GRAIN CONVEYOR OPERATOR S MANUAL SERIESERIES CONVEYORS

Transcription

1 GRAIN CONVEYOR OPERATOR S MANUAL SERIESERIES CONVEYORS

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3 SIGN-OFF FORM Batco Manufacturing Ltd. follows the general Safety Standards specified by the American Society of Agricultural Engineers (ASAE) and the Occupational Safety and Health Administration (OSHA). Anyone who will be operating and/or maintaining the Grain conveyor must read and clearly understand ALL Safety, Operating and Maintenance information presented in this manual. Do not operate or allow anyone else to operate this equipment until such information has been reviewed. Annually review this information before the season start-up. Make these periodic reviews of SAFETY and OPERATION a standard practice for all of your equipment. We feel that an untrained operator is unqualified to operate this machine. A sign-off sheet is provided below for your record keeping to show that all personnel who will be working with the equipment have read and understood the information in the Operator s Manual and have been instructed in Date Employee Signature Date Employee Signature

4 SERIAL NUMBER LOCATION Always give your dealer the serial number of your Batco Grain conveyor when ordering parts or requesting service or other information. The serial number plate is located where indicated. Please mark the number in the space provided for easy reference. Serial number locations (Typical) Model # Serial # Production Year

5 BATCO MANUFACTURING LTD. NEW EQUIPMENT WARRANTY POLICY: Batco Manufacturing Ltd. will warrant each new conveyor to be free from factory defects in material and workmanship under normal use and service when set up and operated in accordance with factory instructions. Commercial applications will reduce the warranty period to 90 days from the original date of delivery. This warranty will apply under the following conditions: CONDITIONS: 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. The warranty is void on any unit that has been tampered with or has been subject to misuse, negligence or accident. The warranty is limited to the supplying of replacement parts in exchange for parts defective due to material or factory workmanship. The warranty covers material only, unless expenditures are pre-authorized by Batco Manufacturing Ltd. in writing. A reasonable allowance may be charged to cover labor for replacement of damaged parts at the discretion of the Batco Warranty Department. Normal wear and service items such as belts, hoses, flashing, etc., will only be considered warranty at the discretion of the Batco Warranty Department. PROCEDURE: All warranty repairs must be performed at an authorized Batco dealership in order to receive credit. All returned parts must be sent to the factory in order to qualify for warranty replacement. All returned parts must be sent to the factory, freight pre-paid, and will be returned freight collect. Please direct all claims to the attention of the Warranty Department at Batco Manufacturing Ltd. ( )

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7 TABLE OF CONTENTS 1. INTRODUCTION SAFETY GENERAL SAFETY OPERATING SAFETY PLACEMENT SAFETY MAINTENANCE SAFETY HYDRAULIC SAFETY TRANSPORT SAFETY REFUELING SAFETY STORAGE SAFETY TIRE SAFETY BATTERY SAFETY GAS MOTOR SAFETY SAFETY SIGNS GENERAL INFORMATION INSTALLATION A-FRAME CONVEYOR DECAL LOCATIONS SCISSOR LIFT CONVEYOR DECAL LOCATIONS SAFETY DECAL LOCATIONS FOR DRIVES OPERATING AND SAFETY INSTRUCTIONS SAFETY OWNER/OPERATOR RESPONSIBILITY MACHINE COMPONENTS MACHINE BREAK-IN PRE-OPERATION CONTROLS CONVEYOR REPLACEMENT CONVEYOR DRIVE SYSTEM OPERATING INSTRUCTIONS STARTING CONVEYOR CONVEYOR SHUTDOWN EMERGENCY SHUTDOWN RE-STARTING (FULL TUBE) CONVEYOR OPERATING ANGLES BELT SPEED OPERATING TIPS.. 4.8

8 TABLE OF CONTENTS 4.10 TRANSPORTING SAFELY PRE-TRANSPORT CHECKLIST TRANSPORT PROCEDURE STORAGE SERVICE AND MAINTENANCE GENERAL SERVICE SERVICING INTERVALS SERVICE CHECKLIST MAINTENANCE CONVEYOR BELT TENSION CONVEYING BELT ALIGNMENT BELT REPLACING CONVEYOR BELT REPLACEMENT DRIVE BELT TENSION AND ALIGNMENT PTO DRIVE LINE GUARD TUBE ALIGNMENT CABLE TRUSS TROUBLE SHOOTING SPECIFICATIONS MECHANICAL BOLT TORQUE HYDRAULIC FITTING TORQUE HYDRAULIC PIPE THREAD FITTINGS, NPT FOUR BOLT SPLIT FLANGE O-RING FITTING, ORB FLARE FITTINGS 37 0, JIC HOSE STEM CONNECTIONS MAXIMUM CONTINUOUS FLOW FOR HYD MOTORS CONVEYOR PRODUCT CHART

9 I N T R O D U C T I O N 1. INTRODUCTION Congratulations on your choice of a Batco conveyor to complement your agricultural operation. This equipment has been designed and manufactured to meet the needs of the discriminating buyer for the efficient moving of grain, pulse crops, fertilizer or most any other granular material. Safe, efficient and trouble free operation of your conveyor requires that you and anyone else who will be operating or maintaining the conveyor, read and understand the Safety, Operation, Maintenance and Trouble shooting information contained within this Operator s manual. This manual covers all standard conveyors made by Batco Manufacturing Ltd. Use the Table of Contents as a guide when searching for specific information. 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, information or additional copies of the manual. Operator Orientation The directions left, right, front, and rear, as mentioned throughout this manual, are as seen from the tractor driver s seat and facing in the direction of travel when the unit is being transported. 1.1

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11 S A F E T Y 2. SAFETY This Safety Alert symbol means: ATTENTION BECOME ALERT! YOUR SAFETY IS INVOLVED The Safety Alert symbol identifies important safety messages on the Batco grain conveyor and in the manual. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message. Why is SAFETY important to you? 3 Big Reasons Accidents Disable and Kill Accidents Cost $$ Accidents Can Be Avoided SIGNAL WORDS: DANGER - Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations, typically for machine components that, for functional purposes, cannot be guarded. NOTE THE USE OF SIGNAL WORDS DANGER, WARNING CAUTION, AND NOTICE WITH THE SAFETY MESSAGES. THE APPROPRIATE SIGNAL WORD FOR EACH MESSAGE HAS BEEN SELECTED USING THE FOLLOWING GUIDELINES: WARNING - Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed. It may also be used to alert against unsafe practices. CAUTION - Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. NOTICE - Indicates a potential for machine malfunction if proper operation and/or maintenance is not done. It may also be used to alert against an improper practice. 2.1

12 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L YOU are responsible for the SAFE operation and maintenance of your Batco Grain Conveyor. YOU must ensure that you and anyone else who is going to operate, maintain or work around the Grain Conveyor be familiar with the operating and maintenance procedures and related SAFETY information contained in this manual. This manual will take you step-by-step through your working day and alerts you to all good safety practices that should be adhered to while operating the conveyor. 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. Be certain that EVERYONE operating this equipment is familiar with the recommended operating and maintenance procedures and follows all the safety prcautions. Most accidents can be prevented. Do not risk injury or death by ignoring good safety practices. Conveyor owners must give operating instructions to operators or employees before allowing them to operate the machine, and at least annually thereafter per OSHA (Occupational Health & Safety Administration) regulations. The most important safety device on this equipment is a SAFE operator. It is the operator s responsibility to read and understand ALL Safety and Operating instructions in the manual and to follow them. A person who has not read and understood all operating and safety instructions is not qualified to operate the machine. An untrained operator exposes himself and bystanders to possible serious injury or death. Do not modify the equipment in any way. Unauthorized modification may impair the function and/or safety and could affect the life of the equipment. Think SAFETY! Work SAFELY! 2.1 GENERAL SAFETY 1. Read and understand the Operator s Manual and all safety signs before operating, maintaining, adjusting or unplugging the conveyor. 2. Only trained competent persons shall operate the conveyor. An untrained operator is not qualified to operate the machine. 3. Have a first-aid kit available for use should the need arise, and know how to use it! 4. Provide a fire extinguisher for use in case of an accident. Store in a highly visible place. 5. Do not allow children, spectators or bystanders within hazard area of the machine. 6. Wear appropriate protective gear. This list includes but is not limited to: A hard hat. Protective shoes with slip resistant soles. Protective goggles. Hearing protection. Respirator or filter mask. 7. Before servicing, adjusting, repairing or unplugging, place all controls in neutral or off, stop engine or motor, remove ignition key or disable power source and wait for all moving parts to stop. 8. Review safety related items annually with all personnel who will be operating or maintaining the conveyor. 2.2

