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AGI BATCO 1800 Series Assembly Manual

Pitstop drive kits, gas, electric, and hydraulic drives
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Pitstop Drive Kits Assembly
Manual
Original instructions
This manual applies to:
AGI BATCO 1800, 2400 Series
AGI HUTCHINSON 1800, 2400 Series
AGI WESTFIELD 1800, 2400 Series
Gas, Electric, and Hydraulic Drives
Original Instructions
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: P1512180 R0
Revised: December 2019

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Summary of Contents for AGI BATCO 1800 Series

  • Page 1 Pitstop Drive Kits Assembly Manual Original instructions This manual applies to: AGI BATCO 1800, 2400 Series AGI HUTCHINSON 1800, 2400 Series AGI WESTFIELD 1800, 2400 Series Gas, Electric, and Hydraulic Drives Original Instructions Read this manual before using product. Failure to...
  • Page 2 PITSTOP DRIVE KITS ASSEMBLY MANUAL – P1512180 R0...

  • Page 3: Table Of Contents

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – CONTENTS 1. Safety............................... 4 1.1 Safety Alert Symbol and Signal Words..................4 1.2 General Product Safety ......................4 1.3 Moving Conveyor Belt Safety....................4 1.4 Rotating Parts Safety......................... 5 1.5 Work Area Safety ........................5 1.6 Guards Safety ..........................

  • Page 4: Safety

    1. SAFETY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 1. Safety 1.1. 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.

  • Page 5: Rotating Parts Safety

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 1. SAFETY 1.4. 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. •...

  • Page 6: Gas Engine Safety

    1. SAFETY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 1.7.1 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.

  • Page 7: Hydraulic Power Safety

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 1. SAFETY 1.7.3 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.

  • Page 8: Tire Safety

    1. SAFETY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 1.8. 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.

  • Page 9: Safety Equipment

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 1. SAFETY Steel-Toe Boots • Wear steel-toe boots to protect feet from falling debris. Work Gloves • Wear work gloves to protect your hands from sharp and rough edges. Dust Mask • Wear a dust mask to prevent breathing potentially harmful dust. 1.10.

  • Page 10: Safety Decal Locations And Details

    1. SAFETY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 1.11.2 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.
  • Page 11 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 1. SAFETY Figure 2. Electric Top Drive Safety Decal Locations * behind guard Figure 3. Hydraulic Top Drive Safety Decal Locations P1512180 R0...
  • Page 12 1. SAFETY PITSTOP DRIVE KITS ASSEMBLY MANUAL – Table 1. Safety Decals Part Number Description P1513001 WARNING 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.
  • Page 13 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 1. SAFETY 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. •...
  • Page 14 1. SAFETY PITSTOP DRIVE KITS ASSEMBLY MANUAL – Table 1 Safety Decals (continued) Part Number Description P1513009 WARNING ELECTROCUTION HAZARD To prevent serious injury or death: • Only qualified personnel should service electrical components. • Disconnect and lockout power before inspecting or servicing unit.
  • Page 15 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 1. SAFETY Table 1 Safety Decals (continued) Part Number Description P1513039 CAUTION For proper raising and lowering of equipment: • After lowering equipment, always tighten brake lock by turning winch handle clockwise at least two clicks. •...
  • Page 16 1. SAFETY PITSTOP DRIVE KITS ASSEMBLY MANUAL – Table 1 Safety Decals (continued) Part Number Description P1513052 NOTICE To prevent damage, wheels must be free to move when raising or lowering equipment. When equipment is positioned, chock all wheels. P1512180 R0...

  • Page 17: Assembly

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY 2. 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. 2.1. Assemble the Lift Hose Figure 4. Assemble the Lift Hose Item Description Lift Control...

  • Page 18: Install The Electric Drive

    2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2.2. Install the Electric Drive Installing the electric drive requires the completion of the following tasks: Step Task Assemble the Motor Mounts Install the Motor Mounts and Rails Install the Guard Mounting Brackets Install the Motor Install the Pulleys, Drive Belts, and Tensioning Bolt Install the Drive Belts Guard...

  • Page 19: Assemble The Motor Mounts

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY 2.2.1 Assemble the Motor Mounts Figure 6. Step 1: Assemble the Motor Mounts (X2) Item Description Quantity (per mount) Bushing Motor Mount 3/8" X 1" Hex Flange Bolt Bushing Retainer P1512180 R0...

  • Page 20: Install The Motor Mounts And Rails

    2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2.2.2 Install the Motor Mounts and Rails Figure 7. Step 1: Install the Motor Mounts and Rails Item Description 5/16" X 1" Screw (provided with collar) 1" Collar Assembled Motor Mounts Motor Mount Rail Figure 8.

