AGI Batco 1500 Series: Batco FX1535FL User manual
Read this manual before using product. Failure to
follow instructions and safety precautions can
result in serious injury, death, or property
damage. Keep manual for future reference.
Part Number: P1512115 R8
Revised: December 2017
Portable Grain Belt Conveyor
Field Loader
Assembly Manual
This manual applies to:
1500 Series: FX1535FL, FX1545FL
Original Instructions
New in this Manual
The following changes have been made in this revision of the manual:
Description Section
Added this section back in manual, which was in
previous revisions. Added further instructions on
lagged roller.
Section 4.7. – Install the Spout Roller on page 35
Inserted conveyor tube layout drawings per model. Section 4.6. – Assemble the Conveyor Tube on page
33
Added 53 L non-EPA tank for outside the USA.
Removed 22 L gas tank.
Section 4.28. – Gas Drive — Tank Kit (for outside
USA) on page 112
Added images, re-ordered content, made corrections,
improved clarity.
Section 4.16. – Install the Collapsible Hopper Cloth on
page 53
Many improvements/corrections, including: exhaust/
muffler components, fuel pump wiring. Many new
images and re-ordered content. Clearly described for
these conveyor models that a gas engine drive must
have a soft start electric clutch, and an electric motor
drive cannot have a soft start electric clutch.
Section 4.24. – Install the Over-Mount Gas/Electric
Drive on page 68
Updated images, re-ordered content, made
corrections, improved clarity. Specifically added
content on rocker arm pivot shaft and sleeve, engine
adjustment plate tap bolt, engine oil drain pipe,
clutch stop bracket, clutch wiring module mount,
pulley keys, exhaust/muffler components, fuel pump
wiring, and fuel filter. Corrections to hydraulic pump/
fittings and added explode of hydraulic pump
engagement handle.
Section 4.25. – Install the Under-Mount Gas Drive
(Option for FX1545FL Only) on page 90
Noting which portions are applicable to over-mount
and under-mount. Corrections to hydraulic pump and
fittings. Improved images.
Section 4.29. – Hydraulic Wet Kit on page 113
Added image and description for fastening extension
harness.
Section 4.26. – Gas Drive — Control Box on page 108
Updated images to show current winch design and
fittings. Tube bracket is now weld-on, so removed
bolt-on bracket.
Section 4.10. – Install the Hydraulic Winch on page 38
Added flat washers on any slotted holes which did
not have them.
Multiple
Updated orientation of wheel bolts and removed
nuts.
Section 4.20. – Install the Wheels on page 63
Added screw-on container type. Section 4.32. – Install the Manual Container on page
122
For conveyors with a hand winch, added new image
showing cable routed through motor mount pipe.
Section 4.22. – Install the Tube Lift Cable on page 66
Adjusted screw locations. Section 4.19. – Install the Spout Hood on page 62
Updated format and added some new decals. 2.10.2 Safety Decal Locations and Details on page 14
Description Section
Removed step/image for assembling cable sheaves
because factory pre-assembled.
Section 4.18. – Install the Collapsible Hopper Cloth
Controls on page 60
Removed specific content on 13–series conveyor
models.
Multiple
Removed whole section on bolt-on brackets because
now weld-on.
Install the S-Drive Brackets
4 P1512115 R8
PORTABLE GRAIN BELT CONVEYOR – FIELD LOADER
PORTABLE GRAIN BELT CONVEYOR – FIELD LOADER
P1512115 R8 5
CONTENTS
1. Introduction ............................................................................................................................................ 7
2. Safety....................................................................................................................................................... 8
2.1. Safety Alert Symbol and Signal Words..................................................................................... 8
2.2. General Product Safety ............................................................................................................ 8
2.3. Moving Conveyor Belt Safety................................................................................................... 9
2.4. Rotating Parts Safety................................................................................................................ 9
2.5. Drives and Lockout Safety........................................................................................................ 9
2.5.1 Gas Engine Safety..................................................................................................... 10
2.5.2 Electric Motor Safety................................................................................................ 10
2.5.3 Hydraulic Power Safety ............................................................................................ 11
2.6. Tire Safety............................................................................................................................... 12
2.7. Battery Safety ......................................................................................................................... 12
2.8. Personal Protective Equipment.............................................................................................. 13
2.9. Safety Equipment ................................................................................................................... 13
2.10. Safety Decals ........................................................................................................................ 13
2.10.1 Decal Installation/Replacement............................................................................. 14
2.10.2 Safety Decal Locations and Details ........................................................................ 14
3. Features................................................................................................................................................. 29
3.1. Model Number ....................................................................................................................... 30
4. Assembly ............................................................................................................................................... 31
4.1. Assembly Safety ..................................................................................................................... 31
4.2. Check Shipment...................................................................................................................... 31
4.3. Required Tools........................................................................................................................ 31
4.4. Before You Begin .................................................................................................................... 32
4.5. Component Locations ............................................................................................................ 32
4.6. Assemble the Conveyor Tube ................................................................................................ 33
4.7. Install the Spout Roller........................................................................................................... 35
4.8. Install the Frame Slider .......................................................................................................... 36
