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Batco 2500 Series Operation Manual

Pitstop
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PITSTOP
2500 SERIES
OPERATION MANUAL
Read this manual before using product. Failure
Part Number: P1511025 R0
to follow instructions and safety precautions can
Revised: Jun/11
result in serious injury, death, or property
damage. Keep manual for future reference.

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Summary of Contents for Batco 2500 Series

  • Page 1 PITSTOP 2500 SERIES OPERATION MANUAL Read this manual before using product. Failure Part Number: P1511025 R0 to follow instructions and safety precautions can Revised: Jun/11 result in serious injury, death, or property damage. Keep manual for future reference.
  • Page 2 This product has been designed and constructed according to general engineering standards . Other local regulations may apply and must be followed by the operator. We strongly recommend that all personnel associated with this equipment be trained in the correct operational and safety procedures required for this product. Periodic reviews of this manual with all employees should be standard practice.

  • Page 3: Table Of Contents

    ATCO 2500 S ERIES TABLE OF CONTENTS 1. Introduction .......................... 5 2. Safety First..........................7 2.1. General Safety ......................8 2.2. Assembly Safety....................... 9 2.3. Operational Safety....................9 2.4. Transport Safety....................... 9 2.5. Storage Safety......................10 2.6. Maintenance Safety....................10 2.7.
  • Page 4 ATCO 2500 S ERIES TABLE OF CONTENTS 9. Maintenance........................37 9.1. Maintenance Schedule ................... 37 9.1.1. Initial start-up servicing ................37 9.1.2. 40 Hours or Weekly: ................. 37 9.1.3. Every 100 Hours or Annually: ..............37 9.2. Maintenance Checklist ................... 38 9.3.

  • Page 5: Introduction

    Keep this manual handy for frequent reference and to pass on to new operators or owners. Call your Batco distributor or dealer if you need assistance, infor- mation, or additional copies of the manual.
  • Page 6 1. I NTRODUCTION ATCO 2500 S ERIES P1511025 R0...

  • Page 7: Safety First

    2. S ATCO AFETY IRST 2500 S ERIES 2. Safety First The Safety Alert symbol to the left identifies important safety messages on the product and in the manual. When you see this symbol, be alert to the possibil- ity of personal injury or death. Follow the instructions in the safety messages. Why is SAFETY important to you? Three big reasons: •...

  • Page 8: General Safety

    2. S AFETY IRST ATCO 2.1. G 2500 S ENERAL AFETY ERIES 2.1. GENERAL SAFETY Important: The general safety section includes instructions that apply to all safety practices. Any instructions specific to a certain safety practice (e.g., assembly safety), can be found in the appropriate section.

  • Page 9: Assembly Safety

    2. S ATCO AFETY IRST 2500 S 2.2. A ERIES SSEMBLY AFETY • Follow good shop practices: • keep service area clean and dry • be sure electrical outlets and tools are properly grounded • use adequate light for the job at hand •...

  • Page 10: Storage Safety

    2. S AFETY IRST ATCO 2.5. S 2500 S TORAGE AFETY ERIES 2.5. STORAGE SAFETY • Store the unit in an area away from human activity. • Do not permit children to play on or around the stored equipment. 2.6. MAINTENANCE SAFETY •...

  • Page 11: Tire Safety

    2. S ATCO AFETY IRST 2500 S 2.9. T ERIES AFETY • Inspect drive belts before using. Replace if frayed or damaged. 2.9. 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.
  • Page 12 2. S AFETY IRST ATCO 2.10. S 2500 S AFETY ECAL OCATIONS ERIES Figure 2.1 Safety Decals P1511025 R0...
  • Page 13 2. S ATCO AFETY IRST 2500 S 2.10. S ERIES AFETY ECAL OCATIONS Figure 2.2 Safety Decal Locations P1511025 R0...
  • Page 14 2. S AFETY IRST ATCO 2.10. S 2500 S AFETY ECAL OCATIONS ERIES P1511025 R0...