  • Page 21: Install The Guard Mounting Brackets

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY 2.2.3 Install the Guard Mounting Brackets Figure 9. Step 1: Install the Guard Mounting Brackets Item Description 3/8" Hex Flange Nut Guard Mount Bracket 3/8" X 1" Hex Flange Bolt Figure 10. Visual Check P1512180 R0...

  • Page 22: Install The Motor

    2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2.2.4 Install the Motor Figure 11. Step 1: Install the Motor Item Description Motor 3/8" Lock Nut 3/8" Flat Washer 3/8" X 2" Hex Bolt (GR 8) P1512180 R0...

  • Page 23: Install The Pulleys, Drive Belts, And Tensioning Bolt

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY 2.2.5 Install the Pulleys, Drive Belts, and Tensioning Bolt Figure 12. Step 1: Installing the Pulleys, Belts, and Tensioning Bolt Item Description 3/4" Hex Nut 3/4" X 5" Tensioning Hex Bolt (GR8) Drive Belts Pulley 3/8"...

  • Page 24: Install The Drive Belt Guard

    2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2.2.6 Install the Drive Belt Guard Figure 13. Step 1: Install the Drive Belt Guard Item Description 3/8" X 1" Hex Flange Bolt Drive Belt Guard P1512180 R0...

  • Page 25: Install The Shaft Guard

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY 2.2.7 Install the Shaft Guard Figure 14. Step 1: Install the Shaft Guard Item Description 5/8" Nylock Nut Shaft Guard Plug Shaft Guard P1512180 R0...

  • Page 26: Install The Hydraulic Wet Kit For The Electric Drive

    2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2.3. Install the Hydraulic Wet Kit for the Electric Drive Installing the hydraulic wet kit for the electric drive requires the completion of the following tasks: Step Task Install the Hydraulic Pump Install the Hydraulic Tank Install the Hydraulic Fittings into the Flow Controller Install the Hoses...

  • Page 27: Install The Hydraulic Pump

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY 2.3.1 Install the Hydraulic Pump Installing the hydraulic pump requires the completion of the following tasks: Step Task Install the Sprockets, Keys, and Chain Couplers Install the Hydraulic Pump Mount Install the Hydraulic Pump Install the Hydraulic Pump Side Guards Figure 16.
  • Page 28 2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – Figure 17. Step 1: Install the Sprockets, Keys, and Chain Couplers Item Description 1/4" Sprocket 1/4" X 1-1/2" Rectangle Key 1–1/4" Sprocket Chain Coupler 5/8" Lock Nut (GR 8) (remove from bearing These lock nuts are used in the following step of this procedure.
  • Page 29 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY Figure 18. Step 2: Install the Hydraulic Pump Mount Item Description Hydraulic Pump Mount 5/8" Lock Nut (GR 8) (removed from bearing These lock nuts were removed in the previous step of this procedure. P1512180 R0...
  • Page 30 2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – Figure 19. Step 3: Install the Hydraulic Pump and Fittings Item Description 90° Swivel (1/2" FPT to #8 ORB) 3/8" Lock Nut (GR 8) 3/8" Flat Washer Hydraulic Pump 90° Swivel (1/2" FPT to #10 ORB) 3/8"...
  • Page 31 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY Figure 20. Step 4: Install the Hydraulic Pump Side Guard (on both sides) Item Description Tek Screw 1/4" Flat Washer 1/4" Plastic Sheet P1512180 R0...

  • Page 32: Install The Hydraulic Tank

    2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2.3.2 Install the Hydraulic Tank Figure 21. Step 1: Install the Hydraulic Tank Step Task 90° Swivel (1/2" FPT to #8 ORB Swivel) 32" Clamp Hydraulic Tank 3/4" Hose Clamp P1512180 R0...

  • Page 33: Install The Hydraulic Fittings Into The Flow Controller

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY 2.3.3 Install the Hydraulic Fittings into the Flow Controller Installing the hydraulic fittings into the flow controller requires completion of the following task: Figure 22. Install the Hydraulic Fittings into the Flow Controller Item Description Flow Controller...

  • Page 34: Install The Hoses

    2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2.3.4 Install the Hoses Use the following illustration to correctly install the hoses. Figure 23. Installing the Hoses Step Task 1/2" X 9'6" Hose (1/2" MPT X 1/2" MPT PC) 1/2" X 7'6" Hose (1/2" MPT X 1/2" MPT ) 3/4"...

