Batco 1800 Series 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: P1512126 R3
Revised: June 2017
Portable Grain Belt Conveyor
PitStop with Hopper
Assembly Manual
This manual applies to:
1800 Series
2400 Series
Gas, Electric, and Hydraulic Drives
Original Instructions

2 P1512126 R3
PORTABLE GRAIN BELT CONVEYOR – PITSTOP WITH HOPPER

PORTABLE GRAIN BELT CONVEYOR – PITSTOP WITH HOPPER
P1512126 R3 3
CONTENTS
1. Introduction ............................................................................................................................................ 4
2. Safety....................................................................................................................................................... 5
2.1. Safety Alert Symbol and Signal Words..................................................................................... 5
2.2. General Safety .......................................................................................................................... 5
2.3. Moving Conveyor Belt Safety................................................................................................... 6
2.4. Rotating Parts Safety................................................................................................................ 6
2.5. Drives and Lockout Safety........................................................................................................ 6
2.5.1 Electric Motor Safety.................................................................................................. 7
2.5.2 Hydraulic Power Safety .............................................................................................. 8
2.6. Tire Safety................................................................................................................................. 9
2.7. Personal Protective Equipment................................................................................................ 9
2.8. Safety Equipment ................................................................................................................... 10
2.9. Safety Decals .......................................................................................................................... 10
2.9.1 Decal Installation/Replacement............................................................................... 10
2.9.2 Safety Decal Locations and Details .......................................................................... 10
3. Features................................................................................................................................................. 16
4. Assembly ............................................................................................................................................... 17
4.1. Assembly Safety ..................................................................................................................... 17
4.2. Required Tools........................................................................................................................ 17
4.3. Check Shipment...................................................................................................................... 18
4.4. Before You Begin .................................................................................................................... 18
4.5. Assemble the Tube Inlet and Return Roller........................................................................... 18
4.6. Install the Wheels and Axle.................................................................................................... 20
4.7. Install the Tube and Rollers.................................................................................................... 22
4.8. Install the Belt ........................................................................................................................ 24
4.9. Install the Flashing.................................................................................................................. 25
4.10. Install the Spout Hood.......................................................................................................... 27
4.11. Assemble the Hopper........................................................................................................... 29
4.12. Install the Electric Top Drive ................................................................................................ 38
4.13. Install the Hydraulic Wet Kit for the Electric Top Drive (Optional) ..................................... 40
4.14. Install the Hydraulic Top Drive............................................................................................. 44
4.15. Install the Manual Container ............................................................................................... 45
5. Specifications ........................................................................................................................................ 47
6. Batco Limited Warranty ....................................................................................................................... 49