  • Page 15: Machine Components

    ERIES 3. Machine Components The Batco PitStop Conveyor is designed to allow trucks to drive-over the machine, and dump into the hopper and conveyor belt from on top. The hopper or intake frame is ramped to allow the truck to drive over the intake when positioning.

  • Page 16: Controls

    3. M ACHINE OMPONENTS ATCO 3.1. C 2500 S ONTROLS ERIES Figure 3.2 Wheel Assembly Lock Pin (in Transport Configuration) 3.1. CONTROLS Before starting, all operators should familiarize themselves with the location and function of the controls. 1. Electric Drive •...

  • Page 17: Matching Equipment

    3. M ATCO ACHINE OMPONENTS 2500 S 3.2. M ERIES ATCHING QUIPMENT 3.2. MATCHING EQUIPMENT To ensure the safe and reliable operation of the PitStop, it is necessary to have a power source with the appropriate specifications. As a guideline, ensure that these requirements are met: YDRAULIC YSTEM...
  • Page 18 3. M ACHINE OMPONENTS ATCO 3.2. M 2500 S ATCHING QUIPMENT ERIES P1511025 R0...

  • Page 19: Assembly

    4. A ATCO SSEMBLY 2500 S 4.1. E ERIES LECTRIC RIVE SSEMBLY 4. Assembly Warning: Before continuing, please read the safety information relevant to this section in the safety section of this manual. Failure to follow the safety instructions can result in serious injury, death, or property damage.
  • Page 20 4. A SSEMBLY ATCO 4.1. E 2500 S LECTRIC RIVE SSEMBLY ERIES Table 4.1 ITEM DESCRIPTION Pulley 2BK140H Pulley 2BK34H Bushing H 1.25 PitStop Plastic Pulley Guard Note: Belts should deflect 1/2” to 3/4” when pushed on with a 5 lb (2.3 kg) force. Check frequently during the first 10 hours of operation to maintain proper tension.

  • Page 21: Hydraulic Drive Kit

    4. A ATCO SSEMBLY 2500 S 4.2. H ERIES YDRAULIC RIVE 4.2. HYDRAULIC DRIVE KIT Note: Refer to Table 4.2 for the quantity of each component used, and Figure 4.3 for illustrations of the assembly of the hydraulic top drive. Remove 1/2” locknuts from the right side flange bearings.

  • Page 22: Electric Wet Kit

    4. A SSEMBLY ATCO 4.3. E 2500 S LECTRIC ERIES Table 4.2 ITEM DESCRIPTION QTY. ITEM DESCRIPTION QTY. Key 1/4” x 1-1/2” Woodruff (#808) 1/4” x 1” Flow Control Bracket Swivel 90 - 1/2 MPT x 1/2 FPT Flow Control Tab Swivel 8 ORB x 1/2 FPT 90 2000 Series PitStop Mount Swivel 10 ORB x 1/2 FS...
  • Page 23 4. A ATCO SSEMBLY 2500 S 4.3. E ERIES LECTRIC Important: In Figure 4.4, note the locations of the pump section port (IN) and the pump pressure port (OUT). Also note the rotation direction of the pump. 7. Tighten fasteners in sequence starting with the mount, the pump, and then the coupler set screws.
  • Page 24 4. A SSEMBLY ATCO 4.3. E 2500 S LECTRIC ERIES Figure 4.6 Table 4.3 ITEM DESCRIPTION Oil Reservoir - 18 L 1-1/4 Hyd. Motor Guard Key 1/4” x 1” Pump Wet Kit Sprocket 5014 W 0.5 (Key 0.125) Bolt Hex 3/8” x 1-1/2” Nut Nylock 3/8”...