  • Page 35: Install The Gas Drive

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY 2.4. Install the Gas Drive Installing the gas drive requires the completion of the following tasks: Step Task Install the Drive and Battery Mounts Install the Motor and Gearbox Install the Battery and Fuel Tank Install the Guards Figure 24.

  • Page 36: Install The Drive And Battery Mounts

    2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2.4.1 Install the Drive and Battery Mounts Installing the drive and battery mounts requires the completion of the following tasks: Step Task Prepare the Motor and Gearbox Mount Install the Motor and Gearbox Mount Install the Battery Mount Figure 25.
  • Page 37 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY Figure 26. Step 1: Prepare the Motor and Gearbox Mount Item Description Quantity 1" Bushing 3/8" Flanged Hex Bolt (GR 5) Bushing Retainer P1512180 R0...
  • Page 38 2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – Figure 27. Step 2: Install the Motor and Gearbox Mount Item Description 1" Collar 5/16" X 1" Screw Motor Mount Rail Motor and Gearbox Mount Figure 28. Step 3: Install the Battery Mount P1512180 R0...
  • Page 39 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY Item Description 3/8" Flanged Hex Bolt (GR 5) Battery Mount P1512180 R0...

  • Page 40: Install The Motor And Gearbox

    2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2.4.2 Install the Motor and Gearbox Installing the motor and gearbox requires the completion of the following tasks: Step Task Install the Guard Mounting Brackets Install the Motor Install the Gearbox Install the Drive Pulleys, Belts, and Tensioning Bolts Install the Motor Pulley, Clutch, and Belts Figure 29.
  • Page 41 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY Figure 30. Step 1: Install the Guard Mounting Brackets Item Description 3/8" Lock Nut (GR 8) Mounting Bracket 3/8" X 1" Hex Flange Bolt (GR 8) P1512180 R0...
  • Page 42 2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – Figure 31. Step 2: Install the Motor Item Description 3/8" X 2" Hex Bolt (GR 8) 3/8" Flat Washer Motor Slide Plate 3/8" Lock Nut (GR 8) Motor Base PLate Motor type varies. Ensure the motor’s base plate is inserted between the slide plate and washer as indicated by the arrows in Figure P1512180 R0...
  • Page 43 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY Figure 32. Step 3: Install the Gearbox Item Description Breather Gear Box 4190 2:1 (1.5" SHAFT) 1/2" Flat Washer 1/2" X 1–1/2" Hex Bolt (GR 8) P1512180 R0...
  • Page 44 2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – Figure 33. Step 4: Install the Drive Pulleys, Belts, and Tensioning Bolts Item Description 3/4" X 5" Tensioning Hex Bolt (GR 8) 3/8" X 2" Key 4" Double Pulley 12" Double Pulley Belts P1512180 R0...
  • Page 45 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY Figure 34. Step 5: Install the Motor Pulley, Clutch, and Belts Item Description 7/16" X 3" Hex Bolt (GR 8) 7/16" Lock Washer Electric Clutch Belts 1/4" X 3" Key 6" Double Pulley (1–1/2" Bore) 1/4"...

  • Page 46: Install The Battery And Fuel Tank

    2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2.4.3 Install the Battery and Fuel Tank Installing the battery and fuel tank requires the completion of the following tasks: Step Task Install the Fuel Tank Install the Battery Figure 35. Battery and Fuel Tank Overview P1512180 R0...
  • Page 47 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY Figure 36. Step 1: Install the Fuel Tank Item Description Fuel Hose and Clamps Fuel Tank 7/16" Lock Nut 32" Clamp Fuel Tank Mounting Bracket 7/16" X 1" Hex Bolt (GR 8) P1512180 R0...
  • Page 48 2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – Figure 37. Step 2: Install the Battery Item Description Battery Clamp Battery 3/8" Flat Washer 3/8" Lock Nut P1512180 R0...

  • Page 49: Install The Guards

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY 2.4.4 Install the Guards Installing the guards requires the completion of the following tasks: Step Task Install the Motor Guard Install the Drive Belt Guard Figure 38. Guards Overview P1512180 R0...
  • Page 50 2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – Figure 39. Step 1: Install the Motor Guard Note The grate on the gearbox and motor guard has been removed for illustration purposes. Item Description 3/8" X 1" Hex Bolt (GR 5) Gearbox and Motor Guard Guard Mounting Bracket 3/8"...
  • Page 51 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY Figure 40. Step 2: Install the Drive Belt Guard Item Description 3/8" X 1" Hex Bolt (GR 5) Drive Belt Guard P1512180 R0...

  • Page 52: Install The Hydraulic Drive

    2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2.5. Install the Hydraulic Drive Installing the hydraulic drive requires the completion of the following tasks: Step Task Install the Hydraulic Motor Install the Flow Controller Install the Hydraulic Fittings into the Lift Control Install the Hoses Note The hoses are not shown in this image.