4.9. Install the Hand Winch........................................................................................................... 37
4.10. Install the Hydraulic Winch .................................................................................................. 38
4.11. Attach the S-Drive ................................................................................................................ 40
4.12. Install the S-Drive Front Guard ............................................................................................ 41
4.13. Assemble the Weather Guard.............................................................................................. 41
4.14. Install the Belt ...................................................................................................................... 44
4.15. Install the Weather Guard Mount Bar ................................................................................. 50
4.16. Install the Collapsible Hopper Cloth .................................................................................... 53
4.17. Attach the Hitch ................................................................................................................... 59
4.18. Install the Collapsible Hopper Cloth Controls...................................................................... 60
4.19. Install the Spout Hood.......................................................................................................... 62
4.20. Install the Wheels................................................................................................................. 63
4.21. Assemble the A-Frame ......................................................................................................... 64
4.22. Install the Tube Lift Cable .................................................................................................... 66
4.23. Align the Winch .................................................................................................................... 68
4.24. Install the Over-Mount Gas/Electric Drive........................................................................... 68
4.24.1 Install the Motor Mount ........................................................................................ 69
4.24.2 Install the Gearbox ................................................................................................. 70
4.24.3 Install the Slider Mount.......................................................................................... 71
PORTABLE GRAIN BELT CONVEYOR – FIELD LOADER
6 P1512115 R8
4.24.4 Install the Motor and Back Plates.......................................................................... 73
4.24.5 Install the Rocker Arm............................................................................................ 76
4.24.6 Electric Drive — Install the Overcenter Handle..................................................... 77
4.24.7 Install the Pulleys and Belts, and if equipped, the Soft Start Electric
Clutch........................................................................................................................... 79
4.24.8 Install the Pulley Guards ........................................................................................ 84
4.24.9 Gas Drive — Battery Kit ......................................................................................... 86
4.24.10 Gas Drive — Fuel Pump ....................................................................................... 87
4.25. Install the Under-Mount Gas Drive (Option for FX1545FL Only) ........................................ 90
4.25.1 Install the Drive Mount and Platform.................................................................... 90
4.25.2 Install the Frame Stabilizers ................................................................................... 91
4.25.3 Install the Hydraulic Pump, Gearbox, and Belt Tightener ..................................... 93
4.25.4 Install the Gas Engine............................................................................................. 96
4.25.5 Install the Pulleys, Belts, and Soft Start Electric Clutch......................................... 97
4.25.6 Install the Battery, Engine Guards, and Fuel Pump ............................................. 101
4.25.7 Install the Guards ................................................................................................. 106
4.26. Gas Drive — Control Box.................................................................................................... 108
4.27. Gas Drive — EPA Tank Kit (for USA only)........................................................................... 109
4.28. Gas Drive — Tank Kit (for outside USA)............................................................................. 112
4.29. Hydraulic Wet Kit ............................................................................................................... 113
4.29.1 Install the Hydraulic Tank Mount (for Over-Mount and Under-Mount)............. 113
4.29.2 Install the Hydraulic Tank (for Over-Mount and Under-Mount)......................... 114
4.29.3 Install the Hydraulic Pump (for Over-Mount)...................................................... 115
4.29.4 Install the Pivot Handle (for Over-Mount)........................................................... 116
4.29.5 Install the Pulleys and Belt (for Over-Mount)...................................................... 117
4.29.6 Attach the Hydraulic Hoses (for Over-Mount and Under-Mount) ...................... 118
4.30. Install the Shaft Guard ....................................................................................................... 120
4.31. Install the Inspection Step.................................................................................................. 121
4.32. Install the Manual Container ............................................................................................. 122
4.33. Attach the Jack ................................................................................................................... 123
5. Specifications ...................................................................................................................................... 125
6. Appendix ............................................................................................................................................. 126
6.1. Bolt Torque........................................................................................................................... 126
7. Batco Limited Warranty ..................................................................................................................... 127
P1512115 R8 7
1. Introduction
This manual describes how to assemble a Batco Portable Grain Belt Conveyor.
Before assembling the conveyor, please read this manual. Familiarize yourself with the process and the
necessary precautions for efficient and safe assembly.
Everyone present at the assembly site is required to be familiar with all safety precautions.
Keep this manual available for frequent reference and review it with new personnel. Call your local
distributor or dealer if you need assistance or additional information.