  • Page 25: Transport

    5.2. TRANSPORT PROCEDURE Batco PitStop Conveyors are designed to be easily and conveniently trans- ported. Since a truck will be used in most instances transport with a truck is covered in this section.
  • Page 26 5. T RANSPORT ATCO 5.2. T 2500 S RANSPORT ROCEDURE ERIES b. Install the jack and secure with the anchor pin. c. Using the jack, raise the hitch end to go over the tongue on the towing vehicle. d. Attach the hydraulic lines if required. e.
  • Page 27 5. T ATCO RANSPORT 2500 S 5.2. T ERIES RANSPORT ROCEDURE Figure 5.3 Transport Configuration 14. Ensure the wheel assembly anchor pins and retainers are installed. 15. Take special care and precautions when transporting during times of limited visibility (rain, fog, snow, dusk, or at night). It may be difficult for oncoming and overtaking traffic to see the unit.
  • Page 28 5. T RANSPORT ATCO 5.2. T 2500 S RANSPORT ROCEDURE ERIES P1511025 R0...

  • Page 29: Placement

    6. P ATCO LACEMENT 2500 S 6.1. S ERIES ONVERSIONS 6. Placement Warning: Before continuing, please read the safety information relevant to this section in the safety section of this manual. Failure to follow the safety instructions can result in serious injury, death, or property damage.
  • Page 30 6. P LACEMENT ATCO 6.1. S 2500 S ONVERSIONS ERIES 15. Remove the wheel assembly anchor pins and stow. 16. Lower the frame to the ground. 17. Provide power to the machine.  a. Electric Drive: • Have a licensed electrician provide power to the machine per the National Electrical Code ANSI / NFPA 70 and local codes.

  • Page 31: Operation

    7. O ATCO PERATION 2500 S 7.1. P ERIES PERATION HECKLIST 7. Operation Warning: Before continuing, please reread the safety information relevant to this section at the beginning of this manual. Failure to follow the safety instructions can result in serious injury, death, or property damage.

  • Page 32: Starting Conveyor

    7. O PERATION ATCO 7.2. M 2500 S ACHINE REAK PERATION ERIES FTER TRANSPORTING OR OPERATING FOR HOUR 1. Retorque all wheel bolts, fasteners, and hardware. 2. Check the drive belt (if equipped) and conveyor belt tension and alignment. Tension or align as required. See “Maintenance” on page 37. FTER PERATING FOR HOURS...

  • Page 33: Conveyor Shutdown

    7. O ATCO PERATION 2500 S 7.2. M ERIES ACHINE REAK PERATION Figure 7.1 Circuit Valve 7.2.2. C ONVEYOR HUTDOWN YDRAULIC RIVE ODELS 1. Run until the machine is empty. 2. Reduce speed of power source. 3. Place hydraulic control lever in neutral. 4.

  • Page 34: Emergency Shutdown

    7. O PERATION ATCO 7.2. M 2500 S ACHINE REAK PERATION ERIES 7.2.4. E MERGENCY HUTDOWN Although it is recommended that the machine be emptied before stopping, in an emergency situation, stop or shut down the power source immediately. Important: Lock out all power and ensure that the machine components come to a complete stop before inspecting.

  • Page 35: Storage

    8. S ATCO TORAGE 2500 S ERIES 8. Storage Warning: Before continuing, please read the safety information relevant to this section in the safety section of this manual. Failure to follow the safety instructions can result in serious injury, death, or property damage. O PROTECT THE CONVEYOR IN STORAGE •...
  • Page 36 8. S TORAGE ATCO 2500 S ERIES P1511025 R0...

  • Page 37: Maintenance

    9. M ATCO AINTENANCE 2500 S 9.1. M ERIES AINTENANCE CHEDULE 9. Maintenance Warning: Before continuing, please read the safety information relevant to this section in the safety section of this manual. Failure to follow the safety instructions can result in serious injury, death, or property damage.

  • Page 38: Maintenance Checklist

    9. M AINTENANCE ATCO 9.2. M 2500 S AINTENANCE HECKLIST ERIES 9.2. MAINTENANCE CHECKLIST See Section 9.1. for details of service. Copy this page to continue record keeping. Use the maintenance checklist provided to keep a record of all scheduled maintenance.