13 S A F E T Y 2.2 OPERATING SAFETY 1. Read and understand the Operator s Manual and all safety signs before using. 2. PTO drives: Stop the engine, place all controls in neutral, set park brake, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing or unplugging. 3. Hydraulic drives: Stop the engine, place all controls in neutral, set park brake, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing or unplugging. 4. Gas engine drives: Stop engine, place all controls in neutral, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing or unplugging. 5. Electric motor drives: Disconnect and disable electrical supply completely and wait for all moving parts to stop before servicing, adjusting, repairing or unplugging. 6. Clear the area of bystanders, especially children, before starting. 7. Be familiar with machine hazard area. If anyone enters hazard areas, shut down machines immediately. Clear the area before re-starting. 8. Keep hands, feet, hair and clothing away from all moving and/or rotating parts. 9. Do not allow riders on the conveyor, tractor or towing vehicle when transporting. 10. Stay away from overhead obstructions and power lines during operation and transporting. Electrocution may occur without direct contact. 11. Do not operate machine when any guards are removed. 12. Set park brake on tractor before starting. 13. Lower conveyor to its lowest position before moving or transporting or when not in use. 14. Inspect lift cable (if equipped) before using conveyor. Replace if frayed or damaged. 15. Be sure that conveyor is empty before raising or lowering. 2.3 PLACEMENT SAFETY 1. Move conveyor only with a tractor/towing vehicle. Never move by hand. The exception to this would be, for example, moving a Top Drive Conveyor around in a yard - as these units are balanced differently. 2. Stay away from overhead power lines when moving conveyor. Electrocution can occur without direct contact. 3. Chock conveyor and tractor wheels front and rear before operating. 4. Keep conveyor as low as possible when moving. Raise only when it is next to storage facility. 5. Be familiar with the machine hazard area. If anyone enters hazard area, shut down machine immediately. Clear the area before restarting. 6. Operate the conveyor on level ground free of debris. If ground is uneven, anchor the conveyor to prevent tipping or upending. WARNING When releasing conveyor from the towing vehicle, test the intake end for downward weight. Do not raise the intake end above drawbar height. Conveyor upending may occur. 2.3

14 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L PTO SUPPORT DISCHARGE END OVERHEAD WIRES KEEP AWAY UNDER CONVEYOR AND UNDERCARRIAGE AREA HAZARD KEEP AWAY WHEEL CHOCKS WHEEL CHOCKS PTO DRIVE AREA KEEP OUT CONVEYOR INTAKE AREA HAZARD KEEP OUT WHEEL CHOCKS WALKING SURFACE - IS IT SLIPPERY? ARE THERE THINGS TO TRIP YOU? WORK AREA AUTHORIZED PERSONNEL ONLY KEEP OUT OF SHADED HAZARD AREA Fig 2.1 Workplace Hazard Area (PTO Drive) 2.4

15 S A F E T Y HYDRAULIC SUPPORT DISCHARGE END OVERHEAD WIRES KEEP AWAY UNDER CONVEYOR AND UNDERCARRIAGE AREA HAZARD KEEP AWAY WHEEL CHOCKS WHEEL CHOCKS HYDRAULIC DRIVE AREA KEEP OUT CONVEYOR INTAKE AREA HAZARD KEEP OUT WHEEL CHOCKS WALKING SURFACE - IS IT SLIPPERY? ARE THERE THINGS TO TRIP YOU? WORK AREA AUTHORIZED PERSONNEL ONLY KEEP OUT OF SHADED HAZARD AREA Fig 2.2 Workplace Hazard Area (Hydraulic Drive) 2.5

16 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L ELEC/GAS SUPPORT DISCHARGE END OVERHEAD WIRES KEEP AWAY UNDER CONVEYOR AND UNDER- CARRIAGE AREA HAZARD KEEP AWAY WHEEL CHOCKS WHEEL CHOCKS WORK AREA AUTHORIZED PERSONNEL ONLY CONVEYOR DRIVE AREA HAZARD KEEP OUT CONVEYOR INTAKE AREA HAZARD KEEP OUT KEEP OUT OF SHADED HAZARD AREA Fig 2.3 Workplace Hazard Area (Electric/Gas Drive) 2.6

17 S A F E T Y 2.4 MAINTENANCE SAFETY 1. Review the Operator s Manual and all safety items before working with, maintaining or operating the conveyor. 2. Place all controls in neutral or off, stop engine or motor, remove ignition key or disable power source and wait for all moving parts to stop before servicing, adjusting, repairing or unplugging. 3. Follow good shop practices: Keep service area clean & dry Be sure electrical outlets and tools are properly grounded. Use adequate light for the job at hand. 4. Before applying pressure to a hydraulic system, make sure all components are tight and that hoses and couplings are in good condition. 2.5 HYDRAULIC SAFETY 1. Always place all tractor hydraulic controls in neutral before disconnecting from tractor or working on hydraulic system. 2. Make sure that all components in the hydraulic system are kept in good condition and are clean. 3. Replace any worn, cut, abraded, flattened or crimped hoses. 4. Do not attempt any makeshift repairs to the hydraulic fittings or hoses by using tape, clamps or cements. The hydraulic system operates under extremely highpressure. Such repairs will fail suddenly and create a hazardous and unsafe condition. 5. Wear proper hand and eye protection when searching for a high-pressure hydraulic leak. Use a piece of wood or cardboard as a backstop instead of hands to isolate and identify a leak. 6. If injured by a concentrated high-pressure stream of hydraulic fluid, seek medical attention immediately. Serious infection or toxic reaction can develop from hydraulic fluid piercing the skin surface. 5. Relieve pressure from hydraulic circuit before servicing or disconnecting from tractor. 6. Keep hands, feet, hair and clothing away from all moving and/or rotating parts. 7. Clear the area of bystanders, especially children, when carrying out any maintenance and repairs or making any adjustments. 8. Place stands or blocks under the frame before working beneath the machine. 9. Before resuming work, install and secure all guards when maintenance work is completed. 10. Support conveyor tube before attempting maintenance on the undercarriage assembly. Where possible, conveyor should be in the full down position. 11. Keep safety signs clean. Replace signs that are damaged or not clearly visible. See chapter 3 for more information on safety sign locations. 2.7

18 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L 2.6 TRANSPORT SAFETY 1. Read and understand ALL the information in the Operator s Manual regarding procedures and Safety when moving or transporting the conveyor. 2. Check with local authorities regarding transport on public roads. Obey all applicable laws and regulations. OVER HEAD WIRES KEEP AWAY 3. Always travel at a safe speed. Use caution when making corners or meeting traffic. Discharge end can swing dramatically on sharp corners. Ensure you are clear of obstructions and oncoming traffic. 4. Make sure the SMV (Slow Moving Vehicle) emblem and all the lights and reflectors that are required by the local highway and transport authorities are in place, are clean and can be seen clearly by all overtaking and oncoming traffic. 5. Do not allow riders on the conveyor or the tractor/ towing vehicle when transporting. 6. Attach conveyor to towing vehicle with a pin and retainer. Always attach safety chain(s). 7. Fully lower conveyor before transporting. 8. Do not exceed 20 mph (32 km/h). Reduce speed on rough roads and surfaces. 9. Stay away from overhead obstructions and power lines when transporting. Electrocution can occur without direct contact. 10. Always use hazard-warning flashers on tractor/towing vehicle when transporting unless prohibited by law. 11. Long conveyors have a large turning radius. Allow ample room for turning, as discharge end may swing dramatically. HAZARD AREA KEEP OUT Fig 2.4 Transport Hazard Area 2.8

19 S A F E T Y 2.7 REFUELING SAFETY 1. Handle fuel with care. It is highly flammable. 2. Shut off engine and allow it to cool for 5 minutes before refueling. Clean up spilled fuel before restarting the engine. 3. Do not refuel the machine while smoking or when near open flame or sparks. 4. Refer to gas engine operators manual for further details GAS MOTOR SAFETY READ AND UNDERSTAND THE OPERATING AND MAINTENANCE INSTRUCTIONS THAT CAME WITH YOUR GAS ENGINE. 2.8 STORAGE SAFETY 1. Store the unit in an area away from human activity. 2. Do not permit children to play on or around the stored machine. 3. Fully lower conveyor before storing. 2.9 TIRE SAFETY 1. Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion, which may result in serious injury or death. 2. Do not attempt to mount a tire unless you have the proper equipment and experience to do the job. 3. Have a qualified tire dealer or repair service perform required tire maintenance. 4. When replacing worn tires, make sure they meet the original tire specifications. Never undersize the replacement tire. 5. Do not weld to tire rim with the tire mounted on rim. This action may cause an explosion which could result in serious injury or death BATTERY SAFETY 1. Wear safety glasses when working near batteries. 2. Keep all sparks and flames away from batteries, as gas given off by electrolyte is explosive. 3. Avoid contact with battery electrolyte. Wash off any spilled electrolyte immediately. 4. Do not tip batteries more than 45 degrees, to avoid electrolyte loss. 5. To avoid injury from sparks or short circuits disconnect battery ground cable before servicing any part of an electrical system. 2.9

