AGI BATCO 1800 Series Page 46 Assembly Manual Download | Manualshive

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46

P1512180 R0

2.4.3 Install the Battery and Fuel Tank

Installing the battery and fuel tank requires the completion of the following tasks:

Step

Task

1

Install the Fuel Tank

2

Install the Battery

Figure 35.

Battery and Fuel Tank Overview

1

2

PITSTOP DRIVE KITS ASSEMBLY MANUAL –

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Summary of Contents for BATCO 1800 Series

Page 1: ...h or property damage Keep manual for future reference Part Number P1512180 R0 Revised December 2019 Pitstop Drive Kits Assembly Manual Original instructions This manual applies to AGI BATCO 1800 2400...

Page 2: ...2 P1512180 R0 PITSTOP DRIVE KITS ASSEMBLY MANUAL...

Page 3: ...nstall the Motor Mounts and Rails 20 2 2 3 Install the Guard Mounting Brackets 21 2 2 4 Install the Motor 22 2 2 5 Install the Pulleys Drive Belts and Tensioning Bolt 23 2 2 6 Install the Drive Belt G...

Page 4: ...ay result in property damage 1 2 General Product Safety It is the owner operator and maintenance personnel s responsibility to read and understand all safety instructions safety decals and manuals and...

Page 5: ...6 Guards Safety Keep guards in place Do not operate with guard removed Do not walk on step on or damage guards Lock out power before removing a guard Ensure all guards are replaced after performing ma...

Page 6: ...Safety Power Source Electric motors and controls shall be installed and serviced by a qualified electrician and must meet all local codes and standards A magnetic starter should be used to protect you...

Page 7: ...l or wood as a backstop when searching for hydraulic leaks and wear proper hand and eye protection Check all hydraulic components are tight and in good condition Replace any worn cut abraded flattened...

Page 8: ...could result in serious injury or death Inflate tires to the manufacturer s recommended pressure Tires should not be operated at speeds higher than their rated speed Keep wheel lug nuts tightened to m...

Page 9: ...mes Replace safety decals that are missing or have become illegible See decal location figures that follow Replaced parts must display the same decal s as the original part Replacement safety decals a...

Page 10: ...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 tak...

Page 11: ...P1512180 R0 11 Figure 2 Electric Top Drive Safety Decal Locations behind guard Figure 3 Hydraulic Top Drive Safety Decal Locations PITSTOP DRIVE KITS ASSEMBLY MANUAL 1 SAFETY...

Page 12: ...rsonnel must be kept outside of the work area Do not modify the equipment Keep in good working order If the manual guards or decals are missing or damaged contact factory or representative for free re...

Page 13: ...sprockets Do not operate with any guard removed or modified Keep guards in good working order Shut off and remove key or lock out power source before inspecting or servicing machine ENTANGLEMENT HAZA...

Page 14: ...d can cause serious injury if it penetrates the skin If it does see a doctor immediately Relieve system pressure before repairing adjusting or disconnecting Wear proper hand and eye protection when se...

Page 15: ...te winch handle until cable has light tension when in towing position Do not lubricate winch brake discs Inspect lift cable periodically replace if damaged Inspect cable clamps periodically tighten if...

Page 16: ...Decals continued Part Number Description P1513052 To prevent damage wheels must be free to move when raising or lowering equipment When equipment is positioned chock all wheels NOTICE 1 SAFETY PITSTO...

Page 17: ...Hose Item Description 1 Lift Control 2 90 Swivel 6 ORB to 1 2 FPT 3 Hex Nipple 1 2 PT 4 1 2 Ball Valve 5 Tee Swivel 1 2 FEM 6 3 8 X 2 Hose 1 2 MPT to 1 2 MPT PC 7 Swivel 3 8 MPT X 1 2 FPT 8 3 8 X 3 7...

Page 18: ...sk 1 Assemble the Motor Mounts 2 Install the Motor Mounts and Rails 3 Install the Guard Mounting Brackets 4 Install the Motor 5 Install the Pulleys Drive Belts and Tensioning Bolt 6 Install the Drive...

Page 19: ...the Motor Mounts Figure 6 Step 1 Assemble the Motor Mounts X2 Item Description Quantity per mount 1 Bushing 4 2 Motor Mount 1 3 3 8 X 1 Hex Flange Bolt 4 4 Bushing Retainer 4 1 2 4 3 PITSTOP DRIVE KI...

