Honeywell Intelligrated IntelliSort WD 2.0 Maintenance Manual
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Honeywell Intelligrated IntelliSort WD 2.0 Maintenance Manual

Honeywell Intelligrated IntelliSort WD 2.0 Maintenance Manual

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IntelliSort WD 2.0
Maintenance Manual
Publication No. 29351003
March 11, 2021

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Summary of Contents for Honeywell Intelligrated IntelliSort WD 2.0

  • Page 1 IntelliSort WD 2.0 Maintenance Manual Publication No. 29351003 March 11, 2021...
  • Page 2 Honeywell customer and the customer's employees (or permitted assigns of each), which Honeywell originally disclosed with the sale of the Honeywell equipment in any form or by any means, electronic or mechanical, for any purpose, without the express written consent of Honeywell.

  • Page 3: Table Of Contents

    Table of Contents SAFETY INSTRUCTIONS ....................1 Introduction ......................1 For Your Safety ......................2 Standard Safety Conventions ................... 2 Safety Precautions ....................4 1.4.1 Guards and Guarding ..................4 1.4.2 Headroom ......................5 Controls ........................5 1.5.1 Control Stations ....................5 1.5.2 Safety Devices ....................
  • Page 4 Micro V-Belt Replacement ..................24 3.5.1 Micro V-Belt Removal ..................24 3.5.2 Micro V-Belt Installation ..................25 Carrier Roller Replacement ..................26 3.6.1 Carrier Roller Removal ..................26 3.6.2 Carrier Roller Installation ..................29 Wheel O-Band Replacement ...................32 Drive O-Band Replacement ..................35 Drive Hub Replacement ..................38 3.9.1 Drive Hub Removal ..................38 3.9.2...
  • Page 5 3.20 PTO Bearing Replacement ..................60 3.20.1 PTO Bearing Removal ..................60 3.20.2 PTO Bearing Installation ................61 3.21 PTO Roller Replacement ..................62 3.21.1 PTO Roller Removal ..................62 3.21.2 PTO Roller Installation ..................63 3.22 Idler Roller Replacement ..................64 3.23 Snub Roller Replacement ..................66 3.24 Return Roller Replacement ..................68 PREVENTIVE MAINTENANCE ..................71...
  • Page 6 Troubleshooting Chart .....................86 Troubleshooting Help ....................86 IntelliSort WD 2.0 | Maintenance Manual | 29351003 March 11, 2021...

  • Page 7: Safety Instructions

    Introduction These safety precautions are to be used as a guide to supplement the following: All other written information provided by Honeywell pertaining to the equipment. Plant and shop safety rules and codes. Federal and state safety laws, regulations, and codes.

  • Page 8: For Your Safety

    Safety Instructions Note: Emphasis is placed on the latest edition of the Occupational Safety and Health Standards, which is available from the Department of Labor, Washington, D.C. These standards (found in Part 1910, Title 29 of the Code of Federal Regulations) contain the current, general industry occupational safety and health regulations set forth by federal legislation.
  • Page 9 Safety Instructions Warning signs and labels posted on or near the equipment shall not be removed, painted over, or altered at any time. Reference: ANSI Z535.4. All safety devices, warning lights, and alarms associated with the conveyor system must be regularly tested (at least monthly) for proper operation and serviced as needed.

  • Page 10: Safety Precautions

    Safety Instructions Safety Precautions The success of any safety program depends primarily on the attitudes and training of the installation, maintenance, and operating personnel. The very nature of their work makes it necessary that they develop a complete and firsthand knowledge of each piece of equipment that is within their care.

  • Page 11: Headroom

    Safety Instructions When the equipment passes over a walkway, roadway, or work station, it is considered guarded by location if all moving parts are at least 8 ft (2.4 m) above the floor or walking surface or are otherwise located so that the employee cannot inadvertently come in contact with hazardous moving parts.

  • Page 12: Safety Devices

    Safety Instructions Equipment that would cause injury when started shall not be started until employees in the area are alerted by a signal, or by a designated person, that the equipment is about to start. When the equipment would cause injury and is automatically controlled or must be controlled from a remote location is started, an audible device shall be provided which can be clearly heard at all points along the conveyor where personnel may be present.

  • Page 13: Operation Safety Precautions

    Safety Instructions Emergency Stops and Restarts The controls shall be arranged so that, in case of emergency stop, manual reset or start at the location where the emergency stop was initiated shall be required of the conveyor(s) and associated equipment to resume operation. Before restarting the equipment that has been stopped because of an emergency, an inspection of the conveyor shall be made and the cause of the stoppage determined.