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21 S A F E T Y S I G N S 3. SAFETY SIGNS 3.1 GENERAL INFORMATION 1. Keep safety signs clean and legible at all times. 2. Replace safety signs that are missing or have become illegible. 3. Replaced parts that display a safety sign should also display the current sign. 4. Safety signs are available from your Distributor or the factory. 3.3 LOCATIONS The types of safety signs and locations on the equipment are shown in the illustrations below. Good Safety requires that you familiarize yourself with the various Safety Signs, the type of warning and the area, or particular function related to that area, that requires your SAFETY AWARENESS. 3.2 INSTALLATION 1. Be sure that the installation area is clean and dry. 2. Decide on the exact position before you remove the backing paper. 3. Align the sign 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 sign in place. 5. Small air pockets can be pierced with a pin and smoothed out using the piece of sign backing paper. REMEMBER: If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied. New safety signs are available from your authorized dealer. Part #:P Fig 3.1 Safety Decal Locations 3.1

22 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L Part #: P BOTH SIDES Part #: P Part #: P Part #: P Part #: P Fig 3.2 Safety Decal Locations (30-55 Conveyors) 3.2

23 S A F E T Y S I G N S Part #: P BOTH SIDES FOR UNITS WITH EXTENDABLE AXLES Part #: P Part #: P Part #: P Part #: P Part #: P Part #: P Part #: P Fig 3.3 Safety Decal Locations ( foot Conveyors) 3.3

24 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L Part #: P Part #: P Part #: P Part #: P Beneath plastic guard Part #: P Part #: P Part #: P Part #: P Fig 3.4 Safety Decal Locations (S-Drive, PTO, Hydraulic & Electric Drives) 3.4

25 S A F E T Y S I G N S Part #: P Beneath plastic guard Part #: P Part #: P Part #: P Beneath plastic guard Part #: P Fig 3.5 Safety Decal Locations (Gas Engine & Electric Drives) 3.5

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27 O P E R A T I N G & S A F E T Y I N S T R U C T I O N S 4. OPERATING & SAFETY INSTRUCTIONS 4.1 SAFETY 1. Read and understand the Operator s Manual and all safety signs before using. 2. PTO drives: Stop the engine, place all controls in neutral, set the park brake, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing or unplugging. 3. Hydraulic drives: Stop the engine, place all controls in neutral, set park brake, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing or unplugging. 4. Gas engine drives: Stop engine, place all controls in neutral, remove ignition key and wait for all moving parts to stop before servicing, repairing or unplugging. 5. Electric motor drives: Disconnect and disable electrical supply completely and wait for all moving parts to stop before servicing, adjusting, repairing or unplugging. 6. Clear the area of bystanders, especially children, before starting. 7. Be familiar with machine hazard area. If anyone enters hazard areas, shut down machine immediately. Clear the area before restarting. 8. Keep hands, feet, hair and clothing away from all moving and/or rotating parts. 9. Do not allow riders on the conveyor, tractor or towing vehicle when transporting. 4.2 OWNER/OPERATOR RESPONSIBILITY The Batco Grain conveyor is designed to efficiently move grain, pulse crops, or granular material between a truck, trailer or wagon and a storage facility. A tractor PTO, electric motor, gas engine or hydraulic motor, provides power. Be familiar with the machine before starting. It is the responsibility of the owner or operator to read this manual and to train all other operators before they start working with the machine. In addition to the design and configuration of equipment, hazard control and accident prevention are dependent upon the awareness, concern and prudence of personnel involved in the operation, transport, maintenance and storage of equipment or in the use and maintenance of facilities. Follow all Safety Instructions exactly. Safety is everyone s business. By following recommended procedures, a safe working environment is provided for the operator, bystanders and the area around the work site. Untrained operators are not qualified to operate the machine. Many features incorporated into this machine are the result of suggestions made by customers like you. Read this manual carefully to learn how to operate the machine safely and how to set it to provide maximum efficiency. By following the operating instructions in conjunction with a good maintenance program, your conveyor will provide many years of trouble-free service. 10. Stay away from overhead obstructions and power lines during operation and transportation. Electrocution can occur without direct contact. 11. Do not operate machine when any guards are moved. 12. Set park brake on tractor before starting. 13. Fully lower the conveyor before moving or transporting or when not in use. 14. Inspect lift cable (if equipped) before using conveyor. Replace if frayed or damaged. 15. Be sure that conveyor is empty before raising or lowering. 4.1

28 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L 4.3 MACHINE COMPONENTS The Batco Conveyor is an endless belt that travels through a tube for moving grain or any granular product. The machine is portable and can be raised or lowered as required for loading and unloading of trucks and storage facilities. A PTO, gas engine, electric motor or hydraulic motor can supply power to the s-drive or top drive located under the tube. Electric and Hydraulic options are available for top drive units. Material enters the system through a hopper or intake on the bottom end and exits through the spout or outlet on the top end. A winch or hydraulic cylinder is used to raise or lower the conveyor. Hood Spout Main Tube Truss Return Roller or WG Roller Axle/Extendable Scissor Lift or A-Frame (not shown) Lift Valve S-Drive Hopper 4.2

29 O P E R A T I N G & S A F E T Y I N S T R U C T I O N S Electric T-Drive Hydraulic T-Drive PTO S-Drive Hydraulic S-Drive Electric S-Drive Elec/Gas Pinch S-Drive Fig 4.1 Machine Drives 4.3

30 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L 4.4 MACHINE BREAK-IN Although there are no operational restrictions on the conveyor when used for the first time, it is recommended that the following items be checked: 1. Before starting: a. Read the conveyor and engine (if so equipped) Operator s Manuals. b. During the first few minutes of operation, check belt alignment to ensure preset alignment does not vary under loaded conditions. See Section 5- Service and Maintenance for further details. 2. After operating or transporting for 1/2 hour: a. Re-torque all the wheel bolts. b. Re-torque fasteners and hardware. c. Check that all safety decals are installed and legible. Apply new decals if required. d. Check the drive and conveyor belt tension and alignment. Tension or align as required. e. Check that all guards are installed and working as intended. 3. After operating for 5 and 10 hours: a. Re-torque all wheel bolts, fasteners and hardware. b. Check that all guards are installed and are working properly. c. Check safety decals. Install new ones if required. d. Check the drive and conveyor belt tension and alignment. Tension or align as required. 4.5 PRE-OPERATION CHECKLIST Efficient and safe operation of the Batco Grain Conveyor requires that each operator reads and understands the operating procedures and all related safety precautions outlined in this section. A pre-operation checklist is provided for the operator. This checklist is important to follow for personal safety and maintaining the mechanical condition of the conveyor. Before operating the conveyor, and each time thereafter, the following areas should be checked off: 1. Service the machine per the schedule outlined in Section 5 Service and Maintenance. 2. Use only a tractor, gas engine or electric motor of adequate power to operate the machine. 3. Check that all guards are installed, secured and functioning as intended. Do not operate with missing or damaged shields. 4. Check work site. Clean up working area to prevent slipping or tripping. 5. Check winch and cable (if equipped). There should be at least 3 complete wraps of cable around the winch drum in transport position. Check cable anchor on winch drum is tight. Inspect cable and replace if frayed or damaged. 6. Check that cable clamps are secure. 7. Check that drive and conveying belts are not frayed or damaged and that they are properly adjusted and aligned. See Section 5- Service and Maintenance. 8. Be sure wheels are chocked. 9. Check that hopper and spout areas are free of obstructions. 4.4

31 O P E R A T I N G & S A F E T Y I N S T R U C T I O N S 4.6 CONTROLS Before starting operating conveyor, all operators should familiarize themselves with the location and function of the controls. 1. GAS ENGINE Refer to engine operator manual for controls operation. 2. ELECTRIC DRIVE Use a licensed electrician to provide power to the machine and to provide convenient shutdown switches. 3. DIRECT DRIVE (GAS/ELEC) BELT ENGAGEMENT (if equipped) Leaver located near hopper allows belt drive to be engaged or disengaged without cutting power to engine. 4. WINCH A winch is located on the top of the tube and is used to raise and lower the conveyor. 5. HYDRAULIC SAFETY BALL VALVE (scissor-lift conveyor) This valve allows oil to flow into or out of the hydraulic cylinder that raises or lowers the tube. If the handle is parallel to the hydraulic line the valve is open. Ensure valve is always closed when machine is positioned. CAUTION Conveyor should not be left in a raised position for extended periods of time. Fully lower conveyor. CAUTION Hydraulic safety ball valve must be fully opened before lifting or lowering the conveyor. Valve must be closed when conveyor is in a fixed position to prevent the hydraulic cylinder from creeping downward during operation. CAUTION Anchoring and/or support of the conveyor during operation is necessary. When emptying the conveyor, the weight balance transfers to the upper end of the machine, which can cause upending. 6. PTO Refer to tractor operators manual. 7. FL COLLASPIBLE HOPPER CONTROL Field Loader conveyors are designed with a collapsible hopper to allow it to go under low discharge units. Move the control handle toward the hopper or intake to release the hopper and move the handle toward the outlet or spout end to collapse the hopper. When loading the collapsible hopper, drive or back the truck into position for loading or unloading the bin. NOTE: Never dump material into the transfer area. Always dump as close to the back of the hopper as possible. Collapsible Hopper Lowered LOADINGZONE TRANSITION Collapsible Hopper Loading Zone Collapsible Hopper Raised 4.5

