KSI JD Air Cart Owner's manual

JDAirCart:ConveyorLowProfile
Owner/Operator’s Manual

Owner/Operator’s Manual
Revision Date April 12, 2023
Prepared By:
KSi
2345 U Road
Sabetha, KS 66534
Office Telephone: [phone]

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This Page Left Blank Intentionally.

Table of Contents
1 - INTRODUCTION.....................................................................................................1
SAFETY 1ST .......................................................................................................................................... 1
GENERAL INFORMATION..................................................................................................................... 2
2 –LIMITED WARRANTY.........................................................................................3
3 –SAFETY INFORMATION .....................................................................................5
WHY IS SAFETY IMPORTANT? .......................................................................................................... 5
SIGNAL WORDS.................................................................................................................................... 5
GENERAL SAFETY STATEMENTS......................................................................................................... 6
EMERGENCY SHUTDOWN .................................................................................................................... 8
PINCH POINTS...................................................................................................................................... 8
SHIELDS AND GUARDS ......................................................................................................................... 8
BEWARE OF ELECTRICAL HAZARDS................................................................................................... 8
PERSONAL PROTECTIVE EQUIPMENT (P.P.E.)................................................................................... 9
OPERATOR QUALIFICATIONS............................................................................................................ 10
4 –INSTALLING SAFETY SIGNS...........................................................................11
5 –INSTALLATION ...................................................................................................13
ASSEMBLY OF CONVEYOR BELT....................................................................................................... 13
TRACKING THE BELT......................................................................................................................... 14
INSTALLATION ................................................................................................................................... 15
INSTALLING CONVEYOR.................................................................................................................... 18
CONVEYOR BELT REPLACEMENT..................................................................................................... 42
6 –OPERATION..........................................................................................................46
OPERATION RECOMMENDATIONS..................................................................................................... 46
EMERGENCY SHUTDOWN .................................................................................................................. 46
STARTUP AND BREAK-IN................................................................................................................... 46
CONVEYOR OPERATION .................................................................................................................... 47
7 –MAINTENANCE ...................................................................................................50
BELT ADJUSTMENT............................................................................................................................ 50
BELT CARE ........................................................................................................................................ 50
LUBRICATION..................................................................................................................................... 50
8 –TROUBLESHOOTING.........................................................................................51
HYDRAULIC SCHEMATIC................................................................................................................... 53
9 –PARTS.....................................................................................................................54

HOW TO ORDER PARTS ..................................................................................................................... 54
CONVEYOR SECTION ......................................................................................................................... 55
CONVEYOR TAIL................................................................................................................................ 57
10 –SPECIFICATIONS..............................................................................................59
CAPACITY........................................................................................................................................... 59
DRIVE UNIT........................................................................................................................................ 59
BELT................................................................................................................................................... 59
SPEED ................................................................................................................................................. 59
WEIGHTS............................................................................................................................................ 59
11 –BOLT TORQUE SPECS.....................................................................................60

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KSi 1612 LO-PRO CONVEYOR
USER'S MANUAL
1 - Introduction
Document Scope and purpose, and general responsibilities.
hank you for purchasing your new JD Air Cart: Lo-Profile conveyor from KSi Conveyors. We are
pleased to have you as a customer, and hope you will enjoy many years of productive service from
our products and staff.
Please readandunderstandthismanualbeforeoperatingthe equipment. Payspecial attentiontothesafety
information to protect yourself from harm. If you need information beyond what can be found in the manual,
please give our friendly staff a call at 888 KSI-CONV.
Safety 1st
Replace missing guards and shields FREE OF CHARGE!
KSi Conveyors are built to provide many years of dependable service to our customers through durable
craftsmanship.
One of the most important aspects of KSi engineering is its SAFETY 1st design throughout all product lines.
At KSi, safety is NO ACCIDENT!
That is why KSi has implemented its SAFETY 1st program. Should you ever need guards, shields, safety
decalsorowner/operatormanuals,simplycontactKSiandwewillsupplyyouwiththemFREEOFCHARGE!
If you need any of the above listed safetyitems or have safetyquestions, please contact KSi:
454 N State Route 49
Cissna Park IL 60924
Phone: [phone]
888-574-2668
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General Information
A. KSi reserves the right to improve its product whenever possibleand practical to do so. Wereserve
the right to change, improve, and modify products at any time without obligation to make changes,
improvements, and modifications on equipment previously sold.
B. When receiving merchandise, it is important to check the quantity of parts and their descriptions
with the packing list enclosed with each package. All claimsfor freight damage or shortage must
be made with the consignee within ten (10) days from the date of the occurrence of freight
damage. The consignee should accept the shipment after noting the damage or loss.
C. KSi does notmake any guarantees on self-cleanout or the cross contamination of seed of any kind
for their conveyors. Manual cleanout will be required.