  • Page 14: Installation And Maintenance Safety

    Safety Instructions Conveyors shall not be newly installed, maintained, or serviced while in operation unless proper installation, maintenance, or service requires the conveyor to be in motion. In this case, personnel shall be made aware of the hazards and how the task may be safely accomplished.

  • Page 15: Lockout / Tagout Guidelines

    Safety Instructions Lockout / Tagout Guidelines Appropriate lockout and tagout policy and procedures shall comply with the Code of Federal Regulations, 29 CFR 1910.147 and the minimum safety requirements outlined in the current publication of the American National Standard Institute’s Control of Hazardous Energy - Lockout/Tagout and Alternative Methods (ANSI Z244.1).

  • Page 17: General Description

    General Description The IntelliSort® Wheel Divert (WD) features a modular design and uses powered wheels to divert product. The wheel diverts are integrated with high-speed belt conveyor that provides drive for each of the diverting mechanisms, with diverts located at points along the main-line sort belt conveyor. The IntelliSort WD is typically used to sort product onto gravity or powered take-away spur conveyors.

  • Page 18: Drive System

    General Description The IntelliSort WD integrates with a high-speed belt conveyor that provides drive for each of the diverting mechanisms. The design includes the divert mechanism in an easily replaceable drawer module. This allows maintenance to stock a complete spare assembly to minimize potential downtime and repair units on a bench.

  • Page 19: Maintaining The Intellisort Wd

    General Description Maintaining the IntelliSort WD Do not touch the rollers or belt while they are in motion. Keep clothing and jewelry away from the rollers or belt. Failure to follow this instruction may result in serious personal injury and/or equipment damage. The IntelliSort WD was designed for ease of maintenance.
  • Page 20 General Description Capacity • Minimum product size: 6-inch L x 4-inch W x 2-inch H • Minimum product weight: 2 lb • Cartons must be edge aligned to divert side of sorter belt and have relatively flat, stable bottoms Minimum Elevation Determined by drive unit.

  • Page 21: Service And Repair

    Service and Repair There may be occasions when various mechanical components must be replaced or repaired due to damage or wear. Like many other pieces of machinery, there are contributing factors that may lead to failure of components. These factors include runtime, products conveyed, preventive maintenance procedures in place, and overall care and cleaning.

  • Page 22: Preliminary Inspection

    Service and Repair Preliminary Inspection Prior to performing any maintenance there are certain things that should be checked regarding the entire conveyor system. • Make sure the clearance between the PTO and idler roller guards are less than inch. • The belt must be cut on a bias not to exceed a maximum of 4.8 degrees.

  • Page 23: Belt Tracking Adjustment

    Service and Repair Belt Tracking Adjustment Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.
  • Page 24 Service and Repair Apply the appropriate lockout/tagout procedures to remove all power and air from the conveyor section. Loosen the roller mounting bolts on both sides of the conveyor. Loosen the roller adjustment jam nuts on both sides of the conveyor. Adjust the roller adjustment bolts so that both roller mounting bolts are square and centered in the adjustment blocks.

  • Page 25: Return Roller Adjustment

    Service and Repair 3.2.2 Return Roller Adjustment Apply the appropriate lockout/tagout procedures to remove all power and air from the conveyor section. IntelliSort WD 2.0 | Maintenance Manual | 29351003 March 11, 2021...
  • Page 26 Service and Repair Loosen the return roller mounting bolts on both sides of the conveyor. Square the return roller on both sides of the conveyor. Tighten the return roller mounting bolts. Check for proper operation. See the Belt Conveyor Maintenance Manual for belt tracking procedure. IntelliSort WD 2.0 | Maintenance Manual | 29351003 March 11, 2021...

  • Page 27: Pto Roller Guard Adjustment

    Service and Repair PTO Roller Guard Adjustment Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.
  • Page 28 Service and Repair Adjust the PTO roller guard so that it is less than in from the PTO roller. Tighten the PTO roller guard mounting nuts. Check for proper operation. IntelliSort WD 2.0 | Maintenance Manual | 29351003 March 11, 2021...

  • Page 29: Micro V-Belt Tensioning

    Service and Repair Micro V-Belt Tensioning Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.