Page 20: ...d Rails Figure 7 Step 1 Install the Motor Mounts and Rails Item Description 1 5 16 X 1 Screw provided with collar 2 1 Collar 3 Assembled Motor Mounts 4 Motor Mount Rail Figure 8 Visual Check 2 1 4 2 1...

Page 21: ...unting Brackets Figure 9 Step 1 Install the Guard Mounting Brackets Item Description 1 3 8 Hex Flange Nut 2 Guard Mount Bracket 3 3 8 X 1 Hex Flange Bolt Figure 10 Visual Check 2 2 3 3 1 2 1 3 3 PITST...

Page 22: ...512180 R0 2 2 4 Install the Motor Figure 11 Step 1 Install the Motor Item Description 1 Motor 2 3 8 Lock Nut 3 3 8 Flat Washer 4 3 8 X 2 Hex Bolt GR 8 4 3 1 2 2 ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MA...

Page 23: ...elts and Tensioning Bolt Figure 12 Step 1 Installing the Pulleys Belts and Tensioning Bolt Item Description 1 3 4 Hex Nut 2 3 4 X 5 Tensioning Hex Bolt GR8 3 Drive Belts 4 Pulley 5 3 8 X 2 Key 3 4 5 2...

Page 24: ...1512180 R0 2 2 6 Install the Drive Belt Guard Figure 13 Step 1 Install the Drive Belt Guard Item Description 1 3 8 X 1 Hex Flange Bolt 2 Drive Belt Guard 1 2 2 ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MAN...

Page 25: ...512180 R0 25 2 2 7 Install the Shaft Guard Figure 14 Step 1 Install the Shaft Guard Item Description 1 5 8 Nylock Nut 2 Shaft Guard Plug 3 Shaft Guard 1 3 2 PITSTOP DRIVE KITS ASSEMBLY MANUAL 2 ASSEMB...

Page 26: ...sk 1 Install the Hydraulic Pump 2 Install the Hydraulic Tank 3 Install the Hydraulic Fittings into the Flow Controller 4 Install the Hoses Note The hoses are not shown in this image Refer to Section 2...

Page 27: ...l the Sprockets Keys and Chain Couplers 2 Install the Hydraulic Pump Mount 3 Install the Hydraulic Pump 4 Install the Hydraulic Pump Side Guards Figure 16 Hydraulic Pump Overview Note The hydraulic pu...

Page 28: ...n Couplers Item Description 1 1 4 Sprocket 2 1 4 X 1 1 2 Rectangle Key 3 1 1 4 Sprocket 4 Chain Coupler 5 5 8 Lock Nut GR 8 remove from bearing1 1 These lock nuts are used in the following step of thi...

Page 29: ...nstall the Hydraulic Pump Mount Item Description 1 Hydraulic Pump Mount 2 5 8 Lock Nut GR 8 removed from bearing1 1 These lock nuts were removed in the previous step of this procedure 1 2 PITSTOP DRIV...

Page 30: ...Hydraulic Pump and Fittings Item Description 1 90 Swivel 1 2 FPT to 8 ORB 2 3 8 Lock Nut GR 8 3 3 8 Flat Washer 4 Hydraulic Pump 5 90 Swivel 1 2 FPT to 10 ORB 6 3 8 X 1 1 2 Hex Bolt GR 8 1 2 6 4 5 3 2...

Page 31: ...1512180 R0 31 Figure 20 Step 4 Install the Hydraulic Pump Side Guard on both sides Item Description 1 Tek Screw 2 1 4 Flat Washer 3 1 4 Plastic Sheet 2 1 3 PITSTOP DRIVE KITS ASSEMBLY MANUAL 2 ASSEMBL...

Page 32: ...2 Install the Hydraulic Tank Figure 21 Step 1 Install the Hydraulic Tank Step Task 1 90 Swivel 1 2 FPT to 8 ORB Swivel 2 32 Clamp 3 Hydraulic Tank 4 3 4 Hose Clamp 1 4 3 2 2 ASSEMBLY PITSTOP DRIVE KI...

Page 33: ...stalling 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 1 Flow Controller...

Page 34: ...wing illustration to correctly install the hoses Figure 23 Installing the Hoses Step Task 1 1 2 X 9 6 Hose 1 2 MPT X 1 2 MPT PC 2 1 2 X 7 6 Hose 1 2 MPT X 1 2 MPT 3 3 4 X 3 Hose 1 2 MPT 4 Hose Clamp 2...

