keep the drive opening
straight.Thisisveryimportantifthetopofthecontainerwascutoutrst.Removeafter
completion.
3.Removeoldooring.
No Bracing at
drive unit opening
1980mm [78"]
Minimum Opening
75362-1
Temporary bracing welded
to outside of container rails
to keep drive opening straight.
Remove after completion.
6mm x 50mm
[1/4" x 2"]
Cross-Bracing
5th Wheel Tunnel
Figure 1
3
2.3 Hydraulic tubing locations
Hydraulic pressure, generated by the tractor’s wet kit, powers the drive unit. Tubing must
connect the drive unit to the tractor.
The location of the hydraulic tubing cut holes are shown so that the tubing will line up with
the drive plumbing. Section 4.4 provides more information on this subject. A central loca-
tion is preferable for the quick-couplers in front of the container. This keeps hose lengths
down, if they stay connected while driving.
2.4 Cross-members
Cross-members function as support for the sub-deck.
Afterremovingtheooring,thecross-membersneedtobeshimmed.Seesection2.5.
Figure 2
SECTION A-A
A
A
75362-2
Holes for tubing cut
thru cross-members
this side of container,
from drive opening
to front of container.
Centerline
697 [27 7/16 in]
789 [31 1/16 in]
38 [1 1/2 in] 35mm [1 1/2"]
Remove cross-members
to make Drive Unit opening.
1980 [78"]
Minimum Opening
5th Wheel Tunnel
DETAIL C
SCALE 1 / 4
DETAIL D
SCALE 1 / 4
CD
75362-3
Shim Attached to Container Cross-Member
#C-3003 Bearing 25mm x 25mm
Tubing
Figure 3
4
Remove cross-members to create an adequate opening for the drive unit (Figure 4). See
Chapter 4 for more information about drive unit location.
Opening between channel at rear of tunnel to cross member.
Side view in container (Figure 4)
2.5 Shimming
1. The cross-members attached to the tunnel to the side rail need to be shimmed to the
same height as the tunnel 32mm [1-1/4”]. See Section B-B.
2. The WALKING FLOOR®system takes 150mm [5-7/8”] clearance from the bottom
of cross-members to the bottom of the sub-deck [25mm x 25mm] tubing. The cross-
members need to be shimmed 35mm [1-3/8”] higher from the rear of the tunnel to the
front of the rear threshold. See Section C-C.
3.TheTunnelareaneedsfurthershimming.Use50mmwideatbarthefullwidthofthe
container.Startingatthefrontcross-member,place8mm[5/16”]thickatbarontherst
5cross-members.Oncross-members#6and#7,place6mm[1/4”]atbar.Oncross-
members#8and#9,place5mm[3/16”]atbar.Oncross-member#10,place3mm[1/8”]
atbar.Clampandweldinplace.(Figure6,SectionD-D)
SECTION E-E
SCALE 1 / 20
E E
75362-4
Tunnel
Channel at
rear of tunnel Drive Unit will be
welded to channel.
1980mm [78"]
Minumum opening
Container
Cross-Members
Figure 4
Figure 4
5
SECTION B-B
SECTION C-C
BBCC
75363
Shim to top of tunnel
at tunnel only.
Existing rear
threshold
35 [1 3/8 in]
32 [1 1/4 in]
Top of
Tunnel
378 [14 7/8 in] Mount 3mm [1/8"]
Baffle Plate on top
of existing rear
threshold.
Shim 1 3/8 [35mm]
above cross-members
Shimming the Cross-Members & Rear Baffle Plate
Mininum Gap 75mm [3"]
Different examples of Shimming
on top of Cross-Members
Shim 35mm [1-3/8"]
above cross-members
Shim level to Tunnel
at tunnel only.
Bracing
Shim level with rear threshold,
mount baffle on top of shim.
64 [2 1/2 in]
clearence for Door
150mm [5 7/8"]
314 [12 3/8 in]
Figure 5
6
DETAIL D
SCALE 1 / 30
SECTION D-D
D
DD
75364
Tunnel
5mm [3/16"]
Shim
8mm [5/16"]
Shim 5x
Shim to go
wall to wall
3mm [1/8"] Shim
35mm [1 3/8"]
Shim
6mm [1/4"] Shim
Figure 6
2.6 Bae plate
Abaeplateextendsforwardfromthedoorthresholdtopreventmaterialfromsifting
throughtheoorwhenslatsareintheforwardposition.