  • Page 30: Micro V-Belt Replacement

    Service and Repair Micro V-Belt Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.

  • Page 31: Micro V-Belt Installation

    Service and Repair 3.5.2 Micro V-Belt Installation Apply the appropriate lockout/tagout procedures to remove all power and air from the conveyor section. Route the micro V-belt around the drive pulley, driven sheaves, and tensioner. Tension the micro V-belt as described in the Micro V-Belt Tensioning section. Reinstall the side cover by inserting the four bolts that attach the side cover to the unit.

  • Page 32: Carrier Roller Replacement

    Service and Repair Carrier Roller Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.
  • Page 33 Service and Repair Remove the finger guards. Insert the roller tool on the roller O-band side of the unit and secure the tool to the side frame using the upstream pin. Disengage the upstream carrier roller from the unit. IntelliSort WD 2.0 | Maintenance Manual | 29351003 March 11, 2021...
  • Page 34 Service and Repair Disengage the downstream carrier roller from the unit. Note: All of the rollers are spring loaded at both ends, so they can be pulled toward you or away from you by pressing in the ends with a blunt tool. Always lift the rollers from the unit, pull them toward you carefully so as not to dislodge the O- bands, and disengage the axles from the opposite side of the unit.

  • Page 35: Carrier Roller Installation

    Service and Repair 3.6.2 Carrier Roller Installation Apply the appropriate lockout/tagout procedures to remove all power and air from the conveyor section. Loosely hang the flat bands and roller O-bands on the center carrier roller. Pass the center carrier roller through the drive O-bands that are attached to the drive hub.
  • Page 36 Service and Repair Insert the roller tool on the roller O-band side of the unit and secure the tool to the side frame using the downstream pin. IntelliSort WD 2.0 | Maintenance Manual | 29351003 March 11, 2021...
  • Page 37 Service and Repair Rotate the roller tool until the second pin is lined up with the hole in the side frame. Tap on the roller axle on the opposite side of the roller O-bands to secure the roller. Secure the carrier rollers with cotter pins on both sides of the unit. IntelliSort WD 2.0 | Maintenance Manual | 29351003 March 11, 2021...

  • Page 38: Wheel O-Band Replacement

    Service and Repair Reinstall the finger guards. Replace any guarding that was removed. Unlock and turn on the power for the conveyor and check for proper operation. Wheel O-Band Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on.
  • Page 39 Service and Repair Remove the side cover by removing the four bolts that attach the side cover to the unit. Remove the micro V-belt as described in the Micro V-Belt Removal section. Remove the carrier rollers as described in the Carrier Roller Removal section. Remove the wheel O-bands from the divert wheels.
  • Page 40 Service and Repair Remove all wheel O-bands showing signs of wear/damage. Note: Replace the drive hub if it shows signs of wear/damage as described in the Drive Hub Installation section. Replace any drive O-bands that show signs of wear/damage as described in the Drive O-Band Installation section. Replace any shaft spools that show signs of wear/damage as described in the Shaft Spool Replacement section.

  • Page 41: Drive O-Band Replacement

    Service and Repair Drive O-Band Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.
  • Page 42 Service and Repair Remove the side cover by removing the four bolts that attach the side cover to the unit. Remove the micro V-belt as described in the Micro V-Belt Removal section. Remove the carrier rollers as described in the Carrier Roller Removal section. Remove all wheel O-bands from the divert wheels.
  • Page 43 Service and Repair Remove all drive O-bands that show signs of wear/damage. Note: Replace the drive hub if it shows signs of wear/damage as described in the Drive Hub Replacement section. Replace any shaft spools that show signs of wear/damage as described in the Shaft Spool Replacement section. Replace any wheel O-bands that show signs of wear/damage as described in the Wheel O- Band Replacement section.

  • Page 44: Drive Hub Replacement

    Service and Repair Drive Hub Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.
  • Page 45 Service and Repair Remove the side cover by removing the four bolts that attach the side cover to the unit. Remove the micro V-belt as described in the Micro V-Belt Removal section. Remove the carrier rollers as described in the Carrier Roller Removal section. Remove all wheel O-bands from the divert wheels.