Page 35: ...equires the completion of the following tasks Step Task 1 Install the Drive and Battery Mounts 2 Install the Motor and Gearbox 3 Install the Battery and Fuel Tank 4 Install the Guards Figure 24 Gas Dr...

Page 36: ...e and battery mounts requires the completion of the following tasks Step Task 1 Prepare the Motor and Gearbox Mount 2 Install the Motor and Gearbox Mount 3 Install the Battery Mount Figure 25 Motor an...

Page 37: ...180 R0 37 Figure 26 Step 1 Prepare the Motor and Gearbox Mount Item Description Quantity 1 1 Bushing 6 2 3 8 Flanged Hex Bolt GR 5 6 3 Bushing Retainer 6 3 2 1 PITSTOP DRIVE KITS ASSEMBLY MANUAL 2 ASS...

Page 38: ...2 Install the Motor and Gearbox Mount Item Description 1 1 Collar 2 5 16 X 1 Screw 3 Motor Mount Rail Motor and Gearbox Mount Figure 28 Step 3 Install the Battery Mount 2 1 4 3 2 1 2 1 2 ASSEMBLY PITS...

Page 39: ...P1512180 R0 39 Item Description 1 3 8 Flanged Hex Bolt GR 5 2 Battery Mount PITSTOP DRIVE KITS ASSEMBLY MANUAL 2 ASSEMBLY...

Page 40: ...n of the following tasks Step Task 1 Install the Guard Mounting Brackets 2 Install the Motor 3 Install the Gearbox 4 Install the Drive Pulleys Belts and Tensioning Bolts 5 Install the Motor Pulley Clu...

Page 41: ...180 R0 41 Figure 30 Step 1 Install the Guard Mounting Brackets Item Description 1 3 8 Lock Nut GR 8 2 Mounting Bracket 3 3 8 X 1 Hex Flange Bolt GR 8 1 3 2 2 3 PITSTOP DRIVE KITS ASSEMBLY MANUAL 2 ASS...

Page 42: ...Bolt GR 8 2 3 8 Flat Washer 3 Motor Slide Plate 4 3 8 Lock Nut GR 8 A Motor Base PLate1 1Motor type varies Ensure the motor s base plate is inserted between the slide plate and washer as indicated by...

Page 43: ...180 R0 43 Figure 32 Step 3 Install the Gearbox Item Description 1 Breather 2 Gear Box 4190 2 1 1 5 SHAFT 3 1 2 Flat Washer 4 1 2 X 1 1 2 Hex Bolt GR 8 2 1 3 4 PITSTOP DRIVE KITS ASSEMBLY MANUAL 2 ASSE...

Page 44: ...ep 4 Install the Drive Pulleys Belts and Tensioning Bolts Item Description 1 3 4 X 5 Tensioning Hex Bolt GR 8 2 3 8 X 2 Key 3 4 Double Pulley 4 12 Double Pulley 5 Belts 1 5 4 2 3 2 2 ASSEMBLY PITSTOP...

Page 45: ...he Motor Pulley Clutch and Belts Item Description 1 7 16 X 3 Hex Bolt GR 8 2 7 16 Lock Washer 3 Electric Clutch 4 Belts 5 1 4 X 3 Key 6 6 Double Pulley 1 1 2 Bore 7 1 4 X 1 1 2 Key 4 2 1 5 7 3 6 PITST...

Page 46: ...d Fuel Tank Installing the battery and fuel tank requires the completion of the following tasks Step Task 1 Install the Fuel Tank 2 Install the Battery Figure 35 Battery and Fuel Tank Overview 1 2 2 A...

Page 47: ...36 Step 1 Install the Fuel Tank Item Description 1 Fuel Hose and Clamps 2 Fuel Tank 3 7 16 Lock Nut 4 32 Clamp 5 Fuel Tank Mounting Bracket 6 7 16 X 1 Hex Bolt GR 8 3 5 2 4 6 1 PITSTOP DRIVE KITS ASSE...

Page 48: ...48 P1512180 R0 Figure 37 Step 2 Install the Battery Item Description 1 Battery Clamp 2 Battery 3 3 8 Flat Washer 4 3 8 Lock Nut 3 2 4 1 2 ASSEMBLY PITSTOP DRIVE KITS ASSEMBLY MANUAL...

Page 49: ...ll the Guards Installing the guards requires the completion of the following tasks Step Task 1 Install the Motor Guard 2 Install the Drive Belt Guard Figure 38 Guards Overview 1 2 PITSTOP DRIVE KITS A...