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2 – Limited Warranty
KSi Conveyors 2 Year Limited Warranty
What Does This Warranty Cover?
KSi will warranty our equipment to be free from defects in material and workmanship under normal
usage and conditions.
What Does This Warranty Not Cover?
The warranty does not cover equipment that has been damaged by:
Normal wear and tear;
Misuse, abuse, or accident;
Failure to follow the operating instructions or maintenance protocols that we provided;
Any improper or unauthorized repairs or modifications to the equipment; or
Fire, flood, "acts of God,” or other contingencies beyond our control.
How Long Does the Coverage Last?
The warranty period for new equipment lasts for 24 months after the delivery date.
What Will We Do to Correct Problems?
KSi will repair or replace the equipment covered by this warranty at no charge. Service trip and travel
expenses will incur additional charges.
How Do You Get Service?
If something goes wrong with your equipment, call your Dealer or KSi Conveyors Parts &
Services. Your dealer or KSi will ask for the equipment’s serial number and a description of
the problem. KSi will determine whether the equipment is covered under warranty.
If the problem can be resolved by providing a replacement part, your dealer or KSi will ship or
deliver the part. Expedited services will incur additional charges. You may be required to
return the defective equipment.
If the problem requires a service call, your dealer or KSi will schedule a service visit at a
mutually convenient time. Expedited services will incur additional charges.
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You will be invoiced for any service or parts provided if we determine that the equipment is
not covered under this warranty or the problem was due to one of the disqualifying causes in
the section entitled “What Does This Warranty Not Cover” on page 3.
What Will KSi Not Do?
KSi will not be liable for any amount that exceeds the amount you paid for the Equipment. However
arising, we will not be liable for:
Expenses incurred without our written authorization;
Direct, indirect, incidental or consequential damages, such as the loss of anticipated profits or
benefits;
Loss or cross contamination of any seed, treatment fluid, or other materials used with the
equipment; or
Modifications or erection defects that create structural or storage quality problems.
We make no warranty of merchantability or
fitness for a particular purpose.
How Does State Law Relate to This Warranty?
This warranty gives you specific legal rights, and you may also have other rights, which vary from
state to state.
Who is Covered?
Only the original end user of the product is covered by this Warranty.

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3 – Safety Information
Tips for safe operation of KSi conveyors
This Safety Alert symbol means
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED
The Safety Alert symbol identifies important safety messages on KSI conveyors and in the
manual. When you see this symbol, be alert to the possibility of personal injury or death.
Follow the instructionsin the safetymessage.
Why is SAFETY important?
The Three Best Reasons
Accidents Disable and Kill
Accidents Cost $$
Accidents Can be Avoided
Signal Words
Note the use of signal words Danger, Warning and Caution with the safetymessages. The appropriate
signal word for eachmessage has been selected using the following guidelines:
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.
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, mayresult in minor or moderate
injury. It may also be used to alert against unsafe practices.
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General Safety Statements
1. KSi’s principal concern is your safety and the safety of others associated with seed handling
equipment. We want to keep you as a customer. This manual is to help you understand safe
operating procedures and some problems which may be encountered by the operator and other
personnel.
2. As the owner and/or operator, it is your responsibility toknow what requirements, hazards, and
precautions exist, and to inform all personnel associated with the equipment or that are in the area.
Safety precautions may be required from the personnel. Avoid any alteration to the equipment.
Such alterations may produce a very dangerous situation, where serious injury or death may occur.
3. This equipment shall be installed in accordance with the current installation codes and applicable
regulations which should be carefully followed in all cases. Authorities having jurisdiction shouldbe
consulted before installations are made.
4. Untrained operators subject themselves and others to the possibility of serious injury or death.
NEVER ALLOW untrained personnel to operate this equipment.
5. Keep children and other unqualified personnel out of the working area at all times.
6. NEVER start equipment until ALL persons are clear of the work area.
7. Be sure ALL operators are adequately rested and prepared to perform all functions of operating
this equipment.
8. Keep hair, loose clothing, and shoestrings away from rotating and moving parts. Never wear
loose-fitting clothing when working around equipment.
9. NEVER allow any person intoxicated or under the influence of drugs or alcohol to operate the
equipment.
10. NEVER allowanyone inside a bin, truck, or wagon which is being loaded or unloaded. Flowing
grain can trap and suffocate in seconds.
11. Make sure someone is nearby who is aware of the proper shutdown sequencein the event of an
accident or emergency.
12. NEVER work alone.
13. ALWAYSthink before acting. NEVER act impulsively around the equipment.
14. Make sure ALL equipment is locked in position before operating.