  • Page 46: Drive Hub Installation

    Service and Repair Loosen the drive hub setscrews and remove the drive hub. Note: Replace any shaft spools that show signs of wear/damage as described in the Shaft Spool Replacement section. Replace any drive O-bands that show signs of wear/damage as described in the Drive O-Band Replacement section. Replace any wheel O-bands that show signs of wear/damage as described in the Wheel O-Band Replacement section.
  • Page 47 Service and Repair Align the drive hub with the center carrier roller and tighten the drive hub setscrews to 6.5 ft-lb. Reinstall the micro V-belt as described in the Micro V-Belt Installation section. Reinstall the side cover by inserting the four bolts that attach the side cover to the unit.

  • Page 48: Shaft Spool Replacement

    Service and Repair 3.10 Shaft Spool Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.
  • Page 49 Service and Repair Remove the side cover by removing the four bolts that attach the side cover to the unit. Remove the micro V-belt as described in the Micro V-Belt Removal section. Remove the carrier rollers as described in the Carrier Roller Removal section. Remove all wheel O-bands from the divert wheels.
  • Page 50 Service and Repair Remove all shaft spools showing signs of wear/damage. Note: Replace the drive hub if it shows signs of wear/damage as described in the Drive Hub Replacement section. Replace any drive O-bands that show signs of wear/damage as described in the Drive O-Band Replacement section. Replace any wheel O-bands that show signs of wear/damage as described in the Wheel O- Band Replacement section.

  • Page 51: Flat Band Replacement

    Service and Repair 3.11 Flat Band Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.

  • Page 52: Roller O-Band Replacement

    Service and Repair 3.12 Roller O-Band Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.

  • Page 53: Drive Pulley Replacement

    Service and Repair 3.13 Drive Pulley Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.

  • Page 54: Drive Pulley Installation

    Service and Repair Remove the drive pulley. 3.13.2 Drive Pulley Installation Apply the appropriate lockout/tagout procedures to remove all power and air from the conveyor section. Place the drive pulley on the PTO roller so that the drive pulley aligns ± 0.060 inch to the driven sheaves.

  • Page 55: Driven Sheave Installation

    Service and Repair Loosen the driven sheave setscrews. Remove the driven sheave. Note: Make sure the shaft key remains in the shaft. 3.14.2 Driven Sheave Installation Apply the appropriate lockout/tagout procedures to remove all power and air from the conveyor section. Place the driven sheave on the shaft so that the driven sheave is flush with the bearing collar and is square +/- 0.060 inch to the other driven sheave.

  • Page 56: Wheel Replacement

    Service and Repair 3.15 Wheel Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.

  • Page 57: Wheel Rack Height Adjustment

    Service and Repair Install the new wheel(s) on the wheel rack assembly by applying 20 lb-ft of torque to the nut. Note: Do not apply torque to the bolt head. Stretch the wheel O-bands over the wheel(s). Reinstall the carrier rollers as described in the Carrier Roller Installation section. Unlock and turn on the power for the conveyor and check for proper operation.
  • Page 58 Service and Repair Unlock the upper bumpers by loosening the hex jam nut. Loosen the mounting bolt to raise the upper bumpers until they are not interfering with the bottom channel. Use the wheel rack adjustment tool to loosen the air cylinder jam nuts. The wheel rack adjustment tool allows a hex key to pass through the tool to provide a counter- hold while loosening the jam nut.

  • Page 59: Wheel Rack Replacement

    Service and Repair Verify wheel rack is level. Thread upper bumpers down until they contact the bottom channel. Turn each upper bumper an additional turn. Tighten the hex jam nuts to lock upper bumpers in place. Reinstall the carrier rollers as described in the Carrier Roller Installation section. Unlock and turn on the power for the conveyor and check for proper operation.
  • Page 60 Service and Repair Remove the wheel O-bands from the wheels. Measure and record the wheel rack height. Use a -inch hex drive and extension to unthread the wheel rack from the air cylinders. Remove the wheel rack from the unit. IntelliSort WD 2.0 | Maintenance Manual | 29351003 March 11, 2021...

  • Page 61: Wheel Rack Installation

    Service and Repair 3.17.2 Wheel Rack Installation Apply the appropriate lockout/tagout procedures to remove all power and air from the conveyor section. Apply anti-seize to the threaded air cylinders. Turn the air cylinder shaft one complete clockwise rotation to mitigate the risk of cross threading the air cylinder shaft.

  • Page 62: Air Cylinder Replacement

    Service and Repair 3.18 Air Cylinder Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.
  • Page 63 Service and Repair Remove the four air cylinder mounting bolts from the air cylinder being replaced and lift the air cylinder out of the divert drawer. Place the new air cylinder in the divert drawer. Connect the air connections to the air cylinder. Install the four mounting bolts to the air cylinder.