Starting 65mm [2-1/2”] from unload end of threshold, leaving clearance for the door,
use 3mm [1/8”] thick material to achieve the 150mm [5-7/8”] from the bottom of cross-
memberstotopofthebaeplate.Comeforward315mm[12-3/8”]thendown100mm[4”]
andweld100%.Grindweldsat.Seepage5,sectionC-C.
7
Chapter 3 SUB-DECK
Thesub-deckisthestructuredirectlyabovethecross-membersandunderneaththeoor
slats.Thesub-deckconsistsofsquaresteeltubingorU-shapedaluminumproles.
Thesquaretubingmountsontopofthecross-members.Plasticoorbearingsconnectto
the tubing.
3.1 Square Tubing
The proper installation of the square tubing is critical for maintaining drive alignment,
oorstraightnessandforoptimalperformanceoftheseallocatedbetweentheoorslats.
Raise the drive unit into position. Do not weld at this time. The drive unit is in place for
locating the end of 25mm x 25mm tubing.
1. Cut 25mm x 25mm [1” x 1”] tubes to proper length according to your container
measurements.Thenumberoftubesinstalledequalsthenumberofoorslats.
All sub-deck tubes must extend beyond cross-members by 50mm [2”], because
bearings require at least 50mm [2”] of tubing on both sides of a cross-member for proper
attachment. See details Page 8, F, G & H.
2. Position and mount the tubes.
TubingforSAEooringison3.65”[92.7mm]centers(Figure7).
Start at the rear of the container. Lay the two outside tubes in the container and separate
them with spacing jigs. Center the jigs so the tubes are the same distance from the side
walls and then weld in place. (See Figure 8)
Figure 7
DETAIL F
SCALE 1 / 3
F
75364-2
92.7
[3.65"]
92.7
[3.65"]
8
SECTION E-E
DETAIL F
DETAIL E
DETAIL D
EE
F
E
D
75365
50mm [2"] 50mm [2"]
50mm [2"] 50mm [2"]
Do not cover
baffle plate with
25mm x 25mm Tubing
25mm x 25mm Tubing
25mm x 25mm Tubing
Do not weld 25mm x 25mm Tubing
to drive unit at this time.
Lift drive unit in place
for tube location only
at this time Do not Weld.
Drive Unit to be placed against
rear Tunnel Channel Channel.
Figure 8
9
Lay out the remaining tubes across the width of the container, spacing them with jigs.
Keeping the jigs above the cross-members, clamp the jig and tubes to every other cross-
member. Be sure all tubes attain the minimum overhang of 50mm. Remember to plan
for the formed cross sill attached to the drive unit. Plan the overhang into the drive gap
according to the drive unit being installed (Page 8, Figure 8).
Weld of huck bolt the square tubes to the shim that is attached to the cross members
between jigs. Move the jigs and make a connection at each intersection of a tube and a
cross-member.Weldsshouldbe3mmllet,20mmto30mmlong,andcenteredonthe
ange.Excessiveweldingandtoolittlecoolingwillcausecross-memberstowarp.Figure
10 suggests a welding pattern. Starting each pass on the same side of the container
givessucientcoolingtime.
75366
Figure 9
Figure 9
Figure 10
75366-2
X= Weld First Pass
O= Weld Second Pass
25mm x 25mm Tube
Container Cross Sils (Typ)
10
Chapter 4 DRIVE UNIT
NOTE: A minimum drive opening of 1980mm [78”] is necessary to maneuver the drive
unit. (See Page 4, Figure 4)
IMPORTANT: Do not damage piston rods. Do not lift drive unit by any of the hydraulic
components.
Align and level drive unit.
Driveunitisbuttedagainstchannelatrearoffth-wheeltunnel.(SeedetailE)
Center the drive unit in the drive gap. The 25mm x 25mm [1” x 1”] tubing should extend
50mm [2”] past the formed cross sills at each end of the drive unit. The cross-drive
should be parallel to container cross-members.