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15. Keep hands and feet away from the conveyor intake and other moving parts.
16. NEVER attempt to assist machinery operation or to remove trash from the equipment while in
operation.
17. Use caution not to hit the conveyor when positioning the fill conveyor.
18. Use caution not to hit overhead electrical lines when positioning the conveyor.
19. NEVER drive, stand, or walk under the equipment.
20. Use caution not to hit the conveyor when positioning the load.
21. Use ample overhead lighting during periods of low light, such as after sunset, to light the work area.
22. ALWAYS lockout and tagout ALL power sources tothe equipment before beginning adjustments
or repairs.
23. Keep the area around intakefree of obstacles such as electrical cords, blocks, etc. that might trip
workers.
24. Components of this equipment have sharp edges which can scrape and/or cut an operator.
25. A moving conveyor can sever an operator’s limb or even kill.

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Emergency Shutdown
1. If you have to immediately shutdown the conveyor under the load, be sure to disconnect
and lockout the power source.
2. Remove as much grain from the hopper and the conveyor that you can before restarting
3. Never attempt to restart the conveyor when it isfull.
4. Whenasmuchgrainaspossiblehasbeenclearedfromthehopperandtheconveyor,reconnect
the power source and clear the remaining grain gradually.
Pinch Points
A pinch point is any constricting area of the equipment which could cause injury if any
body part should enter such place.
1. Components of this equipment have sharp edges which can scrape and/or cut an operator.
2. A moving conveyor can sever an operator’s limb or even kill.
Shields and Guards
1. Always keep all shields and guards in place during operation.
2. Missing shields for guards can be replacedforfree by contacting KSi.
Beware of Electrical Hazards
Electricity can kill! Use extreme caution around electrical components.
Have your electric company check the transformer and lead wires to be sure that they are large
enough to handle the additional load of the motor.
Electrical wiring should be done by a qualified electrician and all components shall comply with applicable
provisions of National Fire Protection Association Standard NFPA No. 70, American National Standard
Inst. ANSI-C1 or with the requirements of the authority having local jurisdiction. KSi assumes no
responsibility for the electrical wiring used with this machine.
KSi will not be liable for failure of the equipment due to poor or improper electrical power installation.
Wires which are too small deliver insufficient voltage causing the motor to overload or burn out.
Improper or inadequate wiring can kill or cause fires.
All electrical devices used on this machine shall be arranged to operate in a “fail safe” manner, that is, if
power failureor failure of device occurs, a hazardous condition must not result. This means, themachine
must not restart byitself after a power failure etc. when power returns.
A means to lock out power must be provided at time of installation to prevent inadvertent starting of the
equipment.

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Personal Protective Equipment (P.P.E.)
1. The proper personal protective equipment should be worn at all time.
2. Always wear safety glasses when in the work area.
3. Properfootwear should be worn during the installation process, as well as
any maintenance functions.
4. It is recommendedto wear protective gloves during the installation process,
as well as any maintenance functions. It is recommended to wear them also
when removing any covers.
5. The use of fall protection is required at all times during the installation
process, as well as maintenance functions.
6. The operator should never wear jewelry.
7. Loose-fitting clothes should not be worn aroundmoving parts onconveyors
or equipment. Any clothing that becomes loosened should be tucked in
tightly.
8. Loose or dangling shoe strings should betucked in.
9. Long hair should be tied up and/or back.