  • Page 64: Divert Drawer Replacement

    Service and Repair 3.19 Divert Drawer Replacement The entire divert unit may need to be removed from the conveyor. The IntelliSort WD design allows the divert drawer to be removed and replaced with a spare drawer. Divert drawer removal also allows maintenance personnel to perform certain maintenance tasks as bench work.

  • Page 65: Divert Drawer Installation

    Service and Repair Disconnect the tubing running from the external air kit into the divert drawer. Remove the micro V-belt as described in the Micro V-Belt Removal section. Remove the four mounting bolts connecting the divert drawer to the divert unit. Remove the divert drawer from the divert unit.

  • Page 66: Pto Bearing Replacement

    Service and Repair 3.20 PTO Bearing Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.

  • Page 67: Pto Bearing Installation

    Service and Repair Remove the PTO bearing mounting bolts and remove the PTO bearing. Note: Leave the shaft key in the PTO roller if the PTO roller is not being replaced. 3.20.2 PTO Bearing Installation Apply the appropriate lockout/tagout procedures to remove all power and air from the conveyor section.

  • Page 68: Pto Roller Replacement

    Service and Repair 3.21 PTO Roller Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.

  • Page 69: Pto Roller Installation

    Service and Repair Remove one PTO bearing as described in the PTO Bearing Removal section. Remove the shaft key from the PTO roller and set aside. Remove the PTO roller from the divert unit. 3.21.2 PTO Roller Installation Apply the appropriate lockout/tagout procedures to remove all power and air from the conveyor section.

  • Page 70: Idler Roller Replacement

    Service and Repair 3.22 Idler Roller Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.
  • Page 71 Service and Repair Loosen the tracking adjustment bolts on both sides of the conveyor. Remove the idler roller mounting bolts on both sides of the conveyor and remove the idler roller. Place the new idler roller in the divert tub and install the idler roller mounting bolts. Tighten the tracking adjustment bolts until the idler roller is square.

  • Page 72: Snub Roller Replacement

    Service and Repair 3.23 Snub Roller Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.
  • Page 73 Service and Repair Loosen the tracking adjustment bolts on both sides of the conveyor. Remove the mounting bolts on both sides of the conveyor and remove the snub roller. Place the new snub roller in the divert tub and install the snub roller mounting bolts. Tighten the tracking adjustment bolts until the snub roller is square.

  • Page 74: Return Roller Replacement

    Service and Repair 3.24 Return Roller Replacement Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.
  • Page 75 Service and Repair Remove the return roller mounting bolts and remove the return roller from the divert tub. Place the new return roller in the divert tub and install the return roller mounting bolts. Note: Make sure the return roller is installed square in the divert unit. Reinstall the bottom pan.

  • Page 77: Preventive Maintenance

    Preventive Maintenance Before performing any maintenance or lubrication services, follow the lockout/ tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage. The satisfactory performance and reliability of this equipment is dependent upon a proficient preventive maintenance (PM) program with scheduled equipment inspections under normal operating conditions.

  • Page 78: Maintenance Precautions

    Preventive Maintenance Preventive maintenance consists of regular and consistent scheduled service (lubrication, adjustments, cleaning, etc.). Part of preventive maintenance is becoming aware of potential problems by simply using your senses. Watch for potential component failure. Listen for abnormal or louder than normal noises. Use your nose to smell a motor running abnormally warm in time to prevent its burnout.

  • Page 79: Cleaning And Inspection

    Preventive Maintenance Cleaning and Inspection Generally, there are many reasons for cleaning: • To allow heat to dissipate (motors and gearboxes). • To prevent wear on moving parts. • To prevent binding. • For proper operation. • Operating personnel will most likely treat clean equipment with more care. Any prescribed cleaning schedule should be modified as experience is gained.
  • Page 80 Preventive Maintenance Daily Checklist Date Checked Changes/ Repairs Made Look for shavings or belt dust under conveyor that would indicate misaligned or damaged components. Weekly Checklist Date Checked Changes/ Repairs Made Check with Conveyor Running Visually inspect the urethane wheels, O-bands, flat bands, and rollers for wear, improper alignment, or buildup of foreign materials and repair/clean as required.

  • Page 81: Lubrication

    Preventive Maintenance Lubrication Before performing any maintenance or lubrication services, follow the lockout/ tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage.