Side to side alignment
Recommended method:
After the sub-deck is welded or bolted down, (to container not drive unit) use a straight
edge to align the drive shoes with respective 25mm x 25mm [1” x 1”] tubing. Do this with
at least two shoes on each side of the container (Figure 11).
Optional method if container is perfectly straight:
Align the drive unit’s “centerline” marks with the container’s centerline.
SECTION F-F
DETAIL F
DETAIL G
SCALE 1 / 16
FF
F
G
75367
Bearing
Bearing
Drive shoe
Straight edge Raise drive shoe
up to straight edge
and level.
Center drive shoes with 25mm x 25mm
tubeing side to side.
Drive unit welded to channel
at rear of 5th wheel tunnel.
Bearing
Figure 12
Figure 11
11
Height
Raise drive frame cross-member to the same height of shimmed cross-member.
This method gives the proper drive height as bearings are 6mm above the 25mm x
25mm[1”x1”]tubeandthedriveshoesconnectdirectlytotheoorslats.SeeDetailF.
Weld the drive unit in place.
Use 25mm x 25mm [1” x 1”] jig to weld 25mm x 25mm [1” x 1”] tubing to drive unit formed
channels.
4.1 Side seal support
Side seal options are discussed in Section 5.3. Some of the options require support from
the sub-deck.
1. Select a side seal option from Section 5.3.
2. Install support for the selected side seal option if necessary.
Planthesupportsothetopofthesidesealwillbelevelwiththerestoftheooring.
Pieces of tube or angle can be attached on the cross-members to support the side seal.
DETAIL A
SCALE 1 / 16
DETAIL G
A
G
2337 [92 in]
8 [5/16 in]
41 [1 5/8 in]
Shim has to be
required height.
41mm is closest
shim can be to
25mm x 25mm Tubing.
NOTE:
Shim material to go
over drive area
both sides.
Side seal shim
both sides
75368
Figure 12
12
4.2 Painting
The factory paints drive units with red oxide primer.
1.Conrmthatthedriveunitiscoatedwellwithprimer.
2.Treatthedriveunitandsub-deckwithanishingpaint.
IMPORTANT: Make sure that the following parts are protected when painting: cylinder
chrome rods, switching valve chrome rod, serial plate and any decals.
4.3 T-block
Plastic T-blocks provide a sliding surface and prevent material from going underneath the
endoftheslatsatthedischargeendoftheooring.(Figure13)
1. Align the T-blocks with installed tubing. Keep the blocks 12mm away from the doors.
2.DrillandcountersinkboltholesthroughtheT-blocksandbaeplates.
3.FastenT-blockstothebaeplate.Self-tappingscrewsmaybenecessaryifaccessis
poor.Countersinkholes6mmbelowtheblocktop.Makesurethebolts(at-head
socket caps) are 4mm [3/16”] below the surface of the block.
SECTION G-G
G
G
12mm [1/2"]
T-Block
T-Block Mounting bolts to
be mounted 4mm [3/16mm]
below flush with top of T-Blocks
Minimum 12mm [1/2"]
gap between door &
T-Block
Door
Rear threshold
Center T-Block with
25mm x 25mm Tubing
75369
Door
Figure 13
13
4.4 Hydraulic tubing
Section 2.3 discusses the location of hydraulic tubing.
IMPORTANT: All components and tubing must be kept absolutely clean to prevent dirt
from entering the system.
1. Determine tube locations and lengths.
2. Cut tubes to length.
3. Position tubes.
Use the weld on tube clamps supplied with the kit or use rubber grommets or PVC
tubes to protect the tubing when installing tubes through cross-members
4. Connect tubes to drive unit.
Connect the pressure line to outside line that is connected to the switching valve
port labeled “PUMP” and return line to inside line that is connected to the
switching valve port labeled “RES”.
5. Mount quick couplers just inside front of container.
Connect the male coupler on the pressure line (outside line to switching valve
port stamped “pump”). Connect the female coupler to the return line (inside line to
switching valve port stamped “res”) (Figure 14). Apply hydraulic sealant.
DETAIL A
SCALE 1 / 40
SECTION H-H
A
H
H
Weld on
tube clamps.