32 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L 4.7 CONVEYOR PLACEMENT Follow this procedure when placing the conveyor into its working position: 1. Clear the area of bystanders, especially children, before starting. 2. Be sure there is enough clearance from overhead obstructions and power lines or other equipment before moving the conveyor. 3. Back the machine up to the storage facility while it is in its lowered configuration. If equipped with extendable axles, place in extended position. Use jack to aid adjustment. 4. Set the park brake on the tractor before dismounting. 5. Use the winch or hydraulic scissor-lift to raise the machine so it clears the storage facility. 6. Slowly back the machine until the outlet is over the opening in the storage facility. 7. Use the winch or hydraulics to slowly lower the machine to the bin. Do not rest the spout or outlet hood on the bin. This may cause hood or belt damage. 8. Place chocks in the front and rear of each wheel. 9. Unhook the unit from the tractor or towing vehicle and lower hopper to the ground. 10. Lower the machine to the bin, but do not rest the spout or outlet hood on the bin. 11. Disconnect hydraulic hose (if equipped) and close ball valve. 12. Remove the hitch from the machine to prevent interfering with other equipment. 13. Review the Workplace Safety Diagram for your model prior to starting work. Follow all set-up instruction and do not allow any unauthorized people into the working area. 14. Check angle of machine. Ensure that the machine angle is less then the angle of repose of the material to be moved. See Section 7 for more help. 4.8 CONVEYOR DRIVE SETUP 1. For the PTO Drive Model: a. Back the tractor into position. b. Chock tractor wheels. c. Attach PTO shaft. 2. For the Hydraulic Drive Model: a. Back tractor into position. b. Chock tractor wheels. c. Plug hydraulic hoses into tractor couplers. Check flow direction to ensure belt moving forward. 3. For the Electric Motor Model: a. Have a certified electrician provide power to the machine. b. Provide convenient shutdown switches and comply with local electrical codes. c. Use a totally enclosed electric motor when conveying in extremely dusty conditions. Be sure electric motor is properly grounded. DANGER Stay away from overhead power lines. Electrocution can occur without direct contact. CAUTION The machine is closely balanced. Do not lift unless there is downward weight on the intake end to prevent upending. NOTICE Attempting to move material at too steep an angle can result in excessive slides back and poor capacity. 4.6

33 O P E R A T I N G & S A F E T Y I N S T R U C T I O N S 4.9 OPERATING INSTRUCTIONS When using the conveyor follow this procedure: 1. Clear the area of bystanders, especially small children, before starting. 2. Review the Section 4.5 Pre-Operation checklist before starting. 3. Review the Section 2 Workplace Hazards schematics and use extra care when inside the hazard area Starting Conveyor I. Electric Drive 1. Turn the electric motor ON. 2. Engage belt drive if equipped II. Gas Engine Drive 1. Disengage gas engine drive belt or electric clutch.. 2. Move throttle to it 1/4 position for starting. 3. Use choke if required. 4. Start engine. 5. Run engine for a couple of minutes until the engine warms. 6. Engage belt drive or electric clutch and increase engine speed to desired speed. III. PTO Drive 1. Place all controls in neutral. 2. Engage tractor parking brake. 3. Start tractor and run at low idle. 4. Engage PTO and steadily increase engine speed to desired speed. IMPORTANT: Position tractor to keep U-joint angles equal and as small as possible. IV. Hydraulic Drive Instructions 1. Place all controls in neutral. 2. Start tractor and run at low idle. 3. Engage hydraulic control lever and increase engine speed to desired speed. NOTE: The correct operation of hydraulic systems is directly linked to the pump s ability to supply the correct oil flow and pressure. If you cannot obtain the correct belt speed, check with the dealer to ensure the power unit is delivering the correct oil volume and pressure. See Section 7.4 for the required hydraulics for various motors used Conveyor Shutdown I. PTO Models: 1. Run until the belting is empty. 2. Reduce engine speed to low idle. 3. Disengage PTO clutch. 4. Shut off engine and remove ignition key. II. Hydraulic Drive Models: 1. Run until the belting is empty. 2. Reduce engine speed to low idle. 3. Place hydraulic control lever in neutral. 4. Shut off engine and remove ignition key. III. Electric Motor Models: 1. Run until the belting is empty. 2. Disengaged belt drive if equipped. 3. Turn off motor and lock out power source. IV. Gas Drive Models: 1. Run until the belting is empty. 2. Reduce engine speed to low idle. 3. Disengage belt drive; or disengage electric clutch if unit is equipped with one. 4. Shut off engine Emergency Shutdown Although it is recommended that the tube be emptied before stopping, in an emergency situation, stop or shut down the power source immediately. Lock out all power and ensure the machine components come to a stop before inspecting. Correct the emergency before resuming work Re-starting (full tube): When the machine is shut down inadvertently, or for an emergency, the tube will still be filled with material. Since the start-up torque loads are much higher than normal when the tube is full, re-start at low idle engine speed for the PTO and gas engine models. It may be necessary to tighten the drive belts slightly to handle the heavier than normal loads. 4.7

34 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L Conveyor Operating Angles The manual or optional hydraulic lift can set the tube angle at any position between 12º and 30º when operating. Because the belt does not have roll back barriers, the material will roll back if the angle is too steep. Do not position the conveyor at an angle steeper then the angle of repose of the material to be moved. See Section 7 for help on determining these angles. NOTE: The lower the angle, the greater the capacity Belt Speed The best results are obtained when the input drives are set to provide a belt speed of 500 to 600 ft/min. on 1300 & 1500 series, 600 to 650 on 1800 & 2000 series. Count the number of belt revolutions per minute to determine belt speed. Approximate belt length is double the length of your machine plus 3 feet. See Section 7.1 for belt lengths. Use the connector splice as a reference when counting belt revolutions. Contact your dealer or the factory for the appropriate drive components to give the recommended belt speed Operating Tips 1. Direct the flow of material into the input hopper in the direction of the belt for the best capacity. NOTICE Attempting to move material at too steep an angle can result in excessive slide back and poor capacity. 2. Always listen for any unusual sounds or noises. If any are heard, stop the machine and determine the source. Correct the problem before resuming work. 3. An optional hydraulic lift is available for the machine. Always close the Hydraulic Safety Ball Valve when the machine is positioned. 4. Do not run the machine for long periods of time without material on the belting. It increases the belt wear. 5. Do not move the machine by hand. Always use a tractor or other towing vehicle. 6. Do not support outlet end directly on the storage facility. Tie down the intake (hopper) or weight it down to prevent upending. 7. To achieve maximum capacity feed material onto belt until material tube clearance is 1/2, do not flood feed hopper. 8. On the PTO drive models, align the tractor axis with the conveyor input shaft to minimize the angles of the universal joints on the PTO driveline. 9. On the standard hopper conveyor, the best capacity is obtained when the material is loaded into the hopper as close to the tube as possible. 4.8

35 O P E R A T I N G & S A F E T Y I N S T R U C T I O N S 4.10 TRANSPORTING SAFETY Pre-Transport Checklist Before transporting conveyor, ensure that: 1. All bystanders are clear of the machine. 2. Conveyor is in the fully lowered position. 3. Extendable axles are placed in transport position (if equipped). Use jack to aid adjustment. 4. The hitch pin and safety chain are in place and secure. 5. On electric motor models, unplug the power cord, wrap around frame and secure to prevent dragging. 6. On hydraulic powered models, disconnect hydraulic hoses, remove power source and wrap hose around frame to prevent dragging. 7. On the PTO drive models, place the driveline in its stowed position before moving or transporting. 8. For gas drive models shut off fuel supply. Table 4.1 Speed versus Weight Ratio Road Speed Up to 32 km/h (20 mph) Up to 16 km/h (10 mph) Weight or fully equipped or loaded implement(s) relative to weight of towing machine 1 to 1, or less 2 to 1, or less Do not tow if More than Transport Procedure 1. Check with local authorities regarding conveyor transport on public roads. Obey all applicable laws and regulations. 2. Always travel at a safe speed. Use caution when making corners or meeting traffic. 3. Make sure the SMV (Slow Moving Vehicle) emblem and all the lights and reflectors that are required by the local highway and transport authorities are in place, are clean, and can be seen clearly by all overtaking and oncoming traffic. 4. Do not allow riders on the conveyor or the tractor when transporting. 5. Stay away from overhead obstructions and power lines when transporting. Electrocution can occur without direct contact. 6. Always use hazard-warning flashers on tractor or towing vehicle when transporting, unless prohibited by law. 7. Never go across slopes of more than 11º. It is better to go straight up or straight down the slope. 8. It is not recommended that the machine be transported faster than 20 mph (32 km/h). Table 4.1 references the acceptable transport speed as per the ratio of tractor weight versus conveyor weight. See Section 7 for conveyor weights. 9. Long conveyors have a large turning radius. Allow ample room for turning, as discharge end may swing dramatically. 10. Use caution when moving conveyors over rolling terrain. In severe dips the discharge end may contact the ground. CAUTION It may be necessary to raise the outlet end above the storage facility to provide clearance to raise the intake end. DANGER STAY AWAY FROM OVERHEAD POWER LINES. ELECTROCUTION CAN OCCUR WITHOUT DIRECT CONTACT. 4.9