  • Page 83: Replacement Parts

    Replacement Parts This chapter identifies the parts in each type of belt conveyor assembly. Many part descriptions contain the Between Frame (BF) length of the part. Check your Bill of Materials for the BF length of the parts in your system. Finding Part Numbers You can use the information in this chapter, in conjunction with the conveyor number, to find part numbers on the Recommended Spare Parts List.

  • Page 84: Locating Part Numbers

    Replacement Parts The sequence of letters at the top of the label identifies the type of device. The sequence of numbers is the conveyor number. In the example above, the conveyor number is 2310. If you cannot locate a device label, you will need to get the conveyor number from the mechanical layouts.

  • Page 85: Part Illustrations

    Replacement Parts Part Illustrations 5.2.1 Divert Drawer Spare Component Part Description Part Number Part Flat Band FLAT BAND 0.100 X 0.500 X 24.264 PYRAMID 27073000 Carrier Roller IWD 2G FLT BAND RLR ASY __BF 3996870_ Roller O-Bands BELT ROUND PYRAMID .218 X 14.154 83A 27115000 BLACK Finger Guard...
  • Page 86 Replacement Parts Spare Component Part Description Part Number Part Shaft Bearing BEARING SC TAB BASE 1.00BR 0185417 DODGE#124465 Driven Sheave IWD 2G DRVN V-BELT PULLEY 39953100 Tensioner Assembly IWD 2G V-BELT TENSIONER ASSEMBLY 39953200 Wheel Bumper RND BMPR PLY, STL CORE, 1.25" OD W/ 3/8-16 27073900 THRD HOLE Internal Air Kit Assembly...

  • Page 87: Divert Assembly

    Replacement Parts 5.2.2 Divert Assembly Spare Component Part Description Part Number Part Divert Drawer IWD 2G DIV DRWR __BF _H-DIV 3997000_ Drive Pulley IWD 2G DRV 39953000 Divert Tub IWD 2G TUB ASY __BF _H-DIV 399501__ External Air Kit IWD EXTERNAL AIR KIT VOELKER# VCC871 399123__ Micro V-belt IWD 2G MICRO-V BELT 440J6...

  • Page 88: Divert Tub

    Replacement Parts 5.2.3 Divert Tub Spare Component Part Description Part Number Part PTO Roller IWD 2G PLLY 3.5OD CR LAG __BF 399304__ Snub Roller ROLLER CHANTLAND 3.19" DIA EDGE-CROWN 7011950_ 34BF Idler Roller ROLLER CHANTLAND 3.19" DIA EDGE-CROWN 7011950_ 34BF Return Roller IWD ROLLER 2.5"...

  • Page 89: Maintenance Tools

    Replacement Parts 5.2.4 Maintenance Tools Spare Component Part Description Part Number Part Wheel Rack Adjustment IWD 2G AIR CYLINDER SOCKET TOOL 39966400 Tool Roller Removal Tool IWD 2G ROL TOOL UHMW 39932700 Wheel Rack Height Gauge IWD 2G WHEEL RACK HEIGHT GAUGE 39967200 IntelliSort WD 2.0 | Maintenance Manual | 29351003 March 11, 2021...

  • Page 91: Troubleshooting

    Troubleshooting Introduction Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage. When troubleshooting equipment problems, it is essential to completely understand how the system functions during normal operation.

  • Page 92: Troubleshooting Chart

    Troubleshooting List short and long term solutions. Select a solution or possible solutions. Implement and document one solution at a time. Troubleshooting Chart Table 6-1 Troubleshooting Problems and Solutions Symptom Probable Cause Corrective Action Packages miss or plow Divert wheel height set Check divert wheel height in through divert too low...
  • Page 93 Index accessories, 14 finish, 14 air cylinder flat bands replacement, 56 replacement, 45 AMSE, 2 frames, 14 ANSI, 3, 7, 8, 9 applications, 13 guard, 4, 5, 6, 7, 8 by location, 4 by position, 4 belt tracking guarding, 4 adjustment, 17 guarding exceptions, 4 capacity, 14...
  • Page 94 signs, 9 safety instructions, 1 product rate, 13 sealed bearings, 75 PTO bearing service, 15 replacement, 60 shaft bearings, 75 PTO roller shaft spools replacement, 62 replacement, 42 PTO roller guard snub roller adjustment, 21 replacement, 66 speed, 13 surfaces, 14 repair, 15 return roller replacement, 68...

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