PORTABLE GRAIN BELT CONVEYOR – FIELD LOADER 1. INTRODUCTION
8 P1512115 R8
2. Safety
2.1. Safety Alert Symbol and Signal Words
This safety alert symbol indicates important safety messages in this manual. When you see
this symbol, be alert to the possibility of injury or death, carefully read the message that
follows, and inform others.
Signal Words: Note the use of the signal words DANGER,WARNING,CAUTION, and NOTICE with the safety
messages. The appropriate signal word for each message has been selected using the definitions below as a
guideline.
Indicates an imminently hazardous situation that, if not avoided, will result in serious injury or
death.
Indicates a hazardous situation that, if not avoided, could result in serious injury or death.
Indicates a hazardous situation that, if not avoided, may result in minor or moderate injury.
Indicates a potentially hazardous situation that, if not avoided, may result in property damage.
2.2. General Product Safety
YOU are responsible for the SAFE use and maintenance of your conveyor. YOU must ensure that you and
anyone else who is going to work around the conveyor understands all procedures and related SAFETY
information contained in this manual.
Remember, YOU are the key to safety. Good safety practices not only protect you, but also the people around
you. Make these practices a working part of your safety program. All accidents can be avoided.
• It is the conveyor owner, operator, and maintenance personnel's responsibility to
read and understand ALL safety instructions, safety decals, and manuals and follow
them when assembling, operating, or maintaining the equipment.
• Owners must give instructions and review the information initially and annually with all personnel before
allowing them to operate the conveyor. Untrained users/operators expose themselves and bystanders to
possible serious injury or death.
• The conveyor is not intended to be used by children.
• Use the conveyor for its intended purposes only.
• Do not modify the conveyor in any way without written permission from the manufacturer. Unauthorized
modification may impair the function and/or safety, and could affect the life of the conveyor. Any
unauthorized modification of the conveyor will void the warranty.
2. SAFETY PORTABLE GRAIN BELT CONVEYOR – FIELD LOADER
P1512115 R8 9
2.3. Moving Conveyor Belt Safety
• DO NOT step on or touch moving conveyor belt.
• Shut off and lock out power to adjust, service, or clean.
2.4. Rotating Parts Safety
• Keep body, hair, and clothing away from rotating pulleys,
belts, chains, and sprockets.
• Do not operate with any guard removed or modified. Keep
guards in good working order.
• Shut off and remove key or lock out power source before
inspecting or servicing machine.
2.5. Drives and Lockout Safety
Inspect the power source(s) before using and know how to shut down in an emergency.
Whenever you service or adjust your equipment, make sure you shut down the power
source and follow lockout and tagout procedures to prevent inadvertent start-up and
hazardous energy release. Know the procedure(s) that applies to your equipment from the
following power source(s). Ensure that only 1 key exists for each assigned lock, and that
you are the only one that holds that key. Ensure that all personnel are clear before turning
on power to equipment.
WARNING
PORTABLE GRAIN BELT CONVEYOR – FIELD LOADER 2. SAFETY
10 P1512115 R8
2.5.1 Gas Engine Safety
Power Source
• Keep guards in place and secure.
• Properly ventilate surrounding area.
• Never fill the fuel tank with the engine running, while
smoking, or near an open flame. Always shut down and allow
engine to cool before filling with fuel.
• Never overfill the tank or spill fuel. If fuel is spilled, clean it
up immediately.
• Be sure to use the correct type and grade of fuel. Ground the
fuel funnel or nozzle against the filler neck to prevent sparks
that could ignite fuel vapors.
• Be sure to replace the fuel fill cap when you are done.
Lockout
• For engines with an electric start, remove the ignition key,
the spark plug wire, or the spark plug.
• For engines with a rope or crank start, remove the spark plug
wire or the spark plug.
2.5.2 Electric Motor Safety
Power Source
• Electric motors and controls shall be installed and serviced by
a qualified electrician and must meet all local codes and
standards.
• A magnetic starter should be used to protect your motor.
• You must have a manual reset button.
• Reset and motor starting controls must be located so that the
operator has full view of the entire operation.
• Locate main power disconnect switch within reach from
ground level to permit ready access in case of an emergency.
• Motor must be properly grounded.
• Guards must be in place and secure.
• Ensure electrical wiring and cords remain in good condition;
replace if necessary.
• Use a totally enclosed electric motor if operating in
extremely dusty conditions.
SERVICE DISCONNECT
ON
OFF
Lockout
• The main power disconnect switch should be in the locked position during shutdown or
whenever maintenance is performed.
• If reset is required, disconnect all power before resetting motor.