36 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L 4.11 STORAGE To protect the conveyor in storage you should: 1. Lower the conveyor to its lowest position for storage. 2. Store the unit in an area away from human activity. 3. Select an area that is dry, level and free of debris. 4. Do not permit children to play on or around the stored machine. 5. Remove all residual material from the conveyor. 6. Stop machine so that the belt lacing is inside the tube. This protects the lacing from weathering. 7. Wash the entire machine thoroughly using a water hose or pressure washer to remove all dirt, mud, debris or residue. 8. Inspect all hydraulic hoses, fittings, lines, couplers and valves. Tighten any loose fittings. Replace any fitting or hose if damaged. DANGER Watch for overhead electrical wires. Stay away from overhead power lines. Electrocution can occur without direct contact. CAUTION Support conveyor discharge end before removing or replacing any parts on the undercarriage. 9. Touch up all paint nicks and scratches to prevent rusting. 10. If machine is not equipped with belt weather guards, position it in such a way as to limit wind exposure to the belt. 11. Place a block under the jack to ensure it will not freeze to the ground in the winter. To prepare the conveyor for use after storage, you should: 1. Check tire pressure and add air if required. See tire for inflation pressure details. 2. Replace any damaged parts or safety decals. 3. Conduce general maintenance. See Section 5-Service and Maintenance for further details. 4. Inspect lift cable (if equipped) and replace cable if damaged. 5. Inspect all hydraulic components. Replace all damaged or loose components. 4.10

37 S E R V I C E & M A I N T E N A N C E I N S T R U C T I O N S 5. SERVICE & MAINTENANCE 5.1 GENERAL 1. Review the Operator s Manual and all safety items before working with, maintaining or operating the conveyor. 2. Place all controls in neutral or off position, stop the engine, remove ignition key or disable power source and wait for all moving parts to stop before servicing, adjusting, repairing or unplugging. 3. Follow good shop practices: a. Keep service area clean and dry. b. Be sure electrical outlets and tools are properly grounded. c. Use adequate light for the job at hand. 4. Before applying pressure from hydraulic system, make sure all components are tight and that hoses and couplings are in good condition. 5. Relieve pressure from hydraulic circuit before servicing or disconnecting from tractor. 6. Keep hands, feet, hair and clothing away from all moving and/or rotating parts. 7. Clear the area of bystanders, especially children, when carrying out any maintenance and repairs or making adjustments. 8. Place stands or blocks under the frame before working beneath the machine. 9. Before resuming work, install and secure all guards when maintenance work is completed. 10. Support conveyor tube before attempting maintenance on the under carriage assembly. Where possible, conveyor should be in the full down position. 11. Keep safety signs clean. Replace any signs that are damaged or not visible. 5.2 SERVICE 1. FLUIDS AND LUBRICANTS a. Grease: Use SAE multi-purpose high temperature grease with extreme pressure (EP) performance. Also acceptable is SAE multi-purpose lithium based grease. b. Engine crankcase oil: See engine operators manual for details. c. Engine Gasoline: See engine operators manual for details. d. Storing Lubricants: Your machine can operate at top efficiency only if clean lubricants are used. Use clean containers to handle all lubricants. Store them in an area protected from dust, moisture and other contaminants. 2. GREASING NOTE: Most original equipment bearings used by Batco are sealed units and will not accept grease. a. Wipe grease fitting with a clean cloth before greasing to avoid injecting dirt and grit. b. Replace and repair broken fittings immediately. c. If fittings will not take grease, remove and clean thoroughly. Also clean lubricant passageway. Replace fitting if necessary. Use the Maintenance Checklist provided to keep a record of all scheduled maintenance (See Section 5.4-Service Checklist). 5.1

38 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L 5.3 SERVICING INTERVALS Initial start up servicing: As the belt alignment is preset to run true under a condition of no load, it is important to check alignment and make adjustments if required during the initial few minutes of loaded operation Hours or Daily Check the conveyor belt tension and alignment. (See Section ). PTO Drive Models Grease all grease fittings at 8-10 hour intervals. Inspect U-Joint for wear. Ensure PTO shaft to spline connection is secure Hours or Weekly Check the conveying belt tension and alignment. (See Section ). Check condition of hopper flashing. Be sure it seals the hopper and prevents grain leakage. Look for hydraulic leaks and repair if required. Clean engine air filter (if equipped) Hours or Annually Check for tube straightness. Adjust cables if required. (See Section 5.5.7). Check roller bearings for wear. Any rollers making noise, getting hot while running, or that have play should be replaced. Re-pack wheel bearings. Wash machine. Check gearbox oil level. Inspect roller lagging. If showing signs of wear. Inspect guards and ensure they are in good condition and are free to rotate. Gas Engine Drive Models Check belt lacing. If any clips are worn through, replace ALL lacing. Check hopper flashing for wear. Worn flashing will cause hopper leakage. Replace any worn flashing. Check fuel level. Add as required. Check gearbox oil level. Check crankcases oil level. Add as required. Check drive belt tension and alignment. Check wet kit oil reservoir level is equipped. Refer to gas engine operator manual for further detail. Electric Drive Models CAUTION OPERATING THE CONVEYOR WITH A DAMAGED ROLLER WILL RESULT IN A DAMAGED CONVEYOR BELT. Check drive belt tension and alignment. Check gearbox oil level. 5.2

39 S E R V I C E & M A I N T E N A N C E I N S T R U C T I O N S 5.4 SERVICE CHECKLIST See Lubrication and Maintenance sections for details of service. Photocopy this page to continue record keeping. ACTION CODES: =Check CL=Clean R=Re-pack L=Lubricate C=Change 8 HOUR OR DAILY DAY Conveyor Belt Tracking L PTO Shaft (3) Fuel & Oil Level(s) Day Conveyor Belt Tracking L PTO Shaft (3) Fuel & Oil Level(s) Day Conveyor Belt Tracking L PTO Shaft (3) Fuel & Oil Level(s) Day Conveyor Belt Tracking L PTO Shaft (3) Fuel & Oil Level(s) 40 HOURS OR WEEKLY Week Belt Tension & Alignment Conveyor Belt Tracking Condition of Hopper Flashing Check for Hydraulic Leaks Electric Drive Models Drive Belt Tens. & Alignment Gas Engine Drive Models Drive Belt Tens. & Alignment CL Air Cleaner Foam 200 HOURS OR ANNUAL YEAR 1 YEAR 2 YEAR 3 YEAR 1 YEAR 2 YEAR 3 Tube Straightness Belt Lacing Roller Bearings Hopper Flashing R Wheel Bearings Hydraulic Drive Models CL Machine L Roller Chain-Input Coupler Gearbox Oil Level Gas Engine Drive Models Roller Lagging C Engine Oil 5.3

40 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L 5.5 MAINTENANCE By following a careful service and maintenance program for your machine, you will enjoy many years of troublefree service CONVEYOR BELT TENSION Adjusting your conveyor belt for proper tension helps to ensure trouble-free operation and long belt life. A conveyor belt only needs to be tight enough to not slip on the drive roller. If the belt is too loose, it will slip on the drive roller making a noticeable sound, slowing the belt down. To correct belt slippage and set proper tension in the belt, follow the steps in Table 5.1 below. Depending on the type of conveyor you have, you will want to follow the steps for the Conveyor Type in the table. Only the steps that apply are numbered. Helpful Tips: If belt is slipping and adjustment bolts are fully tightened, then belt must be shortened. See Section Belt Replacing for further details. Belt should not be easy to pull from the hopper transition sides, otherwise the belt will require tensioning. When conveyor is starting/operating, the belt stretches and the spring extends to take-up the stretched belt. See Table 5.2 for recommended spring compression. Excessive droop between s-drive and hopper should be corrected. Table 5.2- RECOMMENDED SPRING LENGTHS Conveyor WARNING ENSURE IGNITION KEY IS RE- MOVED OR LOCKOUT POWER- SOURCE BEFORE ADJUSTING OR SERVICING CONVEYOR Spring Compressed Length B (See Fig 5.6) 1300 Series Match to Indicator 1500 Series Match to Indicator 2000 Series 5" IMPORTANT: Do not operate conveyor if belt is slipping. Stop conveyor and tighten belt. Failure to do so will damage the belt and may void the warranty. NOTE: Some belts may have uneven edges, appearing misaligned. Wait until the belt makes a complete revolution before adjusting rollers. Note: Refer to Figures for illustrations. Table BELT TENSION INSTRUCTIONS Top Drive S-Drive Steps For Conveyor Type S-Drive w/springs Description Clear bystanders Remove ignition key or lockout power source Remove guards if necessary ** Loosen bearing bolts and jam nut (if included) at tightener roller (see Figure 5.5). 4 Pinch S-Drive Pinch Top Drive Tighten take-up roller bolts so that springs compressed. If springs are already properly 4 compressed then tighten the take-up bolts 1, ensure equal (see Figure 5.6). Tighten take-up bolts 1, ensure equal (see Figure 5.6). 4 Check to ensure pinch roller is moveable. Spring tension should measure 4. 4 Tighten tightener bolts equally, use tape to verify (see Figure 5.5). Belt should deflect 1-2 when pushed down with a 5lb force or be difficult to pull from sides of hopper 5 5 transition. Tighten bearing bolts and jam nut (if included). 6 Check belt tension by running conveyor for one minute. If belt is not slipping, then proceed to next step, otherwise repeat from step ** Check takeup springs under startup. Springs should not come loose under startup. If they do, start machine more softly and increase takeup tension slightly. The takeup 7 spring must not be tensioned more than the pinch spring or slippling will result. If belt is not slipping, but now running to one side, the tensioned roller needs to be realigned, See Belt Alignment section that follows Replace guards if removed