  • Page 39: Greasing

    9.3.2. G REASING Note: Most original equipment bearings used by Batco are sealed units and will not accept grease. Use the maintenance checklist provided in this section to keep a record of all scheduled maintenance.

  • Page 40: Conveyor Belt Alignment

    9. M AINTENANCE ATCO 9.3. S & M 2500 S ERVICE AINTENANCE ROCEDURES ERIES WARNING Ensure ignition key is removed or power is locked out before adjusting or servicing conveyor. 1. Remove guards if necessary. 2. Loosen bearing bolts and jam nuts (if included) at tightener roller. 3.
  • Page 41 9. M ATCO AINTENANCE 2500 S 9.3. S & M ERIES ERVICE AINTENANCE ROCEDURES 4. Restart conveyor and run empty for 1 minute. 5. Stop conveyor and remove ignition key or lock out power source. 6. If belt has centered, then move to the next step below, otherwise repeat from step 3.

  • Page 42: Belt Relacing

    9. M AINTENANCE ATCO 9.3. S & M 2500 S ERVICE AINTENANCE ROCEDURES ERIES 4. Stop conveyor and remove ignition key or lock out power source. 5. If belt has centered, then move to the next step below, otherwise repeat from step 3.

  • Page 43: Electric Drive Belt Tension & Alignment

    9. M ATCO AINTENANCE 2500 S 9.3. S & M ERIES ERVICE AINTENANCE ROCEDURES 10. Check and set belting alignment. (See “Engage conveyor drive. Allow to run for 30 seconds, then shut down conveyor and inspect lacing.Conveyor Belt Replacement” on page 43.) 11.

  • Page 44: Hydraulic Oil Level

    9. M AINTENANCE ATCO 9.3. S & M 2500 S ERVICE AINTENANCE ROCEDURES ERIES ENSION 1. Push on the center of the belt span with a force of approximately 5 lb. 2. The belts will deflect approximately 1” (25 mm) when properly tensioned. 3.
  • Page 45 9. M ATCO AINTENANCE 2500 S 9.3. S & M ERIES ERVICE AINTENANCE ROCEDURES To maintain the system, follow this procedure: • The system is virtually maintenance-free, except for checking the oil level in the reservoir. Check the level when the oil is cold by removing the cap from the reservoir.
  • Page 46 9. M AINTENANCE ATCO 9.3. S & M 2500 S ERVICE AINTENANCE ROCEDURES ERIES P1511025 R0...

  • Page 47: Troubleshooting

    ERIES 10.Troubleshooting The Batco PitStop Conveyor uses an endless flat belt moving through a tube to convey material from one location to another. It is a simple and reliable system that requires minimal maintenance. In the following section, we have listed many of the problems, causes, and solutions to the problems that you may encounter.
  • Page 48 10. T ROUBLESHOOTING ATCO 2500 S ERIES P1511025 R0...

  • Page 49: Appendix

    11. A ATCO PPENDIX 2500 S 11.1. M ERIES ECHANICAL PECS 11. Appendix 11.1. MECHANICAL SPECS Table 11.1 Dimensions Length 25’ Width 8’ Height 4’ Clearance 7-1/2” Weight 2900 lb Power Options Hydraulic 19-22 gpm (US) @ 2000 psi Electric 7.5 hp a.
  • Page 50 11. A PPENDIX ATCO 11.1. M 2500 S ECHANICAL PECS ERIES P1511025 R0...

  • Page 51: New Equipment Warranty

    • The warranty will be limited to one year from the date of purchase. • A “Warranty Registration Form” and “Inspection Report” must be filled out and returned to Batco Manufacturing Ltd. at the time of sale in order to qualify for replacement of defective parts.
  • Page 52 Batco Manufacturing is a Division of Ag Growth Industries LP Part of the Ag Growth International Inc. Group 2165 North Service Road West Swift Current, Saskatchewan CANADA S9H 5K9 PHONE: (306) 773-7779 FAX: (306) 778-2524 EMAIL: info@batcomfg.com WEB: www.batcomfg.com © Ag Growth Industries Limited Partnership 2011...

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