Page 50: ...grate on the gearbox and motor guard has been removed for illustration purposes Item Description 1 3 8 X 1 Hex Bolt GR 5 2 Gearbox and Motor Guard 3 Guard Mounting Bracket 4 3 8 Flat Washer 5 3 8 Loc...

Page 51: ...P1512180 R0 51 Figure 40 Step 2 Install the Drive Belt Guard Item Description 1 3 8 X 1 Hex Bolt GR 5 2 Drive Belt Guard 1 2 PITSTOP DRIVE KITS ASSEMBLY MANUAL 2 ASSEMBLY...

Page 52: ...tep Task 1 Install the Hydraulic Motor 2 Install the Flow Controller 3 Install the Hydraulic Fittings into the Lift Control 4 Install the Hoses Note The hoses are not shown in this image Refer to Figu...

Page 53: ...rockets Keys and Chain Couplers 2 Install the Hydraulic Motor Mount 3 Install the Hydraulic Motor and Fittings 4 Install the Hydraulic Motor Side Guards Figure 42 Hydraulic Motor Overview Note The hyd...

Page 54: ...n Couplers Item Description 1 5 8 Lock Nut GR 8 remove from bearing1 2 1 4 X 1 1 2 Rectangle Key 3 Sprocket 4 Chain Coupler 5 1 4 X 1 Woodruff Key 1 These lock nuts are used in the next step of this p...

Page 55: ...stall the Hydraulic Motor Mount Item Description 1 5 8 Lock Nut GR 8 removed from bearing1 2 Hydraulic Motor Mount 1 These lock nuts were removed in the previous step of this procedure 2 1 PITSTOP DRI...

Page 56: ...tings Item Description 1 1 2 X 2 Hex Bolt GR 8 2 1 4 X 1 Woodruff Key 3 1 2 Swivel straight 4 1 2 Check Valve no reverse flow 5 1 2 PT Hex Nipple 6 1 2 10 ORB X FPT 7 1 2 Lock Nut GR 8 8 Hydraulic Mot...

Page 57: ...512180 R0 57 Figure 46 Step 4 Install the Hydraulic Motor Side Guard on both sides Item Description 1 Tek Screw 2 1 4 Flat Washer 3 1 4 Plastic Sheet 2 3 1 PITSTOP DRIVE KITS ASSEMBLY MANUAL 2 ASSEMBL...

Page 58: ...ller requires the completion of the following tasks Step Task 1 Install the Flow Controller Bracket 2 Install the Hydraulic Fittings into the Flow Controller 3 Install the Flow Controller Figure 47 Fl...

Page 59: ...2180 R0 59 Figure 48 Step 1 Install the Flow Controller Bracket Item Description 1 7 16 Lock Nut GR 8 2 Flow Controller Bracket 3 7 16 X 1 Hex Bolt GR 8 3 2 1 PITSTOP DRIVE KITS ASSEMBLY MANUAL 2 ASSE...

Page 60: ...ure 49 Step 2 Install the Hydraulic Fittings into the Flow Controller Item Description 1 90 Swivel 1 2 PT 2 Flow Controller 3 Hex Nipple 1 2 PT 4 Tee Swivel 1 2 Fem 4 1 3 2 2 ASSEMBLY PITSTOP DRIVE KI...

Page 61: ...61 Figure 50 Step 3 Install the Flow Controller Item Description 1 1 4 X 3 Hex Bolt GR 8 2 Flow Controller with Hydraulic Fittings Installed 3 1 4 Lock Nut GR 8 1 2 3 PITSTOP DRIVE KITS ASSEMBLY MANUA...

Page 62: ...talling 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 1 90 Swivel 10 ORB...

Page 63: ...he Hoses Figure 52 Installing the Hoses Item Description 1 1 2 X 1 10 Hose 1 2 MPT to 1 2 MPT PC 2 1 2 X 6 7 Hose 1 2 MPT to 1 2 MPT PC A Supply In pressure B Supply Out return 2 1 B A PITSTOP DRIVE K...

Page 64: ...art incorporated into the Product is manufactured and sold to the Seller by a third party vendor such part is only warranted to the extent of the warranty given by that third party 4 This warranty doe...

Page 65: ...P1512180 R0 65 PITSTOP DRIVE KITS ASSEMBLY MANUAL 3 LIMITED WARRANTY...

Page 66: ...isted on the cover page in your message 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...

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