41 S E R V I C E & M A I N T E N A N C E I N S T R U C T I O N S BEARING BOLT Figure HOPPER CAUTION JAM NUT TAKEUP SPRINGS MUST NOT BE TENSIONED MORE THAN THE PINCH SPRINGS OR SLIP- PAGE MAY RESULT TIGHTENER BOLT Figure S-DRIVE TAKE UP BOLT PINCH SPRING ROLLER Figure PINCH TOP DRIVE 5.5

42 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L CONVEYOR BELT ALIGNMENT Conveyor belt should be checked weekly to ensure it does not run to one side. If your belt is tracking to one side, use Table 5.3 below, following the steps listed to center it. Follow the steps in the table in order. If you are unsure where the problem is, start in Problem Area A, working your way to Problem Area G, following only the steps noted for each. Skip problem area columns that do not apply. The process can be lengthy but will help ensure trouble free operation and long belt life. Note: Ensure that conveyor is empty of all product before adjusting belt alignment. Helpful Tips: S-Drive If belt tracks to the side of the s-drive, check that it is level with the hopper. U-clamps will have to be loosened slightly and re-tightened to level s-drive. NOTE: If you have a Pinch S-drive, use alternate step D&E for instructions. The only adjustment required on the s-drive should be on the drive roller, if the belt still tracks to one side after adjusting the s-drive roller, then follow the procedure for the wrap roller, if equipped and repeat the same procedure for the s-drive return roller if there are still problems. DO NOT adjust the take-up roller on the s-drive, instead use a tape measure and measure dimension A on both sides of the s-drive in Figure 5.6 to ensure take-up bearings/bolts are tightened equally. Hopper/Spout Rollers Tighten adjustment bolt 1/2 turn on side that the belt is running towards. (see Figure 5.11). If machine is equipped with a field loader hopper, the transition return roller may have to be adjusted to center the belt on the hopper roller. Transition Rollers (Field Loader Conveyors) The top transition roller should be the only one requiring adjustment. Only in extreme cases does the bottom transition roller require adjustment (see Figure 5.10). Note: Refer to Figures for illustrations. 5.6 PROBLEM AREA A B C B/C D E F G Pinch S-Drive S-Drive S-Drive and Transition Drive Wrap Pinch Hopper Spout Roller Roller Rollers Roller Rollers Roller S-Drive Take-up Roller Description Clear bystanders Remove ignition key or lockout power source Remove guards if necessary Loosen bearing bolts and jam nut (if equipped) Loosen 8 drive roller mount plate bolts 4 *** Rotate adjustment bolt 1/2 turn Start at hopper or last adjusted roller and check belt is centered on each belt return bracket. Table 5.3 BELT ALIGNMENT INSTRUCTIONS If belt is not centered, adjust bracket toward hopper slightly on side belt is tracking toward (see Fig. 5.12). 4 Adjust wear blocks if unit has weather protectors (see Fig. 5.9). 5 Measure length A in Figure 5.6 on each side of s-drive. If lengths not equal then adjust nuts until equal. 4 6 Restart conveyor and run empty for one minute Stop conveyor, remove ignition key or lockout power source If belt has centered, then move to next step below, otherwise repeat from *** Tighten bearing bolts and jam nut (if equipped) Tighten 8 drive roller mount plate bolts 10 Replace guards if removed Belt Return 3

43 S E R V I C E & M A I N T E N A N C E I N S T R U C T I O N S Fig 5.7- Spout CAUTION ENSURE IGNITION KEY IS RE- MOVED OR LOCKOUT POWER- SOURCE BEFORE ADJUSTING OR SERVICING CONVEYOR Fig 5.8 Hopper 5.7

44 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L WEAR BLOCK WEAR BLOCK Fig 5.9 Weather Guard Guide Block TOP TRANSITION ROLLER TRANSITION RETURN ROLLER BOTTOM TRANSITION ROLLER Fig 5.10 Transition 5.8

45 S E R V I C E & M A I N T E N A N C E I N S T R U C T I O N S BELT ROLLER TIGHTEN ADJUSTMENT SCREW LOOSEN ADJUSTMENT SCREW BELT TRACKING Fig BELT TRACKING ON ROLLERS TUBE SPOUT TAP BRACKET THIS DIRECTION HOPPER RETURN ROLLER BRACKET BELT BELT TRACKING Fig BELT TRACKING ON RETURN ROLLER 5.9

46 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L BELT RELACING 1. Rotate the belting until the lacing is by the hopper or easily accessible. 2. Loosen conveyor belt and remove lacing retainer clip and pin. 3. Use a square and sharp knife and cut lacing off right behind the lacing clips. MUST ensure that cut belt has a square end. 4. Use knife to cut Chevron pattern off 1 inch back from end of belt. This ensures that the lacing is centered and fully seated on the belt. 5. Use lacing tool to install new lacing clips. Lacing clips are one clip shorter than belt width. For example: the lacing for a 15 inch wide belt is 14 clips. Center lacing on belt and install lacing as per instructions on lacing tool. 6. Reattach conveyor belt ends together. If required, use a ratchet strap clamped to both ends of belt to cinch belting ends together. 7. Install lacing pin and crimp retainer clips onto each end of the lacing pin. 8. Remove ratchet strap and tighten conveyor belt (see Section Conveyor Belt Tension). 9. Check and set belting alignment (see Section Belt Alignment). 10. Clear area of all bystanders and engage conveyor drive. Allow to run for 30 seconds then shut down conveyor and inspect lacing CONVEYOR BELT REPLACEMENT 1. Rotate the belting until the lacing is by the hopper or easily accessible. 2. Move the tension roller to its loosest position. 3. Pull all the slack to the lacing area. 4. Remove the lacing pin (see Figure 5.14). 5. Attach one end of the replacement belt to the belt end being removed, closest to the hopper. 6. Pull the old belt out and the new belt will be threaded into place. 7. Disconnect the old belt. 8. Reattach conveyor belt ends together. If required, use a ratchet strap clamped to both end of belt to cinch belting ends together. 9. Install lacing pin and crimp retainer clips onto each end of the lacing pin. 10. Remove ratchet strap and tighten conveyor belt (see Section Conveyor Belt Tension). 11. Check and set belting alignment (see Section Belt Alignment). 12. Clear area of all bystanders and engage conveyor drive. Allow to run for 30 seconds then shut down conveyor and inspect lacing. Fig S-DRIVE BELT PATH RETAINER CLIP 5.10 Fig BELT LACING PIN

47 S E R V I C E & M A I N T E N A N C E I N S T R U C T I O N S DRIVE BELT TENSION & ALIGNMENT Power to the conveyor is transmitted through a set of V belts. The drive system must be maintained at the proper belt tension and pulley alignment to obtain the desired performance and life. When maintaining the belt drive system for the electric drive model, follow this procedure: PTO DRIVE LINE GUARD The shield must turn freely on the PTO shaft. Daily lubrication of both shield bearings and periodic cleaning will ensure safe operation of the shield. If the shield is damaged or worn, replace the components. 1. Turn motor off and unplug power cord or turn off power at the master panel before starting on drive belt systems. 2. Belt Tension (Gas/Electric Drive): a. Push on the center of the belt span with a force of approximately 5 lbs. b. The belts will deflect approximately 1/4 to 1/2 when properly tensioned. c. Move the motor base to set drive belt tension. d. Close and secure guards. 3. Alignment: a. Lay a straight edge across the pulley faces to check the alignment. b. Use the pulley hub to move the pulley to the required position for alignment. c. Tighten hub bolts to secure pulley on shaft. d. Check belt tension. e. Close and secure guards. 4. Belt Replacement: a. Move motor base to its loosest position. b. Remove old belts and replace with new one. c. Check pulley alignment. Adjust if required. d. Close and secure guards. 5.11