Pressure Line
Male Coupler
Return Line
Female Coupler
After Drive Unit is welded
in place attache Hydraulic
Oil lines.
Front
of
Container
75370
Figure 14
14
5 FLOORING
Afterpaintdries,theooringcanbeinstalled.Theslatsslideonplasticbearings.The
aluminumoorslatsareboltedtoshoesonthecrossdrives.
5.1 Slide bearings
1.Comparebearingdimensionswithshimonthecross-memberangewidth.Thegap
inthebearingshouldexceedtheangewidthoftheshimofthecross-member.The
standard bearing gap is 62mm [2 7/16”]. Milling can enlarge the gap to 100mm [4”].
2. Snap 6 bearings (3003 Long) 100mm [4”] opening on the sub-deck over the load end
of cylinders. (See Detail J of Figure 15)
3. Snap one row of 3003 bearings on the sub-deck over the load end of drive frame.
Snap 1830mm [6’] splash bearing over sub-deck in front of them. Snap another row of
3003 bearings in front of them. Take 12 of the 1830mm [6’] splash bearings and cut
them in half to 915mm [3’] to make a total of 24 splash bearings and snap them on the
sub-deck in front of them. Snap on another row of 3003 bearings in front of them.
(See Detail I of Figure 15)
4. Snap bearings on the square tube at the junction of each cross-member. No tools are
needed.
DETAIL J
J
Cross-Drives Hydraulic Cylinders
in center of drive.
These 6 Bearings have
a 100mm cut out to fit
over stiffener flat bar.
75371-2
Figure 15 Detail J
15
DETAIL I
I
Front of Container
Drive Unit
Install one row of
3003 Bearings.
Install one row of
1830mm [6'] Splash Bearings.
Install one row of 3003 Bearings,
cut off ears on bottom to fit.
Install one row of
915mm [3'] Splash Bearings.
Cut 12 - 1830mm [6'] in half to make
24 - 915mm [3'] Splash Bearings.
Install one row of 3003 Bearings,
cut off ears on bottom to fit.
75371-1
J
Figure 15
IMPORTANT: Donotputabearingonthefrontcross-memberofthecontaineriftheoor
slat will slide beyond the center of this bearing in the backward position.
16
5.2 Floor slats
1.Determinelengthofoorslats.
The slats have to reach from 50mm [2”] from the doors to a minimum of 300mm
[12”]fromtheclosestpointonthefrontwallatoorlevel.Thisimpliesthatthe
maximum length of the slats is 350mm [13 3/4”] shorter than the inner length of
the container. For example, maximum slat length for a 150mm [6”] stroke unit in a
12.04M [39’ 6”] container is 11.69M [38’ 4”].
WARNING: Make sure that the slats do not bump the front wall.
2.Determinedrilledoorboltholelocation.
Make sure the cylinders are all the way to the rear of the container when determining the
oorboltholelocation.
Theooringistobepredrilledbeforeinstallation.Measurethedistancefrom50mm
insidethedoortotherstsetofholesinthedriveshoes.Usethisdistancetosetthe
shoedrilljigatthersthole.
(Note:Ifmultiplecontainersarebeingouttted,itisbenecialtoplacethedriveunitsat
thesamedistancefromtherearofthecontainer.Thenalloftheooringwillbedrilledin
the same location.)
(See Figure 16)
17
SECTION C-C
SCALE 1 / 40
SECTION I-I
CC
I
I
75371-3
50 [2 in]
50 [2 in]End of slat to first
hole in drive shoe.
Door
Door
End of slat to first
hole in drive shoe.
Floor
Slat
Drive Shoe
Figure 16
18
Figure 16
Figure 17
Figure 18
Flooring drill jig
#6121701 for 3.65" flooring
Aluminum
Floor slat
#2188
Seal
Place dowel pins on jig
Tight against against
floor slat.
End of slat to first
hole in drive shoe.
12mm Drill thru
6 places
Clamp jig to slat
when drilling
Flooring drill jig
#6121705 for 3.65"
UHMW flooring
UHMW
Floor Slat
#2558
75371-4
Figure 17
Figure 18
Figure 19
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