4 P1512126 R3
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.
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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 Safety
The safety information in the safety section of this manual applies to all safety practices. Specific safety
information (such as Operation Safety), can be found in the appropriate section.
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.
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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 your 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).
For example:
WARNING
• De-energize, block, and dissipate all sources of hazardous energy.
• Lock out and tag out all forms of hazardous energy.
• Ensure that only 1 key exists for each assigned lock, and that you are the only one that holds that key.
• After verifying all energy sources are de-energized, service or maintenance may be performed.
• Ensure that all personnel are clear before turning on power to equipment.
For more information on occupational safety practices, contact your local health and safety organization.
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2.5.1 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.
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2.5.2 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.
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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. 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.
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Coveralls
• Wear coveralls to protect skin.
Hard Hat
• Wear a hard hat to help protect your head.
2.8. 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.
2.9. Safety Decals
• Keep safety decals clean and legible at all times.
• 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.
2.9.1 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.
2.9.2 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
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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.
Figure 1. Safety Decal Location
P1513001
Figure 2. Electric Drive Safety Decal Locations
22950
22948
22949
20804
22957
22952
20813
20805
P1513002
1513008
P1513009
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Figure 3. Hydraulic Drive Safety Decal Location
P1513035
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Table 1. Safety Decals
Part Number Description
P1513001
Country of Origin Part Number
To prevent serious injury or death:
• Read and understand the manual before
assembling, operating, or maintaining the
equipment.
• Only trained personnel may assemble, operate,
or maintain the equipment.
• Children and untrained personnel must be kept
outside of the work area.
• Do not modify the equipment. Keep in good
working order.
• If the manual, guards, or decals are missing or
damaged, contact factory or dealer for
replacements.
• Lock out power before performing maintenance.
• To prevent equipment collapse, support equipment
tube while disassembling certain components.
• Electric motors must be grounded. Disconnect
power before resetting overloads.
WARNING
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Table 1 Safety Decals (continued)
Part Number Description
P1513002
WARNING
ENTANGLEMENT HAZARD
To prevent serious injury or death:
•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.
To prevent serious injury or death:
• 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.
ENTANGLEMENT HAZARD
WARNING
Country of Origin Part Number
P1513008
WARNING
MISSING GUARD HAZARD
To prevent serious injury or
death, shut off power and
reattach guard before operating
machine.
To prevent serious injury or
death, shut off power and
reattach guard before operating
machine.
MISSING GUARD HAZARD
WARNING
Country of Origin Part Number
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Table 1 Safety Decals (continued)
Part Number Description
P1513009
To prevent serious injury or death:
• Before operating on uneven ground, extend outrigger leg, if provided.
Retract leg before moving.
• If no outrigger leg is provided, use extreme caution when operating on
any slope.
• Follow vehicle instructions when driving on slopes.
ROLLOVER HAZARD
WARNING
To prevent serious injury or death:
• Only qualified personnel should service
electrical components.
• Disconnect and lockout power before
inspecting or servicing unit.
• Keep electrical components in good repair.
ELECTROCUTION HAZARD
WARNING
To prevent serious injury or death:
• Only qualified personnel should service
electrical components.
• Disconnect and lockout power before
inspecting or servicing unit.
• Keep electrical components in good repair.
ELECTROCUTION HAZARD
WARNING
Country of Origin
Country of Origin Part Number
P1513035
To prevent serious injury or death:
• Relieve system pressure before repairing, adjusting or
disconnecting.
• Wear proper hand and eye protection when searching
for leaks. Use wood or cardboard instead of hands.
• Keep all components in good repair.
HIGH PRESSURE FLUID HAZARD
WARNING
Hydraulic fluid can cause serious injury if it
penetrates the skin. If it does, see a doctor
immediately.
• Relieve system pressure before repairing, adjusting or
disconnecting.
• Wear proper hand and eye protection when searching
for leaks. Use wood or cardboard instead of hands.
Hydraulic fluid can cause serious injury if it
penetrates the skin. If it does, see a doctor
immediately.
• Relieve system pressure before repairing, adjusting or
disconnecting.
• Wear proper hand and eye protection when searching
for leaks. Use wood or cardboard instead of hands.
HIGH PRESSURE FLUID HAZARD
WARNING
Country of Origin Part Number
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3. Features
Below are some of the main features of the Batco Portable Grain Belt Conveyor.
Figure 4. Typical PitStop with Hopper Components
Table 2. Typical PitStop with Hopper Components
ITEM DESCRIPTION ITEM DESCRIPTION
1 Hopper 4 Hitch
2Spout Assembly 5Jack
3Hood
2
3
1
5
4
2
3
1
5
4
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4. Assembly
Before continuing, ensure you have completely read and understood this manual’s
Safety section, in addition to the safety information in the section(s) below.
4.1. Assembly Safety
• Do not take chances with safety. The components can be large, heavy, and hard to handle.
Always use the proper tools, rated lifting equipment, and lifting points for the job.
• Carry out assembly in a large open area with a level surface.
• Always have two or more people assembling the conveyor.
• Make sure you have sufficient lighting for the work area.
• Tighten all fasteners according to their specifications. Do not replace or substitute bolts,
nuts, or other hardware that is of lesser quality than the hardware supplied by the
manufacturer.
• Stay away from overhead power lines and other obstructions during assembly. Contact with
power lines can cause electrocution.
• Do not work in high winds.
4.2. Required Tools
• 2 sawhorse(s) • 1 tape measure(s)
• 1 jack or forklift or overhead crane
(850 lb [386 kg] lifting capacity)
• 1 level
(2’ [61 cm])
• 1 standard socket set(s) • 1 level magnetic
(2’ [61 cm])
• 1 wrench set(s)
1-1/2” ratchet & wrench (to attach axle)
• 1 ratchet strap
• 1 1-1/8” ratchet • 1 air impact with ratchet set
• 1 torque wrench(es) • 2 C-clamp(s) or vise grip(s)
• 1 power drill(s) • 1 tire pressure gauge
• 1 self-tapping screw bit
(3/8")
• 1 fish tape
(120’ [36.6 m])
• 1 pry bar • 1 tire chuck
• 1 hammer and punch • 1 set(s) of Allen wrenches
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4.3. Check Shipment
Unload the conveyor parts at the assembly site and compare the packing slip to the shipment. Ensure that all
items have arrived and that none are damaged.
Report missing or damaged parts immediately to ensure that proper credit is received from Batco or your
distributor/dealer, and to ensure that any missing parts can be shipped quickly to avoid holding up the assembly
process.
Important
Do not assemble or install damaged components.
4.4. Before You Begin
Before you assemble the conveyor:
• Familiarize yourself with all the sub-assemblies, components, and hardware that make up the equipment.
• Have all parts and components on hand, and arrange them for easy access.
• Separate the hardware (bolts, nuts, etc.) and lay them out into groups for easier identification during
assembly.
• If assembling inside, the ceiling must be at least 16' (4.8 m) high and 12'6" (3.81 m) wide to provide
clearance when installing the undercarriage.
• Perform assembly on a firm and level surface in an area large enough to allow access to all sides of the
conveyor.
• Ensure there is adequate space to remove the assembled conveyor from the assembly area.
4.5. Assemble the Tube Inlet and Return Roller
Table 3. Tube Inlet and Return Roller Components
ITEM DESCRIPTION QTY
1Bolt 3/8" x 1" 1
2Bent Adjustment Tab Left 1
3Locknut 3/8" 1
4Adjustment Link Bar 1
5Pitstop Guiding Return Roller 1
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Figure 5. Assembling the Tube Inlet and Return Roller
2
3
1
4
5
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4.6. Install the Wheels and Axle
Table 4. Wheel and Axle Components
ITEM DESCRIPTION QTY
1 Pitstop Base 1
2Axle Weldment 1
36–Bolt Tire 2
4Hair Pin 3/16" x 3-1/4" 4
5Hitch Pin 1" x 3-1/2" 4
6Wheel Bolt 12
7Wheel Nut 1/2" GR5 12
4. ASSEMBLY PORTABLE GRAIN BELT CONVEYOR – PITSTOP WITH HOPPER