48 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L TUBE ALIGNMENT CABLE TRUSS 1. Loosen cable clamps on trusses. 2. Support spout end of unit. 3. Starting from the outermost cables and working your way in, tighten cable eyebolts evenly on both sides until the spout just starts to bow upward (See Figure 5.15). The tube should not deflect to the left or right if tightened evenly. When material is conveyed, the tube may deflect down. Tension should be greater on longer cables than on shorter cables. If the conveyor tubes remain straight then the cables are tensioned properly. 4. Tighten cable clamps on trusses. 5. Secure jam nut on cable eyebolt. Fig 5.15 CABLE TRUSS ASSEMBLY 5.12

49 T R O U B L E S H O O T I N G 6. TROUBLE SHOOTING The Batco grain 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. If you encounter a problem that is difficult to solve, even after having read through this troubleshooting section, please call your local Batco dealer or distributor. Before you call, please have this Operator s Manual and the serial number from your machine ready. OVERALL Problem Cause Solution Low conveying capacity Conveyor angle is too high Reposition with lower tube angle (see section 7.3) Incorrect belt speed Verify and adjust belt speed to appropriate speed (see section 4) Conveyor belt slipping See belt slipping Drive belts slipping See belt slipping Low capacity for some grains Smaller and smoother grains will slide at shallower angles See low conveying capacity BELT Problem Cause Solution Belt slipping Conveying belt loose Tighten and align belt (see section 5) Drive roller lagging worn or damaged Replace drive roller lagging Drive belts loose Tighten and align (see section 5) Belt frozen to tube from operating in high humidity in cold conditions Remove conveyor from area of high humidity and warm belt to de-ice Excessive belt edge fraying Belt not aligned Align and tension belt (see section 5) Belt loose Belt stretches over time Re-tension belt (see section 5) Can also be caused by oily grain/ product If tightener is fully engaged you may need to shorten belt HOPPER Problem Cause Solution Grain leaking from conveyor Belt not tracked (centered) Track belt (see section 5) hopper Flashing installed incorrectly or worn Inspect flashing for wear and replace if required Hopper cloth wor or damaged Replace damaged hopper cloth Transition filler rings are worn or need Adjust transition filler rings, replace if replacement. worn. Hopper cloth collapsing under grain Misaligned or broken spring(s) Check spring installation and repair as required Pivot shafts improperly installed On some machines switching pivot shafts left to right will increase hopper tension TUBE Problem Cause Solution Conveyor Tube appears curved or sags Support cables tightened unevenly Align cables (see section 5) 6.1

50 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L DRIVE Problem Look For Solution Drive making noise Slipping belt See belt slipping Hot shaft, pulley or bearing Overheated components indicate a failed bearing that must be repaired Broken drive roller Replace damaged component SPOUT Problem Cause Solution Grain leaking from conveyor Belt not tracked (centered) Track belt (see section 5) spout between belt and tube Grain leaking from conveyor spout between hood and belt Belt speed is too fast, hood plugging Decrease belt speed or feed rate FRAME Problem Cause Solution Scissor lift not lifting conveyor Ball valve on lift line closed Open ball valve Inadequate hydraulic pressure from source Use alternate hydraulic pressure source. Contact your local dealer for Conveyor lifts slowly Inadequate hydraulic pressure from source Use alternate hydraulic pressure source. Contact your local dealer for If conveyor lowers faster than it lifts then the check valve may be installed in opposite direction Lower machine to transport position and inspect check valve. Re-install in opposite direction if required. See indicator arrow on valve Machine will lift but not lower Foreign object clogging check valve Contact your local dealer for assistance Conveyor will not stay elevated (Scissor) Conveyor will not stay elevated (A-frame) Conveyor makes noise while lifting Lift cylinder discharges oil from breather while lifting Ball valve not closed while in elevated position Leaking hydraulic hose or fitting Leaking seal in hydraulic cylinder Faulty winch Faulty cable Frame parts loose and move while lifting If machine lifts, this is just captured oil in the top of cylinder If machine will not lift, seal in hydraulic cylinder is damaged Close ball valve Lower machine to transport position and repair leaks as required Lower machine to transport position and repair hydraulic cylinder as re- Lower machine to transport position and repair or replace winch Lower machine to transport position and repair or replace cable Replace damaged components and retension frame fasteners Cleanup oil spill and continue operation as normal Lower machine to transport position and repair hydraulic cylinder as re- BRACKETS Problem Cause Solution U-clamps sliding on tube Clamp not properly crimped to tube Contact your local dealer for correct positioning 6.2

51 S P E C I F I C A T I O N S 7. SPECIFICATIONS 7.1 MECHANICAL 1300 SERIES NOTE: ALL ANGLES AND MEASUREMENTS SHOWN ARE MACHINE LIMITS. THE MAX OP- ERATION ANGLE DEPENDS ON THE PRODUCT BEING CONVEYED, USUALLY LESS THAN 30DEG. UP - OPERATION DOWN - TRANSPORT HP HYD (CU.IN.) TOTAL WEIGHT A B ANGLE C B ANGLE LENGTH WIDTH HP PTO HP ELEC HP GAS BELT LENGTH MODEL # 1300 SERIES 1314LP 28' 4" n/a (H) SWING TRANSFER 35' 0" 571 n/a n/a n/a n/a n/a n/a n/a n/a n/a 5.0 n/a 5.9 (H) 1330 TOP DRIVE 58' 8" n/a 7.5 n/a 5.0 n/a 5.9 (H) 1335 TOP DRIVE 68' 8" n/a 7.5 n/a 5.0 n/a 5.9 (H) 1340 TOP DRIVE 78' 8" n/a 7.5 n/a 7.5 n/a 5.9 (H) 1345 TOP DRIVE 88' 8" n/a 7.5 n/a 7.5 n/a 5.9 (H) 1350 TOP DRIVE 98' 8" n/a 7.5 n/a 7.5 n/a 5.9 (H) 1335 TDFL 76' 4" n/a (2000) 1345 TDFL 96' 4" n/a (2000) 1335 FL S-Drive 80' 4" n/a (2000) 1345 FL S-Drive 100' 4" n/a (2000) ' 8" n/a (2000) ' 8" n/a (2000) ' 8" n/a (2000) ' 10" n/a (2000) 7.1

52 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L 1500 SERIES 7.2 NOTE: ALL ANGLES AND MEASUREMENTS SHOWN ARE MACHINE LIMITS. THE MAX OP- ERATION ANGLE DEPENDS ON THE PRODUCT BEING CONVEYED, USUALLY LESS THAN 30DEG. HP HYD (CU.IN.) HP PTO HP ELEC HP GAS MODEL # BELT TOTAL UP OPERATION DOWN TRANSPORT 1500 SERIES LENGTH WEIGHT A B ANGLE C B ANGLE LENGTH WIDTH ' 8" n/a (H) SWING TRANSFER 34' 6" 700 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 5.9 (H) 1530 TOP DRIVE 60' 8" n/a 7.5 n/a 7.5 n/a 5.9 (H) 1535 TOP DRIVE 70' 8" n/a 7.5 n/a 7.5 n/a 5.9 (H) 1540 TOP DRIVE 80' 8" n/a 7.5 n/a 7.5 n/a 5.9 (H) 1545 TOP DRIVE 90' 8" n/a 7.5 n/a 7.5 n/a 5.9 (H) 1550 TOP DRIVE 100' 8" 1689 n/a n/a n/a n/a n/a n/a n/a 7.5 n/a 7.5 n/a 5.9 (H) 1535 TDFL 80' 5" n/a (2000) 1545 TDFL 100' 5" n/a (2000) 1535 FL S-Drive 85' n/a (2000) 1545 FL S-Drive 105' n/a (2000) ' 3" n/a (2000) ' 3" 1620 n/a n/a n/a n/a n/a n/a n/a (2000) ' 3" n/a (2000) ' 6" n/a (2000) ' 6" n/a (2000) ' 3" n/a n/a ' 0" n/a n/a ' 0" n/a 11.3/ n/a ' 0" n/a 11.3/ n/a ' 0" n/a 11.3/ n/a

53 S P E C I F I C A T I O N S 1800 SERIES NOTE: ALL ANGLES AND MEASUREMENTS SHOWN ARE MACHINE LIMITS. THE MAX OP- ERATION ANGLE DEPENDS ON THE PRODUCT BEING CONVEYED, USUALLY LESS THAN 30DEG. DOWN TRANSPORT UP-OPERATION HP HYD (CU.IN.) MODEL # A B ANGLE C B ANGLE LENGTH WIDTH HP PTO HP ELEC HP GAS TOTAL WEIGHT BELT LENGTH 1800 SERIES 1814LP 29' 0" n/a (2000) 1835 TOP DRIVE 69' 5" n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 1835 FIELD LOADER 82' 11" n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 1845 FIELD LOADER 101' 4" n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a ' 9" n/a n/a 14.9 (2000) ' 9" n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a ' 9" n/a n/a 14.9 (2000) ' 9" n/a n/a 14.9 (2000) ' 8" n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a ' 8" n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a ' 8" n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a ' 8" n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a PITSTOP (NEW) 47' 0" n/a 7.5 n/a 6.2 (2000) 7.3