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Operator Qualifications
1. The User/Operator must be competent and experienced to operate the equipment. Anyone who works
around conveyors must have good common sense in order to be qualified. These persons must also
know andmeet all other qualifications, such as:
A. Any person who has not read and/or does not understand all operation and safety procedures
is not qualified to operate any conveyor system.
B. Certain regulations apply to personnel operating power machinery. Personnel underthe age of
18 years may not operate power machinery, including conveyors. It is your responsibility, as
owner and/or supervisor, to know what these regulations are in your area or situation.
C. Unqualified or incompetent persons are to remain out of the work area.
D. O.S.H.A. (Occupational Safety & Health Administration) regulations state:
“At the time of initial assignment, and at least annually thereafter, the employer shall
instruct every employee in the safe operation and servicing of all equipment with which the
employee is, or will be, involved.” (FederalOccupational Safety & Health Standards for
Agriculture. Subpart D, Section 1928.57 (a) (6).
2. As a requirement of OSHA, it is necessaryfor the employer to train the employee in the safe operating
and safety procedures for this conveyor. We have included this sign-off sheetfor your convenience
and personalrecord keeping. All unqualified persons are to stay out of the work area at all times. It is
recommended that another qualified person who knows the shutdown procedure is in the area at all
times in the event of an emergency. A person who has not read this manual or doesn’t understand all
operating and safety instructions is not qualified to operate this machine.
Date
Employee’s Name (printed)
Employee’s Signature
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

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4 – Installing Safety Signs
Location and installation of Safety signage
he safety decals listed below are included with the conveyor. The following pages show the
location of the decals on the conveyor. Inspect all decals and replace any that are worn, illegible,
or missing. Contact your dealer or thefactory to order replacement decals.
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KS-0035

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KS-0020

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5 – Installation
Assembly of Conveyor Belt
Squaring One End of Belt
Lay a framing square along a straight edge of the belt to make a cut line on the back side of the belt. Cut
belt along this line using a utility knife. If the belt has uneven edges, create an average centerline, and
squareoff of this line. A clean, straight, square cut is required for the belt to run true on the pulleys.
Installing Belt Splice
1. Center and press the fastener strip on the belt.
2. Press the Application Tool on the center of the fastener strip with the cam lever in the “up” position.
3. Lower the cam lever. Strike staple driver on each staple until staple clinches on Application Tool anvil.
4. Raise cam leverand move tool to outer edge of belt.
5. Clinch staples. Repeat until all staples arecomplete.
6. Place the splice over a piece of flat steel and clinch each staple with a hammer. Turn belt over and
peen staple endsflush with surface of fastener strip.
7. Bend fastener strips until they break apart.
Installing Belt into the Conveyor
1. Remove the conveyor tail end door assembly.
2. Slide a fish tape from the discharge end to the tail end of the conveyor. Pull a rope with a belt splice
back through the conveyor. Fasten the conveyor to the rope splice, and pull the belt into the top of the
conveyor with the rope.
3. Using the fish tape, pull the bottom side of the belt through the conveyor. Make sure the belt is free of
any twists before pulling it in.
4. Check to see that the idler is all the way forward (toward the discharge end).
5. Pull the belt up tight at the discharge end and cut off the excess length so that there is ½” overlap after
the end is squared.
6. Follow the procedure above for install the second belt splice.
7. Insert the hinge pin. Crimp the pin washers on the ends of the pin using pliers.
8. Tighten the belt tensioning bolts to 50 in.-lbs., so that each side is adjusted equally.
9. Re-assemble the tail end door assembly.
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Tracking the Belt
1. Basic rule: The belt moves toward the end of the roller that it contacts first.
2. Rollers must be square with the housing and parallel to each other.
3. Belt tension must be great enough to prevent slippage.
CAUTION: Make sure everyone is clear of the machine before running.
4. Run the conveyor. Check to see that the belt runs centered on the drive roller. Turn off the machine.
Adjust drive roller as necessary.
WARNING: Do not run the machine while adjusting. Failure to heed may result in personal
injury or death.
5. To adjust the drive roller, loosen the four nuts on the bearing holder plate, and the jam nut on the
treaded adjuster. Retighten after adjusting is complete.
CAUTION: Make sure everyone is clear of the machine before running.
6. Run the machine for two minutes. Make sure belt runs centered on drive pulley.
7. Open the tail end door to view the idler.
8. Run the machine. Check to see that the belt is running centered on the idler roller. Turn themachine
off.
WARNING: Do not run the machine while adjusting. Failure to heed may result in personal
injury or death.
9. If adjustment is necessary, adjust the tensioning bolts on the idler housing to 50 in.-lbs. torque
10. Check adjustment by running the machine. Make sure belt runs centered on idler pulley. The clearance
between the belt and thehousing should be the same on both sides.
11. Close the tail end door when complete.