  • Page 53: Install The Hydraulic Motor

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY 2.5.1 Install the Hydraulic Motor Installing the hydraulic motor requires the completion of the following tasks: Step Task Install the Sprockets, Keys, and Chain Couplers Install the Hydraulic Motor Mount Install the Hydraulic Motor and Fittings Install the Hydraulic Motor Side Guards Figure 42.
  • Page 54 2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – Figure 43. Step 1: Install the Sprockets, Keys, and Chain Couplers Item Description 5/8" Lock Nut (GR 8) (remove from bearing 1/4" X 1-1/2" Rectangle Key Sprocket Chain Coupler 1/4" X 1" Woodruff Key These lock nuts are used in the next step of this procedure.
  • Page 55 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY Figure 44. Step 2: Install the Hydraulic Motor Mount Item Description 5/8" Lock Nut (GR 8) (removed from bearing Hydraulic Motor Mount These lock nuts were removed in the previous step of this procedure. P1512180 R0...
  • Page 56 2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – Figure 45. Step 3: Install the Hydraulic Motor and Fittings Item Description 1/2" X 2" Hex Bolt (GR 8) 1/4" X 1" Woodruff Key 1/2" Swivel (straight) 1/2" Check Valve (no reverse flow) 1/2"...
  • Page 57 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY Figure 46. Step 4: Install the Hydraulic Motor Side Guard (on both sides) Item Description Tek Screw 1/4" Flat Washer 1/4" Plastic Sheet P1512180 R0...

  • Page 58: Install The Flow Controller

    2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2.5.2 Install the Flow Controller Installing the flow controller requires the completion of the following tasks: Step Task Install the Flow Controller Bracket Install the Hydraulic Fittings into the Flow Controller Install the Flow Controller Figure 47.
  • Page 59 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY Figure 48. Step 1: Install the Flow Controller Bracket Item Description 7/16" Lock Nut (GR 8) Flow Controller Bracket 7/16" X 1" Hex Bolt (GR 8) P1512180 R0...
  • Page 60 2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – Figure 49. Step 2: Install the Hydraulic Fittings into the Flow Controller Item Description 90° Swivel (1/2" PT) Flow Controller Hex Nipple (1/2" PT) Tee—Swivel (1/2" Fem) P1512180 R0...
  • Page 61 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY Figure 50. Step 3: Install the Flow Controller Item Description 1/4" X 3" Hex Bolt (GR 8) Flow Controller with Hydraulic Fittings Installed 1/4" Lock Nut (GR 8) P1512180 R0...

  • Page 62: Install The Hydraulic Fittings Into The Lift Control

    2. ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2.5.3 Install the Hydraulic Fittings into the Lift Control Installing the hydraulic fittings into the lift control requires the following task be completed. Figure 51. Step 1: Install the Hydraulic Fittings into the Lift Control Item Description 90°...

  • Page 63: Install The Hoses

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 2. ASSEMBLY 2.5.4 Install the Hoses Figure 52. Installing the Hoses Item Description 1/2" X 1'10" Hose (1/2" MPT to 1/2" MPT PC) 1/2" X 6'7" Hose (1/2" MPT to 1/2" MPT PC) Supply In (pressure) Supply Out (return) P1512180 R0...

  • Page 64: Limited Warranty

    PITSTOP DRIVE KITS ASSEMBLY MANUAL – 3. Limited Warranty This warranty relates to Belt Conveyors (the “Product”) sold by AGI (referred to herein as the “Seller”) and applies only to the first user of the Product (meaning a purchaser directly from the Seller or from an authorized dealer or distributor of the Product, referred to herein as the “Buyer”).
  • Page 65 PITSTOP DRIVE KITS ASSEMBLY MANUAL – 3. LIMITED WARRANTY P1512180 R0...
  • Page 66 Shipping: 201 Industrial Drive, Swift Current, Saskatchewan S9H 5R4, CANADA Mailing: Box 1750, Swift Current, Saskatchewan S9H 4J8, CANADA Toll-Free: (877) 667-7421 (Canada & USA) Phone: (306) 773-7779 Fax: (306) 778-2524 Web: www.batcomfg.com Email: info@batcomfg.com ©Ag Growth International Inc. 2019 Printed in Canada If you have any comments or questions on this manual, or find an error, email us at comments@aggrowth.com.

This manual is also suitable for:

Batco 2400 seriesHutchinson 1800 seriesHutchinson 2400 seriesWestfield 1800 seriesWestfield 2400 series

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