2. SAFETY PORTABLE GRAIN BELT CONVEYOR – FIELD LOADER
P1512115 R8 11
2.5.3 Hydraulic Power Safety
Power Source
• Refer to the rules and regulations applicable to the power
source operating your hydraulic drive.
• Do not connect or disconnect hydraulic lines while system is
under pressure.
• Keep all hydraulic lines away from moving parts.
• Escaping hydraulic fluid under pressure will cause serious
injury if it penetrates the skin surface (serious infection or
toxic reaction can develop). See a doctor immediately if
injured.
• Use metal or wood as a backstop when searching for
hydraulic leaks and wear proper hand and eye protection.
• Check all hydraulic components are tight and in good
condition. Replace any worn, cut, abraded, flattened, or
crimped hoses.
• Clean the connections before connecting to equipment.
• Do not attempt any makeshift repairs to the hydraulic fittings
or hoses with tape, clamps, or adhesive. The hydraulic
system operates under extremely high pressure; such repairs
will fail suddenly and create a hazardous and unsafe
condition.
Lockout
• Always place all hydraulic controls in neutral and relieve
system pressure before disconnecting or working on
hydraulic system.
PORTABLE GRAIN BELT CONVEYOR – FIELD LOADER 2. SAFETY
12 P1512115 R8
2.6. Tire Safety
Failure to follow proper procedures when mounting a tire on a
wheel or rim can produce an explosion that may result in
serious injury or death.
• DO NOT attempt to mount a tire unless you have the proper
equipment and experience to do the job.
• Have a qualified tire dealer or repair service perform
required tire maintenance.
• When replacing worn tires, make sure they meet the original
tire specifications. Never undersize the replacement tire.
• DO NOT weld to the tire rim with the tire mounted on the
rim. This action may cause an explosion which could result in
serious injury or death.
• Inflate tires to the manufacturer’s recommended pressure.
• Tires should not be operated at speeds higher than their
rated speed.
• Keep wheel lug nuts tightened to manufacturer’s
recommendations.
• Never reinflate a tire that has been run flat or seriously
under-inflated without removing the tire from the wheel.
Have the tire and wheel closely inspected for damage before
remounting.
2.7. Battery Safety
• Wear safety glasses and protective gloves when working near
batteries.
• Make certain the battery or terminal covers are in place and
in good working order.
• Keep all sparks and flames away from batteries; gas given off
by electrolyte is explosive.
• Avoid contact with battery electrolyte. Wash off any spilled
electrolyte immediately.
• Do not tip batteries more than 45° to avoid electrolyte loss.
• To avoid injury from sparks or short circuits, disconnect
battery ground cable before servicing any part of an electrical
system.
2. SAFETY PORTABLE GRAIN BELT CONVEYOR – FIELD LOADER
P1512115 R8 13
2.8. Personal Protective Equipment
The following Personal Protective Equipment (PPE) should be worn when assembling the equipment.
Safety Glasses
• Wear safety glasses at all times to protect eyes from debris.
Work Gloves
• Wear work gloves to protect your hands from sharp and rough edges.
Steel-Toe Boots
• Wear steel-toe boots to protect feet from falling debris.
Coveralls
• Wear coveralls to protect skin.
Hard Hat
• Wear a hard hat to help protect your head.
2.9. Safety Equipment
The following safety equipment should be kept on site:
Fire Extinguisher
• Provide a fire extinguisher for use in case of an accident. Store in a highly visible and
accessible place.
First-Aid Kit
• Have a properly-stocked first-aid kit available for use should the need arise, and
know how to use it.
2.10. Safety Decals
• Keep safety decals clean and legible at all times.
PORTABLE GRAIN BELT CONVEYOR – FIELD LOADER 2. SAFETY
14 P1512115 R8
• Replace safety decals that are missing or have become illegible. See decal location figures that follow.
• Replaced parts must display the same decal(s) as the original part.
• Replacement safety decals are available free of charge from your distributor, dealer, or factory as applicable.
2.10.1 Decal Installation/Replacement
1. Decal area must be clean and dry, with a temperature above 50°F (10°C).
2. Decide on the exact position before you remove the backing paper.
3. Align the decal over the specified area and carefully press the small portion with the exposed sticky backing
in place.
4. Slowly peel back the remaining paper and carefully smooth the remaining portion of the decal in place.
5. Small air pockets can be pierced with a pin and smoothed out using the sign backing paper.
2.10.2 Safety Decal Locations and Details
Replicas of the safety decals that are attached to the conveyor and their messages are shown in the figure(s)
that follow. Safe operation and use of the conveyor requires that you familiarize yourself with the various safety
decals and the areas or particular functions that the decals apply to, as well as the safety precautions that must
be taken to avoid serious injury, death, or damage.
2. SAFETY PORTABLE GRAIN BELT CONVEYOR – FIELD LOADER
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