54 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L 2000 SERIES 7.4 NOTE: ALL ANGLES AND MEASUREMENTS SHOWN ARE MACHINE LIMITS. THE MAX OP- ERATION ANGLE DEPENDS ON THE PRODUCT BEING CONVEYED, USUALLY LESS THAN 30DEG. HP HYD (CU.IN.) LENGTH WIDTH HP PTO HP ELEC HP GAS MODEL # BELT TOTAL UP-OPERATION DOWN-TRANSPORT 2000 SERIES LENGTH WEIGHT A B ANGLE C B ANGLE SWING TRANSFER 41' 9" n/a n/a n/a 2035 TOP DRIVE 71' 3" n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a ' 4" n/a n/a n/a ' 4" n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a ' 4" n/a n/a n/a ' 4" n/a n/a n/a ' 4" n/a n/a n/a ' 4" n/a n/a n/a ' 4" n/a 11.3/ n/a n/a ' 4" n/a 11.3/ n/a n/a ' 4" n/a 11.3/ n/a n/a ' 4" n/a 11.3/ n/a n/a ' 4" n/a n/a n/a

55 S P E C I F I C A T I O N S 7.2 BOLT TORQUE Checking Bolt Torque The tables shown below give correct torque values for various bolts and cap screws. Tighten all bolts to the torque specified in the chart unless otherwise noted. Check tightness of bolts periodically, using bolt torque chart as you guide. Replace hardware with the same strength bolt. ENGLISH TORQUE SPECIFICATIONS Bolt Torque* Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/ /8 1-1/4 1-1/2 Dry or Lubricated Threads per inch (Course/ Fine) Recommended Bolt Torque Area of Bolt Recommended Torque Grade 2 Grade 5 Grade S/S Coarse Fine Coarse Fine Coarse Fine Coarse Fine Coarse Fine Dry /28 Lubricated Dry / Lubricated Dry /24 Lubricated Dry /20 Lubricated Dry /20 Lubricated Dry / Lubricated Dry / Lubricated Dry / Lubricated Dry / Lubricated Dry / Lubricated Dry / Lubricated Dry / Lubricated Dry / Lubricated Sizes from 1/4 up are in ftlb. Established at 75% of yield strength of bolt given the cross sectional area. * Torque value for bolts and cap screws are identified by their head markings. NOTE: Torque figures indicated above are valid for non-greased or non-oiled threads and head unless otherwise specified. Therefore, do not grease or oil bolts or cap screws unless otherwise specified in this manual. When using locking elements, increase torque values by 5%. 7.5

56 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L 7.3 HYDRAULIC FITTING TORQUE The following sub sections indicate the procedure and required torque for install the following types of fittings: 1. Pipe Thread Swivel, NPT 2. Pipe Thread Straight, NPT 3. Four Bolt Split Flange 4. O-Ring Adjustable, ORB 5. O-Ring Straight, ORB Flare, JIC 7. Hose Stem * Refer to the appropriate section for the fittings you are installing HYDRAULIC PIPE THREAD FITTINGS, NPT ADAPTER UNIONS/FEMALE PIPE SWIVEL ENDS 1. Inspect components for damage or contamination. 2. Check for 30º female seat on male pipe end. 3. Lubricate assembly. 4. Align tube/hose to mating swivel allowing hand connection. To assure proper alignment, two to three turns of nut should be easily permitted. 5. Tighten swivel nut to recommended torque listed in the following table. Note: Ensure that the male pipe end to be assembled has been machined with the optional 30º female seat. A standard 45º chamfer will not seal properly. Assembly Torque, NPT Swivel Pipe Fittings (T.F.F.T. 2 for Tapered Pipe Only) 1 Pipe Adaptor Unions Tapered Pipe Pipe Size Ft. Lbs. Max Nm. Max Ft. Lbs. Max. Nm. Max. T.F.F.T. 2 (Turns) 1/ /4-1 3/4 3/ /4-1 3/4 1/ /2-1 1/2 3/ /2-1 1/ /2-1 1/2 1 1/ /2-1 1/2 1 1/ /2-1 1/ /2-1 1/2 1) Lubricated assembly. 2) T.F.F.T. turns from finger tight. This method of torquing involves turning nut the indicated number of flat shoulders past finger tight rather then using a torque wrench. NPTF Pipe Threads Method A. Installation Torque 1. Inspect components for damage or contamination. 2. Lubricate or apply compatible sealant to male pipe thread. 3. Screw fitting into port until hand tight. For shape fittings, take note of the intended alignment of the mating connectors. 4. For straight fittings, tighten to recommended torque listed in table. For shape fittings, approximately 1/2 turns should be made and then torque to the desired orientation without exceeding maximum recommended torque. Method B. Turns from Finger Tight Note: Due to the variety of factors which affect the turns method, the values indicated are approximate and should be used only for initial installation, by experienced installation personnel. 1. Inspect components for damage or contamination. 2. Lubricate or apply compatible sealant to male pipe thread. 3. Screw fitting into port and lightly wrench to seat threads. 4. Mark fitting and adjacent surface to indicate initial seating position. 5. For straight fittings, tighten using mean to maximum recommended T.F.F.T. listed in table. 6. For shape fittings, tighten to minimum T.F.F.T., and turn past to desired orientation. 7.6

57 S P E C I F I C A T I O N S 7. Mark final tightening position by extending the existing mark from the fitting to the adjacent surface O-RING FITTINGS, ORB 1. Inspect components for damage or contamination. 2. Back off locknut from washer. 3. Lubricate O-ring and threads with light oil or system fluid, install O-ring in groove on the fitting. 4. Screw stud into the O-ring port until the washer fully bottoms out on face of the port FOUR BOLT SPLIT FLANGE 1. Inspect components for damage or contamination. 2. Install correct O-ring in flange groove. 3. Lubricate O-ring and bolt threads. 4. Align flange and clamp halves to port. 5. Install bolts, hand tighten evenly to seat O-ring on port face. 6. Gradually tighten bolts in equal increments, alternating in a diagonal pattern, to recommended torque listed in following table. 5. Position the fitting as required by backing out (ccw) up to one turn maximum. 6. Maintain fitting orientation while tightening locknut to recommended torque listed in the following table. Assembly Torque, SAE J Light Duty Stud Ends (Ref. SAE J514 Tube fittings and Port Plugs) 1 Tube Size Thread Size Nm.Max Ft. Lbs. -3 3/ / / / / / / / / / / / ) Lubricated assembly. Assembly Torque, 4 Bolt Flange 1 Dash Size Flange Size Bolt Size Ft. Lbs Nm. -8 1/2 5/16-18X1-1/ /4 3/8-16X1-1/ /8-16X1-1/ /4 7/16-14X1-1/ /2 1/2-13X1-1/ /2-13X1-1/

58 G R A I N C O N V E Y O R O P E R A T O R S M A N U A L O-Ring Port Straight Stud Ends 1. Inspect components for damage or contamination. 2. Lubricate O-ring and threads with light oil or system fluid, install O-ring in groove on the fitting. 3. Screw stud into the O-ring port and tighten to recommended torque listed in the previous table Method B. Flats from Finger Tight 1. Inspect components for damage or contamination. 2. Lubricate assembly. 3. Align tube/hose to mating fitting allowing hand connection. To assure proper alignment, two to three turns of nut should be easily permitted. 4. Finger tighten or lightly wrench nut to seat sealing surfaces FLARE FITTINGS 37 0, JIC Method A. Installation Torque 1. Inspect components for damage or contamination. 2. (Flare-O only) Install correct O-ring in Flare-O groove (if not installed). 3. Lubricate assembly. 4. Align tube/hose to mating fitting allowing hand connection. To assure proper alignment, two to three turns of nut should be easily permitted. 5. Tighten tube nut to torque listed in the following table. NOTE: Only use flats from finger tight if torque method is not possible. 7.8 Assembly Torque, 37 0 Tube Fittings 1 Tube Thread 37 0 Tube/ Swivel Nut Flare-O Tube/ Swivel Nut Size Size Ft. Lbs. Nm. Ft. Lbs. Nm. -2 5/ / / / / / / / / / / / / ) Lubricated assembly. 5. Mark nut and adjacent fitting surface to indicate initial seating position. 6. Finish tightening nut by turning the appropriate F.F.F.T. as indicated in the following table. 7. Mark final tightening position on fitting by extending the existing mark from the nut to the adjacent fitting surface. Flats From Finger Tight Installation Method Tube Nut F.F.F.T. Flare-O Tube Nut F.F.F.T. Swivel Nut F.F.F.T. Flare-O Swivel Nut F.F.F.T. Tube Straight Size Thread Size -2 5/ / / / / / / / / / / / / ) Recommended for use only when installation by torque method is not practical.